CN114728439A - 真空成形用树脂一体化纤维片、采用其的成形体和成形体的制造方法 - Google Patents
真空成形用树脂一体化纤维片、采用其的成形体和成形体的制造方法 Download PDFInfo
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- CN114728439A CN114728439A CN202080078377.2A CN202080078377A CN114728439A CN 114728439 A CN114728439 A CN 114728439A CN 202080078377 A CN202080078377 A CN 202080078377A CN 114728439 A CN114728439 A CN 114728439A
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Abstract
一种用于通过真空成形得到纤维增强树脂成形体的真空成形用树脂一体化纤维片(1),含有将连续纤维组开纤且并列状排列在一个方向的单方向连续纤维(2)、与单方向连续纤维(2)交错的方向的搭桥纤维(3)、存在于单方向连续纤维(2)的至少表面上且使单方向连续纤维(2)与搭桥纤维(3)一体化的热塑性树脂(4)。本发明的纤维增强树脂成形体是将树脂一体化纤维片(1)层叠2片以上并真空成形的。本发明的成形体的制造方法是从具有真空管的下模对树脂一体化纤维片(1)进行真空成形,从上模进行压空模压。由此,提供一种赋形性优异、不产生气孔的真空成形用树脂一体化纤维片、采用其的成形体和成形体的制造方法。
Description
技术领域
本发明涉及采用半浸渗材料的真空成形用树脂一体化纤维片、采用其的成形体和成形体的制造方法。
背景技术
通过将增强纤维材料即碳纤维与各种基体树脂复合化而得到的纤维增强塑料被广泛地用于各种领域及用途。而且,在要求高度的机械特性及耐热性等的航空及宇宙领域或一般产业领域中,采用以热塑性树脂作为基体树脂的单方向性的连续纤维。以往,采用将树脂完全浸渗到碳纤维基体材料中的预浸渗材料(prepreg),暗示有形成复合材料时的耐冲击性优异、成形时间短、且降低成形成本的可能性。可是,在使用完全浸渗的预浸渗材料时,需要对预浸渗材料的片材层叠而成的成形体进行一定时间的预加热,在原样状态时因硬度高而需要成形时间。因此,着眼于未完全浸渗的未浸渗的半浸渗材料(semipreg)。半浸渗材料是基体树脂附着、熔合在纤维基体材料上的状态或半浸渗状态的未浸渗的基体片,柔软且赋形性优异。此外,能够直接进行成形,因而成形效率也优异。
可是,在对增强纤维树脂进行成形时,需要使热塑性树脂浸渗在纤维基体材料中,在短纤维的情况下需要加工成无纺布,效率非常差。此外,在连续纤维的情况下有时取向偏移混乱,产生气孔或皱纹等缺陷。因此,一直在寻求能够用于直接成形的更适合的基体材料。
专利文献1中,公开了一种在制作了无纺布后在最外层层叠有薄膜的基体材料。如果采用这样的基体材料则搬运性等优异,但需要将增强纤维加工成无纺布的工序,难以用于连续纤维。而且,存在在为了贴合薄膜而规定基体材料的制造条件、不能任意地设定基体材料的质量的问题。此外,如果薄膜位于最外层,则基体材料***,赋形性也出现问题。专利文献2中,公开了一种采用预浸渗材料或半浸渗材料制造预浸渗材料的成形品的装置,但关于成形方法存在问题。
现有技术文献
专利文献
专利文献1:日本特开2014-50981号公报
专利文献2:日本特开2017-109408号公报
发明内容
发明要解决的问题
如以上说明的,现有技术在赋形性上存在问题,有难以防止发生气孔的问题。
本发明为解决上述以往的问题,提供一种赋形性优异、不产生气孔的真空成形用树脂一体化纤维片、采用其的成形体和成形体的制造方法。
