CN114867595A - 纤维增强树脂中空成形体及其制造方法 - Google Patents

纤维增强树脂中空成形体及其制造方法 Download PDF

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Publication number
CN114867595A
CN114867595A CN202080088199.1A CN202080088199A CN114867595A CN 114867595 A CN114867595 A CN 114867595A CN 202080088199 A CN202080088199 A CN 202080088199A CN 114867595 A CN114867595 A CN 114867595A
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China
Prior art keywords
resin
fiber
integrated
fibers
fiber sheet
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CN202080088199.1A
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Inventor
饭尾隼人
高野直哉
平石阳一
田中忠玄
中明裕太
驹井优贵
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Kurashiki Spinning Co Ltd
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Kurashiki Spinning Co Ltd
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Abstract

本发明提供一种使用了树脂一体化纤维片的纤维增强树脂中空成形体(30)，所述树脂一体化纤维片含有由连续纤维组开纤的、且并列状排列在一个方向的单方向连续纤维和存在于所述单方向连续纤维的至少表面上的热塑性树脂，所述中空成形体(30)中，所述树脂一体化纤维片以1片或多片层叠的状态、以产生搭接部的方式卷绕，通过使所述热塑性树脂浸渗在所述单方向连续纤维内，使所述树脂一体化纤维片一体化。

Description

纤维增强树脂中空成形体及其制造方法
技术领域
本发明涉及使用了半浸渗材料的纤维增强树脂中空成形体及其制造方法。
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能够广泛应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)，暗示具有作为复合材料时的耐冲击性优异、成形时间短、且成形成本降低的可能性。可是，树脂完全浸渗的预浸渗材料因硬度高、缺乏柔软性而难以进行圆形加工。因此，注重于树脂未浸渗到增强纤维基体材料内的半浸渗材料(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材料的基体片，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，而且产生气孔及皱纹等缺陷。因此，一直在寻求能够用于直接成形的更适合的半浸渗基体材料。
专利文献1中，提出了通过使用可膨胀的芯型来使纤维强化树脂预成型品与金属成形体一体化。专利文献2中，提出了在附带内压保持管的芯型的外周上卷绕长纤维取向预浸渗片，在节状部附近进而卷绕短纤维二维随机预浸渗片，通过在模具内使内压保持管膨胀而进行加热加压成形的高尔夫球轴的制造方法。专利文献3中，提出了将含有特定的氟树脂和增强纤维的带状的纤维强化复合材料卷绕在第1层的外周上的管材的制造方法。专利文献4中，提出了作为管材的成形基体材料，使用在使增强纤维并丝在一个方向而成的片材上重叠由热塑性树脂形成的无纺布而得到的片状的成形基体材料。
现有技术文献
专利文献
专利文献1：日本特开2018-172116号公报
专利文献2：日本特开2013-106782号公报
专利文献3：WO2017/191735说明书
专利文献4：日本特开2011-62818号公报
发明内容
发明要解决的问题
可是，上述以往技术中存在原料基体材料硬、或者不能单独处理的问题，还有中空成形加工也困难的问题。
本发明为了解决上述以往的问题，通过采用处理性良好的半浸渗材料，提供一种既薄且赋形性又优异的纤维增强树脂中空成形体及其制造方法。
用于解决课题的手段
