JP2020525586A - 強化用繊維及び形状記憶合金ワイヤを含む製品及びその製造方法 - Google Patents
強化用繊維及び形状記憶合金ワイヤを含む製品及びその製造方法 Download PDFInfo
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- JP2020525586A JP2020525586A JP2019571448A JP2019571448A JP2020525586A JP 2020525586 A JP2020525586 A JP 2020525586A JP 2019571448 A JP2019571448 A JP 2019571448A JP 2019571448 A JP2019571448 A JP 2019571448A JP 2020525586 A JP2020525586 A JP 2020525586A
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- preform
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- woven
- reinforcing fibers
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Classifications
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Abstract
Description
・良好な耐衝撃性、
・良好な貫通抵抗、
・良好な層内特性(例えば、良好な層内剪断強度)、
・複雑な3D構造体を単一部品(例えば、T及びX形物)でかつ単一プロセス(例えば、厚さを増大するための層状化が不要である)でニアネットシェイプの状態で製作することができること、
・良好な曲げ弾性率、
・良好な圧縮強度、
・例えば、樹脂注入時間を減少させることができる高い多孔質、
・強化用繊維又はSMAワイヤのクリンプ加工の減少。
本明細書において説明する3Dプリフォームは、強化用繊維及びSMAワイヤを含む。「3Dプリフォーム」という用語は、任意の一体形三次元構造体を意味している。3Dプリフォームは、未硬化ポリマーマトリックス内に埋め込まれても良く、ポリマーマトリックス内に埋め込まれるのに適しているが、依然としてポリマーマトリックスと接触状態にはなくても良い。3Dプリフォームは、3つの相互に垂直な平面関係に配置された多数の繊維(例えば、繊維のトウ(tow))を含むのが良い。3Dプリフォームは、X(長手方向)及びY(横断方向)繊維がZ(垂直方向)繊維と結び付けられる(例えば、撚り合わされ、交絡され又は絡み合わされる)よう第3の寸法を有する布であるのが良い。Z方向繊維は、X/Yの2D平面以外の任意の方向に位置決めされるのが良い。
強化用繊維は、繊維強化ポリマー(FRP)複合材で用いられる通常の(非SMA)形式のうちの任意のものであって良い。ある特定の実施形態では、強化用繊維は、50GPaを超える引張り弾性率を有する。ある特定の実施形態では、強化用繊維は、約60GPa以上、約80GPa以上、約100GPa以上、約120GPa以上、約140GPa以上、約150GPa以上、約160GPa以上又は約180GPa以上の引張り弾性率を有する。ある特定の実施形態では、強化用繊維は、200GPaを超える引張り弾性率を有する。引張り弾性率は、例えば、ASTM・D3379により測定されるのが良い。
SMAワイヤは、本明細書においてはSMA繊維と言う場合がある。明細書が一般に各層中の繊維に言及する場合、これは、強化用繊維又はSMAワイヤを含む場合がある。
本発明の構造体中のマトリックス材料は、FRP複合材で用いられている通常の形式のうちの任意のものであって良い。例えば、マトリックス材料は、熱硬化性樹脂又は熱可塑性樹脂であるのが良く、ただし、熱硬化性樹脂は、これらの処理温度が低いので現在においては好ましく、処理温度が低いことは、混ぜ込まれるSMAの変態温度に対する制約が少ないことを示唆している。
また、本明細書では、本明細書に開示した任意の観点又は実施形態に係る複合材料を製造する方法が提供される。さらに、本明細書においては、本明細書に開示した任意の観点又は実施形態に係る3Dプリフォームを製造する方法が提供される。
また、製造品を作るために本明細書において開示した任意の観点又は実施形態に係る複合材料及び/又は3Dプリフォームの使用が提供される。また、本明細書において開示する複合材料及び/又は3Dプリフォームから作られ又はこれらを有する製造品が提供される。