用于解决课题的手段
本发明的真空成形用树脂一体化纤维片,其特征在于:
是用于通过真空成形得到纤维增强树脂成形体的真空成形用树脂一体化纤维片,所述树脂一体化纤维片含有:
A连续纤维组被开纤且并列状排列在一个方向的单方向连续纤维、
B与所述单方向连续纤维交错的方向的搭桥纤维、
C存在于所述单方向连续纤维的至少表面上、且使所述单方向连续纤维与所述搭桥纤维一体化的热塑性树脂。
本发明的纤维增强树脂成形体是通过层叠2片以上的所述树脂一体化纤维片,进行真空成形而成的成形体。
本发明的纤维增强树脂成形体的制造方法的特征在于:是通过对所述树脂一体化纤维片进行真空成形来制造纤维增强树脂成形体的方法,从具有真空管的下模对所述树脂一体化纤维片进行真空成形,从上模进行压空模压。
发明效果
本发明的树脂一体化纤维片通过含有(A)连续纤维组被开纤且并列状排列在一个方向的单方向连续纤维、(B)与所述单方向连续纤维交错的方向的搭桥纤维、和(C)存在于所述单方向连续纤维的至少表面上、且使所述单方向连续纤维与所述搭桥纤维一体化的所述热塑性树脂,通过真空成形使热塑性树脂在树脂一体化纤维片内及树脂一体化纤维片间同样地浸透且扩散,可得到赋形性(成形性)优异、不产生气孔的成形体。此外,本发明的纤维增强树脂成形体的制造方法中,成形循环快,能够用短时间得到高质量的成形体。
附图说明
图1是本发明的一个实施方式的树脂一体化碳纤维片的示意立体图。
图2是同图的树脂一体化碳纤维片的宽度方向的示意剖视图。
图3是表示同图的树脂一体化碳纤维片的制造方法的示意工序图。
图4是同图的真空压空成形装置的示意剖视图。
图5A-D是表示同图的成形方法的示意工序图,图5A表示准备工序、图5B表示加热升温工序、图5C表示加热真空压空成形工序、图5D表示冷却、脱模工序。
图6是表示同图的工序操作的坐标图。
图7是表示本发明的一个实施例中的试样的切下方向的示意说明图。
具体实施方式
本发明的真空成形用树脂一体化纤维片的纤维的主成分是被开纤且并列状排列在一个方向的单方向连续纤维。纤维的辅助成分是排列在与单方向连续纤维交错的方向的搭桥纤维。这里所谓的主成分,在将纤维设为100质量%时,优选为75~99质量%,所谓的辅助成分,优选为1~25质量%。热塑性树脂以粉体附着在单方向连续纤维及搭桥纤维上,在单方向连续纤维的至少表面上热熔合,且使单方向连续纤维与搭桥纤维一体化。该片材由于通过热熔合的热塑性树脂使单方向连续纤维与搭桥纤维一体化,因此处理性良好,在层叠时及真空成形时的操作性优异。
所述树脂一体化纤维片优选为在单方向连续纤维及搭桥纤维的表面上附着且热熔合有成为基体的热塑性粉体树脂而形成的半浸渗材料。该半浸渗材料通过真空成形使表面的热塑性树脂在树脂一体化纤维片内及树脂一体化纤维片间同样地浸透且扩散。由此,可得到赋形性(成形性)优异、不产生气孔的成形体。
在将所述单方向连续纤维和搭桥纤维的合计设为100质量%时,单方向连续纤维优选为75~99质量%,更优选为80~97质量%,进一步优选为85~95质量%。此外,搭桥纤维优选为1~25质量%,更优选为3~20质量%,进一步优选为5~15质量%。只要在上述的范围,就能形成单方向连续纤维的一体性高、宽度方向的拉伸强度高的树脂一体化纤维片。
优选所述树脂一体化纤维片的纤维体积(Vf)为20~65体积%、热塑性树脂为35~80体积%,更优选纤维为25~60体积%、树脂为40~75体积%。由此,能够使树脂一体化纤维片的树脂成分直接成为成形体的基体树脂成分。也就是说,在制造成形体时,不需要追加新的树脂。树脂一体化纤维片的每单位面积的质量优选为10~3000g/m2,更优选为20~2000g/m2,进一步优选为30~1000g/m2。