本发明涉及使用了树脂一体化纤维片的纤维增强树脂中空成形体，其中，所述树脂一体化纤维片含有由连续纤维组开纤的、且并列状排列在一个方向上的单方向连续纤维和存在于所述单方向连续纤维的至少表面上的热塑性树脂；所述中空成形体是所述树脂一体化纤维片以1片或多片层叠的状态以产生搭接部的方式卷绕，通过使所述热塑性树脂浸渗在所述单方向连续纤维内而使所述树脂一体化纤维片一体化的纤维增强树脂中空成形体。
本发明的纤维增强树脂中空成形体的制造方法中，采用含有由连续纤维组开纤的、且并列状排列在一个方向的单方向连续纤维和存在于所述单方向连续纤维的至少表面上的热塑性树脂的树脂一体化纤维片，在弹性体的表面上，将所述树脂一体化纤维片以1片或多片层叠的状态以产生搭接部的方式卷绕，将缠卷了所述树脂一体化纤维片的所述弹性体配置在具有中空形状的加热模具内，通过向所述弹性体的内部供给压力流体来进行压空成形，使所述热塑性树脂熔化，使所述热塑性树脂浸渗在所述单方向连续纤维中，使所述树脂一体化纤维片一体化。
发明效果
本发明的纤维增强树脂中空成形体通过采用含有由连续纤维组开纤的且并列状排列在一个方向的单方向连续纤维和存在于所述单方向连续纤维的至少表面上的热塑性树脂的树脂一体化纤维片，能够提供半浸渗材料的处理性好、既薄且赋形性又优异的纤维增强树脂中空成形体及其制造方法。此外，本发明的中空成形体的制造方法，因成形循环快而能够以短时间得到高质量的中空成形体。
附图说明
图1A是本发明的一个实施方式的纤维增强树脂中空成形体的示意立体图，图1B是同图的示意剖视图。
图2是表示图1的纤维增强树脂中空成形体的成形中所使用的树脂一体化碳纤维片的层叠方法的示意说明图。
图3A是中空成形中所使用的芯型的示意立体图，图3B是同图的将树脂一体化碳纤维片卷绕在芯型上时的示意立体图，图3C是图3B的剖视图。
图4A是表示将卷绕了树脂一体化碳纤维片的芯型装入成形模具中的状态的示意俯视图，图4B是图4A的I-I线剖视图。
图5是本发明的一个实施方式的纤维增强树脂中空成形体的成形中所使用的树脂一体化碳纤维片的示意立体图。
图6是图5所示的树脂一体化碳纤维片的宽度方向的示意剖视图。
图7是表示图5所示的树脂一体化碳纤维片的制造方法的示意工序图。
图8是实施例1的纤维增强树脂中空成形体的端部及中央部上的试验力-变位测定坐标图。
图9是实施例2的纤维增强树脂中空成形体的端部及中央部上的试验力-变位测定坐标图。
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 树脂未附着的部分
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 中空成形体
31 纤维增强树脂部
32 树脂一体化碳纤维片的搭接部
33a、33b 树脂一体化碳纤维片
34 搭接部分
35 芯型
36 夹具
37 树脂一体化碳纤维片
39 下模
40 上模
41 空气供给口
具体实施方式
本发明是使用了树脂一体化纤维片的纤维增强树脂中空成形体(以下，有时将纤维增强树脂中空成形体简称为“中空成形体”)。所述树脂一体化纤维片含有由连续纤维组开纤的、且并列状排列在一个方向上的单方向连续纤维；和存在于所述单方向连续纤维的至少表面上的热塑性树脂。本发明的中空成形体中，树脂一体化纤维片以1片或多片层叠的状态以产生搭接部的方式卷绕，通过使热塑性树脂浸渗在纤维片内而使树脂一体化纤维片一体化。中空成形体的制造中使用的所述树脂一体化纤维片，优选含有与所述单方向连续纤维交错的方向的搭桥纤维，且所述热塑性树脂使所述单方向连续纤维和所述搭桥纤维一体化。所述树脂一体化纤维片也可以含有在所述单方向连续纤维上配置在其它方向上的辅助丝。所谓辅助丝，是固定地保持纤维片的方向性的丝，作为辅助丝，例如可列举玻璃纤维、芳香族聚酰胺纤维、聚酯纤维、尼龙纤维、维纶纤维等。
本发明中使用的树脂一体化纤维片的纤维的主成分是被开纤了的、且并列状排列在一个方向的单方向连续纤维，是单方向长纤维。纤维的辅助成分优选是排列在与单方向连续纤维交错的方向的搭桥纤维。这里，在将树脂一体化纤维片所含的纤维设定为100质量％时，所谓主成分，优选为75～99质量％，所谓辅助成分，优选为1～25质量％。优选热塑性树脂以粉体的形式附着在单方向连续纤维及搭桥纤维上，热熔合在单方向连续纤维的至少表面上，且使单方向连续纤维和搭桥纤维一体化。该片材由于通过热熔合的热塑性树脂而使单方向连续纤维和搭桥纤维一体化，所以处理性良好，在层叠(也包含伴随着卷绕的层叠)时及成形时的操作性优异。
所述树脂一体化纤维片优选为通过在单方向连续纤维的表面上附着且热熔合了成为基体的热塑性粉体树脂而形成的半浸渗材料。该半浸渗材料通过成形而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、不产生气孔的中空成形体。