上述单方向连续纤维,优选为选自碳纤维、玻璃纤维及弹性模量为380cN/dtex以上的高弹性模量纤维中的至少一种。作为上述高弹性模量纤维,例如有芳香族聚酰胺纤维、特别是对位芳香族聚酰胺纤维(弹性模量:380~980cN/dtex)、聚丙烯酸酯纤维(弹性模量:600~741cN/dtex)、杂环聚合物(PBO,弹性模量:1060~2200cN/dtex)纤维、高分子量聚乙烯纤维(弹性模量:883~1413cN/dtex)、聚乙烯醇纤维(PVA,强度:14~18cN/dtex)等(纤维百科辞典,522页,2002年3月25日,丸善)。这些纤维作为树脂增强纤维是有用的。尤其碳纤维是有用的。
上述树脂一体化纤维片的1片的厚度优选为0.01~5.0mm。厚度在该范围的纤维片容易进行真空成形。真空成形时,将该树脂一体化纤维片层叠2片以上。优选的层叠数为2~70片,更优选为5~50片。
作为上述热塑性树脂,可使用聚酰胺系树脂、聚碳酸酯系树脂、聚丙烯系树脂、聚酯系树脂、聚乙烯系树脂、丙烯酸酯系树脂、苯氧基树脂、聚苯乙烯系树脂、聚酰亚胺系树脂及聚醚醚酮系树脂等,但也并不局限于这些树脂。
关于本发明的树脂一体化纤维片的树脂的附着状态,树脂熔融固化而附着在开纤了的纤维片的表面附近,优选树脂不浸渗到纤维片内部或部分浸渗到纤维片内部。如果是上述状态,则对于多片层叠树脂一体化纤维片、进行真空成形是优选的。
关于开纤了的纤维片(以下也称为“开纤片材”)的宽度,在碳纤维的情况下,优选每构成纤维根数1000根为0.1~5.0mm。具体地讲,关于开纤片材的宽度,在50K或60K等的粗丝束的情况下,每构成纤维根数1000根为0.1~1.5mm的范围,在12K或15K等的标准丝束的情况下,每构成纤维根数1000根为0.5~5.0mm的范围。这里K为1000根。每1根的丝束的构成纤维根数越增加,纤维的扭曲就越大,越难开纤,因而开纤片材的宽度也变窄。由此,通过将碳纤维厂家出售的未开纤丝束展开,形成容易使用的开纤片材,能够供给各式各样的成形物使用。供给丝的碳纤维束(丝束)优选为5000~50000根/束,优选以10~280根供给该碳纤维束(丝束)。如果如此通过多根供给碳纤维束(丝束)进行开纤,形成1张的片材,则碳纤维束(丝束)与碳纤维束(丝束)之间容易开裂,但如果具有多个方向性的搭桥纤维通过树脂粘接锚固在片材上,则能够防止丝束间的开裂。
搭桥纤维的平均长度优选为1mm以上,更优选为5mm以上。只要搭桥纤维的平均长度在上述的范围内,就可形成宽度方向的强度高、处理性优异的碳纤维片。
本发明的树脂一体化纤维片的制造方法包括以下工序。作为纤维片,以碳纤维片为例进行说明。
(1)通过选自通过多个辊、通过开纤杆及空气开纤中的至少一种手段使碳纤维长丝组开纤,在并列状排列在一个方向时,在所述开纤时或在开纤后从碳纤维长丝组中产生搭桥纤维,或在开纤时或开纤后使搭桥纤维下落在碳纤维片上,所述搭桥纤维按碳纤维片的每10mm2的面积中平均为1根以上。在通过辊或开纤杆将碳纤维长丝组开纤时,通过对碳纤维长丝组施加张力,开纤时能够从碳纤维长丝组中产生搭桥纤维。可将碳纤维长丝组的张力例如设为每15000根为2.5~30N的范围。采用空气开纤时,优选在其后通过辊或开纤杆产生搭桥纤维。在从碳纤维长丝组中产生搭桥纤维时,搭桥纤维形成与构成碳纤维片的碳纤维交错的状态。这里所谓交错,包括缠绕在一起。例如,搭桥纤维的一部分或全部存在于碳纤维片内,与排列在一个方向的碳纤维立体地交错。
(2)对开纤了的碳纤维片赋予粉体树脂。
(3)在无压力状态下将粉体树脂加热熔化,并冷却,使树脂局部地存在于碳纤维片的至少表面的一部分中。此时,通过表面的树脂将搭桥纤维粘接锚固在碳纤维片上。
本发明的纤维增强树脂成形体是将上述的树脂一体化纤维片层叠2片以上并真空成形而得到的。在2片以上层叠树脂一体化纤维片时,也可以改变单方向连续纤维的方向进行层叠。例如,能够如0°/45°/90°/135°/180°/……,0°/90°/180°/……等那样变化。由此,可得到具有成形体所要求的力学特性的成形体。作为成形体,汽车的发动机罩、门、保险杠、桌面板等大型片状物是适合的。
本发明的纤维增强树脂成形体的制造方法中,在对树脂一体化纤维片进行真空成形来制造纤维增强树脂成形体时,从具有真空管的下模对所述树脂一体化纤维片进行真空成形,从上模进行压空模压。所述真空成形优选为真空压空成形。具体地讲,优选下述的方法。也就是说,采用包含具有真空管的下模和下表面具有衬垫薄膜的上模的真空成形装置,通过以下工序来成形。
a在下模上载置层叠了2片以上的树脂一体化纤维片,覆盖衬垫薄膜的工序,
b从下模的真空管进行减压,在减压的同时进行升温的工序,
c以将所述树脂一体化纤维片加热至热塑性树脂的软化点以上的温度的状态,从衬垫薄膜的上部通过压空对树脂一体化纤维片进行加压,进行真空压空成形的工序,
d以维持压力条件的原状进行冷却,冷却后将成形体脱模的工序。
通过以上的成形方法,可进行10分钟/1个循环,优选7分钟/1个循环。所述衬垫薄膜也称为脱模薄膜或真空气胎薄膜。
以下采用附图进行说明。在以下的附图中,同一符号表示同一物。图1是本发明的一个实施方式的树脂一体化碳纤维片1的示意立体图,图2是同图的树脂一体化碳纤维片1的宽度方向的示意剖视图。在开纤了的单方向碳纤维2的表面上在各种方向配置有搭桥纤维3。此外在单方向碳纤维2的表面附近,树脂4熔融固化而附着,树脂4为未浸渗到或部分浸渗到单方向碳纤维2的内部的程度。树脂4将搭桥纤维3粘接锚固在单方向碳纤维2的表面上。如图2所示的那样,在单方向碳纤维2的表面存在搭桥纤维3a、3b。搭桥纤维3a全部在单方向碳纤维2的表面上。搭桥纤维3b为一部分在单方向碳纤维2的表面、一部分进入到内部而与碳纤维交错的状态。树脂4将搭桥纤维3粘接锚固在单方向碳纤维2的表面上。此外,存在附着有树脂4的部分和未附着树脂的部分5。未附着树脂的部分5在以多片层叠状态对树脂一体化碳纤维片1进行加热、真空而成形为纤维增强树脂成形品时,成为将纤维片内部的空气从该部分排出的通路,通过加压容易将表面的树脂浸渗到整个纤维片内。由此,树脂4成为纤维增强树脂成形体的基体树脂。
图3是表示本发明的一个实施方式的树脂一体化碳纤维片的制造方法的示意工序图。从多个供给绕线管7引出碳纤维长丝组(丝束)8,使其通过开纤辊21a-21j间,进行开纤(辊开纤工序23)。也可以替代辊开纤而设为空气开纤。开纤辊也可以固定或旋转,也可以在宽度方向上振动。
开纤工序后,将开纤了的丝束夹在夹持辊9a、9b间,使其通过设置在此之间的多个搭桥辊12a-12b间,通过例如按每15000根(相当于从1个供给绕线管供给的碳纤维长丝组)2.5~30N的范围施加丝束张力,产生搭桥纤维(搭桥纤维产生工序24)。搭桥辊也可以旋转,也可以在宽度方向振动。搭桥辊例如通过表面有皱纹、凹凸或镜面的多个辊使碳纤维长丝组弯曲、固定、旋转、振动或通过它们的组合来产生搭桥纤维。13a-13g为导辊。
然后,从粉体供给漏斗14向开纤片材的表面喷撒干粉树脂15,以无压力状态将其供给加热装置16内进行加热,将干粉树脂15熔化,在导辊13e-13g间进行冷却。然后,从粉体供给料斗17也向开纤片材的背面喷撒干粉树脂18,以无压力状态将其供给加热装置19内进行加热,将干粉树脂18熔化、冷却,卷起在卷起辊20上(粉体树脂赋予工序25)。干粉树脂15、18例如设定为苯氧基树脂(熔点180℃),加热装置16、19内的各温度例如设定为树脂的熔点+20~60℃、滞留时间例如设定为各4秒。由此,碳纤维开纤片材的宽度方向的强度提高,构成碳纤维不会变得零零散散,能以片材进行处理。
粉体树脂的赋予可采用粉体涂布法、静电涂装法、喷涂法或流动浸渍法等。优选采用将粉体树脂撒落在碳纤维片表面上的粉体涂布法。例如将干粉状的粉体树脂喷撒在开纤了的碳纤维片上。