在将所述单方向连续纤维和搭桥纤维的合计设定为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85～97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3～15质量％。只要质量比例在上述的范围内，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中空成形体的基体树脂成分。也就是说，在制造中空成形体时，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。碳纤维尤其是有用的。
上述树脂一体化纤维片的1片的厚度优选为0.01～5.0mm。厚度在该范围的树脂一体化纤维片容易进行成形。在中空成形体的成形时，将该树脂一体化纤维片层叠1片或2片以上进行卷绕。优选的层叠数为2～20片，更优选为3～15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，优选将树脂通过熔融固化而附着在开纤了的纤维片的表面附近上，优选树脂不浸渗或部分浸渗到开纤了的纤维片内部。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，在碳纤维时，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等的粗丝束时，每构成纤维根数1000根为0.1～1.5mm的范围，在12K或15K等的普通丝束时，每构成纤维根数1000根为0.5～5.0mm的范围。这里，K表示构成纤维根数为1000根。每1根的丝束的构成纤维根数越增加，纤维的扭转就越大，越难开纤，因而开纤片材的宽度变窄。通过如此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中空成形体使用。为了制造树脂一体化纤维片而供给的碳纤维束(丝束)优选为5000～50000根/束，优选以10～280根向开纤装置供给该碳纤维束(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片的片材，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的、处理性优异的碳纤维片。
本发明的中空成形体的制造中使用的树脂一体化纤维片的制造方法，例如包括以下工序。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。将上述搭桥纤维设定为碳纤维片的每10mm2的面积平均为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产生搭桥纤维。可将碳纤维长丝组的张力例如设定为每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(未加压)状态下将粉体树脂加热熔化，然后冷却，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。
本发明的中空成形体是通过在弹性体的表面上将上述的树脂一体化纤维片以1片或2片以上层叠、以产生搭接部的方式卷绕、成形而成的。优选以1片或多片层叠的状态将上述树脂一体化纤维片至少卷绕2圈以上。上述搭接部的宽度优选为3mm以上，更优选为10mm以上。再者，本发明中，在卷绕2圈时，视为产生圆周程度的宽度的搭接部，在卷绕3圈时，视为产生圆周的两倍程度的宽度的搭接部。在将树脂一体化纤维片层叠2片以上时，也可以以单方向连续纤维的方向性(单方向连续纤维的纤维的长度方向)不同的方式层叠。此外，弹性体也可以是芯型。例如，在层叠2片时，能够设定为0°/90°。由此，可得到具有中空成形体所要求的力学特性的中空成形体。在采用1片树脂一体化纤维片时，例如可得到相对于芯型的长度方向在斜方向卷绕的长尺寸的成形体、或相对于芯型的长度方向在90°方向多次卷绕的中空成形体。作为中空成形体，为管、轴、框架等，可以是截面为圆形中空、四方形中空、其它多种形状的中空体。
本发明的中空成形体优选通过从中空部向外侧膨胀的流体来成形。作为流体，例如可列举压力空气等压力流体。
本发明的中空成形体的制造方法在一个实施方式中，具有以下的工序。
(a)在弹性体的表面上，将上述树脂一体化纤维片以1片或多片、产生搭接部的方式进行卷绕的工序。
(b)将缠卷了上述树脂一体化纤维片的上述弹性体配置在具有中空形状的加热模具内，通过向上述弹性体的内部供给压力流体而进行压空成形(例如通过压缩空气使上述树脂一体化纤维片密合在上述加热模具上，得到目的的形状)的工序。
(c)使热塑性树脂熔化，浸渗在单方向连续纤维中，并使所卷绕的上述树脂一体化纤维片一体化的工序。
本发明的中空成形体的制造方法在其它实施方式中，包含以下工序。
(a′)在弹性体的表面上，将树脂一体化纤维片1片或多片卷绕的工序。
(b′)将缠卷了上述树脂一体化纤维片的上述弹性体配置在具有中空模腔的加热模具内的工序。
(c′)将压力流体供给至上述弹性体的内部，通过从上述弹性体朝外侧使树脂一体化纤维片膨胀而进行中空成形，同时使热塑性树脂熔化浸渗在层叠部全体(所卷绕的上述树脂一体化纤维片全体)中的工序。
(d′)接着进行冷却的工序。
在上述工序(a)及上述工序(a′)中，在多片卷绕树脂一体化纤维片时，优选以单方向连续纤维的方向性不同的方式层叠卷绕多片树脂一体化树脂片。由此，可得到具有中空成形体所要求的力学特性的中空成形体。此外，也可以直接在弹性体的表面上卷绕树脂一体化纤维片，也可以在通过卷绕树脂一体化纤维片而形成预成型品后，将其配置在弹性体的表面上。
以下参照附图进行说明。在以下的附图中，同一符号表示同一物。图1A是本发明的一个实施方式的中空成形体30的示意立体图，图1B是同图的示意剖视图。该中空成形体30的内部在长度方向为中空，纤维增强树脂部31中，树脂一体化碳纤维片被多片层叠且被一体化。32为树脂一体化碳纤维片的搭接部。中空成形体30的优选的直径(外径)为10～200mm，优选的长度为50～5000mm，优选的厚度为0.03～5mm，更优选的厚度为0.04～5mm。
图2是表示图1的纤维增强树脂中空成形体的成形中所使用的树脂一体化碳纤维片的层叠方法的示意说明图。树脂一体化碳纤维片33a的单方向连续纤维为0°，树脂一体化碳纤维片33b的单方向连续纤维为90°。切取树脂一体化碳纤维片33a与33b重叠的部分34，缠卷在芯型上。缠卷的次数可以是1次，也可以是多次。在缠卷为1次时，使一部分重合。
图3A是中空成形中所使用的芯型35的示意立体图，图3B是同图的将树脂一体化碳纤维片37卷绕在芯型35上时的示意立体图，图3C是图3B的剖视图。在芯型35的前端安装夹具36，将芯型内的压力流体密封。芯型例如为氟橡胶(耐热极限温度230℃)、或硅橡胶(耐热极限温度230℃)制的管，例如可使用外径19mm、内径15mm、长度500mm的管。图3C中，为将树脂一体化碳纤维片卷绕n圈时的情况，搭接部的宽度为n-1圈程度的圆周的长度和用图中38表示的部分的长度的合计。
图4A是表示将卷绕了树脂一体化碳纤维片37的芯型35装入成形模具中的状态的示意俯视图，图4B是图4A的I-I线剖视图。成形模具由下模39和上模40构成，成形模被预先加热，模具内装入有卷绕了树脂一体化碳纤维片37的芯型35，从固定在芯型35的一端上的空气供给口41供给压缩空气，使芯型膨胀。由此，卷绕在芯型35上的树脂一体化碳纤维片37一直膨胀到模具，通过从模具接受加热，使树脂一体化碳纤维片37表面的热塑性树脂熔化，浸渗到层叠部全体(所卷绕的树脂一体化碳纤维片37全体)中。接着，通过水冷将模具冷却。由此，可得到纤维增强树脂中空成形体。
图5是本发明的一个实施方式的中空成形体的制造中使用的树脂一体化碳纤维片1的示意立体图，图6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的表面上在各个方向配置有搭桥纤维3。此外树脂4通过在单方向碳纤维2的表面附近熔化及固化而附着在其上，树脂4为未浸渗或一部分浸渗到单方向碳纤维2的内部的程度。树脂4使搭桥纤维3粘接固定在单方向碳纤维2的表面上。如图6所示的那样，在单方向碳纤维2的表面上存在搭桥纤维3a、3b。搭桥纤维3a全部位于单方向碳纤维2的表面上。搭桥纤维3b为一部分位于单方向碳纤维2的表面上、一部分进入到内部与碳纤维交错的状态。树脂4使搭桥纤维3粘接固定在单方向碳纤维2的表面上。此外，单方向碳纤维2的表面具有附着树脂4的部分和未附着树脂的部分5。未附着树脂的部分5在以多片层叠的状态对树脂一体化碳纤维片1进行加热而成形为纤维强化树脂成形品时，成为从该部分排出纤维片内部的空气的通路，通过加压容易使表面的树脂浸渗到纤维片内全体中。由此，树脂4成为纤维强化树脂中空成形体的基体树脂。
图7是表示本发明的一个实施方式的中空成形体的制造中使用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(图7中只记载1个，其它的被省略)引出碳纤维长丝组(丝束)8，通过经过开纤辊21a-21j之间，使碳纤维长丝组8开纤(辊开纤工序23)。也可以替代辊开纤而规定为空气开纤。开纤辊可以固定或旋转，也可以在宽度方向振动。