图4是本发明的一个实施方式中的真空压空成形装置的示意剖视图。该真空压空成形装置30具有下模33和上模39,下模33固定在底座31、模台32上,真空管34通到成形面35。上模39上具有压空管40,能够从空气槽37、面板38的空气孔41朝下供给压空。下模33通过电磁感应加热、电阻线加热、红外线加热等加热器42和水冷管43从而能够将加热及冷却控制在规定的温度。
图5A-D是表示同图的成形方法的示意工序图,图5A表示准备工序、图5B表示加热升温工序、图5C表示加热真空压空成形工序、图5D表示冷却及脱模工序。首先,如图5A所示的那样,在下模33上载置2片以上层叠的树脂一体化纤维片44,覆盖衬垫薄膜45,从下模33的真空管34进行减压。接着,如图5B所示的那样,将树脂一体化纤维片44加热升温至热塑性树脂的软化点以上的温度。接着,如图5C所示的那样,从衬垫薄膜45的上部通过压空对树脂一体化纤维片44加压,进行真空压空成形。最后,如图5D所示的那样,将成形体46冷却后取出。作为衬垫薄膜,可使用聚四氟乙烯等氟树脂薄膜、或聚酰亚胺树脂薄膜、硅树脂薄膜等耐热性薄膜。
图6是表示同图的工序操作的坐标图。在工序1中,在下模上载置2片以上层叠的树脂一体化纤维片44,覆盖衬垫薄膜45。在工序2中,从下模33的真空管34进行减压,在减压的同时进行升温。在工序3中,在温度达到例如225℃后,维持120秒钟,同时从衬垫薄膜45的上部通过压空对树脂一体化纤维片44加压,进行真空压空成形。在工序4中,以维持压力条件的原状进行冷却,冷却后将成形体46脱模。下模33的来自真空管34的减压度优选为0~0.1MPa,上模39的来自压空管40的空气压优选为0.1~2.0MPa。
本发明的优点汇总如下。
(1)与预浸渗材料不同,因是半浸渗材料而能够直接成形。
(2)与预浸渗材料不同,因是半浸渗材料而能够进行高循环成形,赋形性、成形性优异。
(3)由于热塑性树脂以粉末状进行热熔合,因而向纤维间的浸渗性好。也就是说,与薄膜不同,成形时空气排出性优异,气孔难发生。
(4)纤维一体化树脂片的纤维例如如碳纤维那样为连续纤维(不是短纤维)。因此,可得到较薄且强度较高的成形体。
(5)真空成形优选通过从下部吸引而进行减压,从上部通过空气进行加压(真空压空成形)。
(6)真空成形由于是通过衬垫薄膜均匀地施加压力的成形方法,因而可成形较大的成形体。
(7)真空成形由于是采用衬垫薄膜的成形,因此不仅能以平板状,还能以深冲状的三维的形状进行成形。
(8)能够减小相对于树脂的热经历。
·预浸渗材料:片材制成时长时间+压模片制成时+预加热时+成形时
·半浸渗材料:片材制成时短时间+只在成形时进行加热
如以上所述,半浸渗材料能够使成形时间高速化。
(9)即可对成形预浸渗材料(中间层叠体)进行成形,也可对完成品的成形体进行成形。
(10)预浸渗材料由于在软化后向成形模移动时变冷,因而成形品表面的平滑性(模具的转印性)差。本发明由于是直接成形,因此成形品表面的平滑性好。
(11)预浸渗材料由于在软化后向成形模移动时变冷,因而成形品需要某种程度的厚度(不能是薄的成形品)。本发明由于是直接成形,因此不需要基体材料的向成形模的移动替换。
实施例
以下,采用实施例对本发明具体地进行说明。另外,本发明并不限定于下述的实施例。
(实施例1)
(1)碳纤维未开纤丝束
碳纤维未开纤丝束使用了日本三菱化学公司制造的型号:PYROFILE TR 50S15L、形状:标准丝束长丝15K(15000根)、单纤维直径7μm。在该碳纤维未开纤丝束的碳纤维上,作为上浆剂附着有环氧系化合物。
(2)未开纤丝束的开纤手段
采用图3的开纤手段进行开纤。在开纤工序中,将碳纤维长丝组(丝束)的张力设为每15000根为15N。如此形成碳纤维长丝构成根数15K、宽500mm、厚0.08mm的开纤片材。搭桥纤维为3.3质量%。
(3)半浸渗材料