在开纤工序后，将开纤了的丝束夹在夹持辊9a、9间，使其通过设置在此之间的多个搭桥辊12a-12b间，通过按例如每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，从而产生搭桥纤维(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。搭桥辊例如为表面具有皱纹、凹凸或镜面的多个辊，相对于碳纤维长丝组以弯曲状态配置搭桥辊，通过使搭桥辊固定、旋转、在宽度方向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，然后进行冷却，卷起在卷起辊20上(粉体树脂赋予工序25)。干粉树脂15、18例如设定为聚丙烯树脂(熔点：150～165℃)，加热装置16、19内的各温度例如设定为干粉树脂的熔点、软化点或流动化点的+5～60℃，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。
本发明的优点汇总如下。
(1)树脂一体化碳纤维片与预浸渗材料不同，因是半浸渗材料而能够直接成形。因此，即使不进行成形前的软化及使软化了的材料向成形模具中的移动，也能进行中空成形体的成形。此外，可大致同时进行对树脂一体化碳纤维片的赋形和热塑性树脂向纤维基体材料全体中的浸渗。
(2)树脂一体化碳纤维片与预浸渗材料不同，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热熔合，因而向纤维间的浸渗性好。也就是说，与薄膜状的树脂不同，中空成形体的成形时排气性优异，气孔难产生。
(4)纤维一体化树脂片的纤维的主成分例如如碳纤维那样为连续纤维(不是短纤维)。因此，可得到薄而强度高的中空成形体。
(5)通过以下的比较得知，本发明中由于采用半浸渗材料，所以能够减小相对于树脂的热经历。由此，能够防止树脂的劣化。
·预浸渗材料：片材制成时长时间+预加热时(预浸渗材料的软化)+成形时+热固化时
·半浸渗材料：片材制成时短时间+只在成形时加热
如以上，半浸渗材料能够使成形时间变得高速。
(6)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(模的复制性)差。本发明因是直接成形而成形品表面的平滑性好。
(7)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(不能成形较薄的成形品)。本发明因可直接成形而在预加热后不需要成形前的基体材料(预浸渗材料)的向成形模的移动替换。因此，还能够制造较薄的中空成形体。
实施例
以下，通过实施例对本发明进行具体的说明。再者，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日本三菱化学公司制造的型号：PYROFILE TR50S15L、形状：标准丝束长丝15K(15000本)、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7的开纤手段进行开纤(开纤工序)。在开纤工序中，将碳纤维长丝组(丝束)的张力设定为每15000根为15N。如此形成碳纤维长丝构成根数15K、开纤宽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1m 2平均单面赋予28.2g、两面赋予56.4g。加热装置16、19内的温度各设定为220℃，滞留时间各设定为8秒(粉体树脂赋予工序)。所得到的树脂一体化纤维片的质量为132.4g/m 2，厚度为0.2mm，纤维体积(Vf)为40体积％，热塑性树脂为60体积％。
(4)层叠条件
·树脂一体化纤维片的层叠片数：2片(搭接部为4片程度、搭接部的宽度为53.9mm)
·树脂一体化纤维片的纤维方向：二方向(在直行方向层叠)、0°/90°(外侧为90°)
(5)中空成形
通过图4所示的装置，按以下条件实施了中空成形。
·模具温度200℃
·空气压0.6MPa
·加热成形时间3分钟
·水冷却时间5分钟
冷却后切断空气管道，使中空成形体脱模。
(实施例2)
除了将层叠条件规定为下述，将加热成形时间设定为5分钟以外，与实施例1同样地进行了实验。
·树脂一体化纤维片的层叠片数：4片(搭接部为8片程度、搭接部的宽度为53.1mm)
·树脂一体化纤维片的纤维方向：二方向(在直行方向层叠)、0°/90°/0°/90°(外侧为90°)
(评价)
测定了实施例1、2的中空成形体(管)的尺寸。采用卡尺测定了直径(外径)及长度，采用千分尺测定了厚度。关于厚度，分别在5点进行了测定，取其平均值。表1中示出了结果。
表1
Figure BDA0003699528650000141
此外，对实施例1及2的中空成形体进行了在直径方向的压缩试验。压缩试验采用自动绘图仪(日本岛津制作所公司制造的型式：AG-50kNXplus)，通过使φ50mm的圆盘与中空成形体(端部或中央部)接触来进行。实施例1中进行了行程2.5mm及5.0mm的压缩，实施例2中进行了行程2.5mm的压缩，但是实施例1及2的中空成形体没有发生断裂及变形。表2及图8～9中示出压缩试验的结果。图8是实施例1的中空成形体的端部及中央部上的试验力-变位测定坐标图，图9是实施例2的中空成形体的端部及中央部上的试验力-变位测定坐标图。图8～9中，a表示中空成形体的端部的测定结果，b表示中空成形体的中央部的测定结果。
表2
Figure BDA0003699528650000142
如上所示，得知实施例1及2的中空成形体，具有充分的实用性能。
工业上的可利用性
本发明的中空成形体为管、轴、框架等，可以是截面为圆形中空、四方形中空、其它多种形状的中空体。本发明能够广泛地应用于建筑构件、体育用品、风车、自行车、汽车、铁道、船舶、航空、宇宙等一般工业用途等中。

Claims (15)

1.一种纤维增强树脂中空成形体，其特征在于：是使用了树脂一体化纤维片的纤维增强树脂中空成形体，
所述树脂一体化纤维片含有由连续纤维组开纤的、且并列状排列在一个方向上的单方向连续纤维；和存在于所述单方向连续纤维的至少表面上的热塑性树脂；
所述中空成形体中，所述树脂一体化纤维片以1片或多片层叠的状态以产生搭接部的方式卷绕，通过使所述热塑性树脂浸渗在所述单方向连续纤维内，使所述树脂一体化纤维片一体化。
2.根据权利要求1所述的纤维增强树脂中空成形体，其中，所述多片层叠的树脂一体化纤维片以单方向连续纤维的方向性不同的方式进行层叠。
3.根据权利要求1或2所述的纤维增强树脂中空成形体，其中，所述树脂一体化纤维片以层叠1片或多片的状态至少卷绕两圈以上。
4.根据权利要求1～3中任一项所述的纤维增强树脂中空成形体，其中，所述树脂一体化纤维片含有与所述单方向连续纤维交错的方向的搭桥纤维，且所述热塑性树脂使所述单方向连续纤维与所述搭桥纤维一体化。
5.根据权利要求1～4中任一项所述的纤维增强树脂中空成形体，其中，所述中空成形体通过从中空部向外侧膨胀的流体而成形。
6.根据权利要求1～5中任一项所述的纤维增强树脂中空成形体，其中，所述纤维增强树脂中空成形体的制造中所使用的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热熔合在所述单方向连续纤维的表面上而成的半浸渗材料。
7.根据权利要求4所述的纤维增强树脂中空成形体，其中，在将所述单方向连续纤维和所述搭桥纤维的合计设定为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％。
8.根据权利要求1～7中任一项所述的纤维增强树脂中空成形体，其中，所述树脂一体化纤维片的厚度为0.01～5.0mm。
9.根据权利要求1～8中任一项所述的纤维增强树脂中空成形体，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。
10.一种纤维增强树脂中空成形体的制造方法，其中，
采用含有由连续纤维组开纤的、且并列状排列在一个方向的单方向连续纤维和存在于所述单方向连续纤维的至少表面上的热塑性树脂的树脂一体化纤维片；
在弹性体的表面上，将所述树脂一体化纤维片以1片或多片层叠的状态、以产生搭接部的方式卷绕；
将缠卷了所述树脂一体化纤维片的所述弹性体配置在具有中空形状的加热模具内；
通过向所述弹性体的内部供给压力流体来进行压空成形，使所述热塑性树脂熔化，使所述热塑性树脂浸渗在所述单方向连续纤维中，以及使所述树脂一体化纤维片一体化。
11.根据权利要求10所述的纤维增强树脂中空成形体的制造方法，其中，所述树脂一体化纤维片为多片，将所述多片树脂一体化纤维片以单方向连续纤维的方向性不同的方式层叠并卷绕。
12.根据权利要求10或11所述的纤维增强树脂中空成形体的制造方法，其中，所述纤维增强树脂中空成形体的制造中所使用的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热熔合在所述单方向连续纤维的表面上而成的半浸渗材料。
13.根据权利要求10～12中任一项所述的纤维增强树脂中空成形体的制造方法，其中，所述纤维增强树脂中空成形体的制造中所使用的所述树脂一体化纤维片含有与所述单方向连续纤维交错的方向的搭桥纤维，且所述热塑性树脂使所述单方向连续纤维与所述搭桥纤维一体化。
14.根据权利要求13所述的纤维增强树脂中空成形体的制造方法，其中，在将所述单方向连续纤维和所述搭桥纤维的合计设定为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％。
15.根据权利要求10～14中任一项所述的纤维增强树脂中空成形体的制造方法，其中，所述树脂一体化纤维片的厚度为0.01～5.0mm。
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