作为干粉树脂,使用聚丙烯,熔点:150~165℃(普瑞曼聚合物公司制造)。干粉树脂的平均粒径为80μm。该树脂相对于碳纤维1m2平均单面赋予27.8g、两面赋予55.6g。加热装置16、19内的温度各设为170℃,滞留时间各设为4秒。所得到的树脂一体化纤维片的质量为75g/m2,纤维体积(Vf)为45体积%,热塑性树脂为55体积%。
(4)层叠条件
·树脂一体化纤维片的层叠片数:10片
·树脂一体化纤维片的纤维方向:二方向(层叠在直进方向)
设为0°/90°/0°/90°/0°/0°/90°/0°/90°/0°。
(5)真空压空成形
用图4~图6所示的装置及条件实施了真空压空成形。
·工序1:在下模上载置2片以上层叠的树脂一体化纤维片,覆盖衬垫薄膜。衬垫薄膜使用厚度2mm的氟树脂薄膜。
·工序2:从下模的真空管按0.1MPa进行减压,在减压的同时开始升温。
·工序3:在温度达到225℃后,维持120秒钟,同时从衬垫薄膜的上部通过压空以0.8MPa对树脂一体化纤维片进行加压,进行真空压空成形。
·工序4:以维持压力条件的原状冷却到60℃,冷却后切断减压管和加压管,将成形体脱模。
工序1~工序4的1个循环为400秒。
(实施例2)
除了变动表1所示的成形条件以外,与实施例1同样地得到了成形体。
表1中示出成形条件。
表1
从按各实施例得到的成形品中如图7所示的那样切下测定试样。也就是说,分别切下6个沿着成形品50的纵向(箭头51、表面的纤维方向0°)长形的试样52和表面的纤维方向90°的试样53。然后,在23℃、相对湿度50%的条件下静置48小时以上。然后,测定各试样的长度、宽度、厚度,表2中示出平均值。
表2
试样 | 厚度(mm) | 宽度(mm) | 长度(mm) |
实施例1(0°方向) | 1.04 | 14.38 | 80.00 |
实施例1(90°方向) | 1.07 | 14.64 | 80.00 |
实施例2(0°方向) | 1.09 | 14.67 | 80.00 |
实施例2(90°方向) | 1.05 | 14.52 | 80.00 |
<3点弯曲试验>
按照JIS K7074对制作的试样进行了3点弯曲试验。测定条件如下述。表3中示出各试样的测定值的平均值。
·夹具:压头=R5,支点=R2(R为角的半径,单位mm)
·下部支持间隔:60mm
·试验速度5mm/min
<表面粗糙度试验>
按照JIS B0601对制作的试样进行了表面粗糙度试验。测定条件如下述。表4中示出各试样的测定值的平均值。
·测定器:Surftest 201(日本三丰)
·触针材质:金刚石
·触针前端半径:5μm
·测定力:4mN
·驱动方式:1次的往复移动(自动后退)
·驱动速度:测定时0.5mm/sec、后退时1mm/sec
·裁切长度:0.8mm
·标准长度:0.8mm
·评价长度:4mm
·取样间隔:0.8μm
表3
表4
从表3得知,实施例1及2的成形品的3点弯曲试验的结果是在实用上具有充分的性能。此外,从表4得知,实施例1~2的成形品的表面粗糙度为光滑的表面,可作为完成品的成形体使用。
工业上的可利用性
本发明的纤维增强树脂成形体被广泛应用于建筑构件、笔记本电脑的框体、IC框架、运动靴及杠杆等体育用品、风车、汽车、铁道、船舶、航空、宇宙等一般产业用途等中。
符号说明
1-树脂一体化碳纤维片
2-单方向碳纤维
3、3a、3b-搭桥纤维
4-树脂
5-未附着树脂的部分
6-开纤装置
7-供给绕线管
8-碳纤维长丝组(碳纤维未开纤丝束)
9a、9b-夹持辊
12a-12b-搭桥辊
13a-13g-导辊
14、17-粉体供给料斗
15、18-干粉树脂
16、19-加热装置
20-卷起辊
21a-21j-开纤辊
23-辊开纤工序
24-搭桥纤维产生工序
25-粉体树脂赋予工序
30-真空压空成形装置
31-底座
32-模台
33-下模
34-真空管
35-成形面
36-上模本体
37-空气槽
38-面板
39-上模
40-压空管
41-空气孔
42-加热器
43-水冷管
44-树脂一体化纤维片
45-衬垫薄膜
46-成形体
50-成形品
51-成形品的纵向
52-表面的纤维方向0°的试样
53-表面的纤维方向90°的试样
Claims (12)
1.一种真空成形用树脂一体化纤维片,其特征在于:
是用于通过真空成形得到纤维增强树脂成形体的真空成形用树脂一体化纤维片,
所述树脂一体化纤维片含有:
A连续纤维组被开纤且并列状排列在一个方向的单方向连续纤维、
B与所述单方向连续纤维交错的方向的搭桥纤维、
C存在于所述单方向连续纤维的至少表面上、且使所述单方向连续纤维与所述搭桥纤维一体化的热塑性树脂。
2.根据权利要求1所述的真空成形用树脂一体化纤维片,其中,所述树脂一体化纤维片是将成为基体的热塑性粉体树脂附着并热熔合在所述单方向连续纤维及所述搭桥纤维的表面上而成的半浸渗材料。
3.根据权利要求1或2所述的真空成形用树脂一体化纤维片,其中,在将所述单方向连续纤维和搭桥纤维的合计设为100质量%时,所述单方向连续纤维为75~99质量%,所述搭桥纤维为1~25质量%。
4.根据权利要求1~3中任一项所述的真空成形用树脂一体化纤维片,其中,所述树脂一体化纤维片的纤维体积(Vf)为20~65体积%、热塑性树脂为35~80体积%。
5.根据权利要求1~4中任一项所述的真空成形用树脂一体化纤维片,其中,所述单方向连续纤维为选自碳纤维、玻璃纤维及弹性模量为380cN/dtex以上的高弹性模量纤维中的至少一种。
6.根据权利要求1~5中任一项所述的真空成形用树脂一体化纤维片,其中,所述树脂一体化纤维片的厚度为0.01~5.0mm。
7.根据权利要求1~6中任一项所述的真空成形用树脂一体化纤维片,其中,所述热塑性树脂为选自聚酰胺系树脂、聚碳酸酯系树脂、聚丙烯系树脂、聚酯系树脂、聚乙烯系树脂、丙烯酸酯系树脂、苯氧基树脂、聚苯乙烯系树脂、聚酰亚胺系树脂及聚醚醚酮系树脂中的至少一种。
8.根据权利要求1~7中任一项所述的真空成形用树脂一体化纤维片,其中,所述树脂一体化纤维片的每单位面积的质量为10~3000g/m2。
9.一种纤维增强树脂成形体,其是将权利要求1~8中任一项所述的树脂一体化纤维片层叠2片以上、进行真空成形而得到的。
10.一种纤维增强树脂成形体的制造方法,其特征在于:
是通过将权利要求1~8中任一项所述的树脂一体化纤维片层叠2片以上、进行真空成形来制造纤维增强树脂成形体的方法,其中,
从具有真空管的下模对所述树脂一体化纤维片进行真空成形,从上模进行压空模压。
11.根据权利要求10所述的纤维增强树脂成形体的制造方法,其中,所述真空成形为真空压空成形。
12.根据权利要求10或11所述的纤维增强树脂成形体的制造方法,其中,
所述真空成形采用包含具有真空管的下模和可加压的上模的真空成形装置进行,
具备以下工序:
a在下模上载置层叠了2片以上的树脂一体化纤维片,覆盖衬垫薄膜的工序,
b从下模的真空管进行减压,在减压的同时进行升温的工序,
c以将所述树脂一体化纤维片加热至热塑性树脂的软化点以上的温度的状态,从衬垫薄膜的上部通过压空对树脂一体化纤维片进行加压,进行真空压空成形的工序,
d以维持压力条件的原状进行冷却,冷却后将成形体脱模的工序。
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EP4059684A1 (en) | 2022-09-21 |
CN114728439B (zh) | 2024-05-14 |
JP7519374B2 (ja) | 2024-07-19 |
JPWO2021095626A1 (zh) | 2021-05-20 |
WO2021095626A1 (ja) | 2021-05-20 |
US20220388275A1 (en) | 2022-12-08 |
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