ある特定の実施形態では、3Dプリフォームは、強化用繊維、SMAワイヤ又はこれらの組み合わせの非交絡層から成り、これらの層は、層の全てを横切るタフティングされ又はステッチングされたフィラメントによって互いに結合される。タフティングされたフィラメントは、強化用繊維、SMAワイヤ又はこれらの組み合わせである。ある特定の実施形態では、非交絡層は、ノンクリンプ布を形成するよう安定化繊維又は糸を含む。ある特定の実施形態では、安定化繊維又は糸は、ポリエステルである。SMAワイヤは、例えば、Ti‐Ni合金であるのが良い。
Claims (30)
- 複合材料であって、三次元(3D)プリフォームが埋め込まれたポリマーマトリックスを含み、前記3Dプリフォームは、強化用繊維及び形状記憶合金(SMA)ワイヤを有する、複合材料。
- 前記3Dプリフォームは、各々が別個独立に、強化用繊維、SMAワイヤ又はこれらの組み合わせを有する2つ又は3つ以上の層を含み、前記層は、互いの上に積み重ねられるとともに前記層のうちの2つ又は3つ以上を横切る1本又は2本以上のフィラメントによって互いに結合されている、請求項1記載の複合材料。
- 前記3Dプリフォームは、強化用繊維及びSMAワイヤの組み合わせトウを含む、請求項1又は2記載の複合材料。
- 前記層のうち2つ又は3つ以上を横切る前記フィラメントのうちの1本又は2本以上は、強化用繊維、SMAワイヤ又はこれらの組み合わせである、請求項2又は3記載の複合材料。
- 前記層の各々は、別個独立に交絡されておらず(例えば、ノンクリンプ布又はノンクリンプ織布)、織成され、組成され、又は編成されている、請求項2〜4のうちいずれか一に記載の複合材料。
- 前記2つ又は3つ以上の層を横切る前記フィラメントのうちの1本又は2本以上は、織成され、ステッチングされ、タフティングされ又はzピンニングされている、請求項2〜5のうちいずれか一に記載の複合材料。
- 前記3Dプリフォームは、直交三次元織成プリフォーム、アングルインターロック三次元織成プリフォーム又は層間三次元織成プリフォームである、請求項1〜6のうちいずれか一に記載の複合材料。
- 前記3Dプリフォームは、完全交絡織成プリフォーム、完全組成プリフォーム又は完全編成プリフォームである、請求項1記載の複合材料。
- 前記SMAワイヤは、各々が別個独立に、所定の動作温度又は該所定動作温度範囲で構造体の耐衝撃性又は貫通抵抗を実質的に高める組成及び比率のものである、請求項1〜8のうちいずれか一に記載の複合材料。
- 各SMAは、別個独立に、Ti‐Ni、Ti‐Ni‐Cu、Ti‐Ni‐Nb、Ti‐Ni‐Hf、Cu‐Zn‐Al、Cu‐Al‐Ni、Cu‐Al‐Zn‐Mn、Cu‐Al‐Ni‐Mn、Cu‐Al‐Mn‐Ni、Fe‐Mn‐Si、Fe‐Cr‐Ni‐Mn‐Si‐Co、Fe‐Ni‐Mn、Fe‐Ni‐C及びFe‐Ni‐Co‐Ti合金から成る群から選択される、請求項1〜9のうちいずれか一に記載の複合材料。
- 前記複合材料中の前記SMAワイヤの体積分率は、約2%から約25%までの範囲にある、請求項1〜10のうちいずれか一に記載の複合材料。
- 前記SMAワイヤは、各々が別個独立に、第1の方向において前記第1の方向に垂直な第2の方向よりも実質的に長い断面を有しかつ前記長い方の寸法が前記層の平面に全体として平行であるように前記3Dプリフォーム中に位置決めされている、請求項2〜7又は請求項9〜11のうちいずれか一に記載の複合材料。
- 前記強化用繊維は、各々が別個独立に、50GPaを超え、例えば、200GPaを超える引張り弾性率を有する、請求項1〜12のうちいずれか一に記載の複合材料。
- 前記強化用繊維は、各々が別個独立に、炭素繊維、ガラス繊維、アラミド繊維、ポリエチレン繊維及び硼素繊維から選択される、請求項1〜13のうちいずれか一に記載の複合材料。
- 前記三次元(3D)プリフォームであって、強化用繊維及び形状記憶合金(SMA)ワイヤを含む、3Dプリフォーム。
- 前記3Dプリフォームは、各々が別個独立に強化用繊維、SMAワイヤ又はこれらの組み合わせを有する2つ又は3つ以上の層を含み、前記層は、互いの上に積み重ねられるとともに前記層のうちの2つ又は3つ以上を横切る1本又は2本以上のフィラメントによって互いに結合されている、請求項15記載の3Dプリフォーム。
- 前記3Dプリフォームは、強化用繊維及びSMAワイヤの組み合わせトウを含む、請求項15又は16記載の3Dプリフォーム。
- 前記層のうち2つ又は3つ以上を横切る前記フィラメントのうちの1本又は2本以上は、強化用繊維、SMAワイヤ又はこれらの組み合わせである、請求項16又は17記載の3Dプリフォーム。
- 前記層の各々は、別個独立に交絡されておらず(例えば、ノンクリンプ布又はノンクリンプ織布)、織成され、組成され、又は編成されている、請求項16〜18のうちいずれか一に記載の3Dプリフォーム。
- 前記2つ又は3つ以上の層を横切る前記フィラメントのうちの1本又は2本以上は、織成され、ステッチングされ、タフティングされ、zピンニングされ又はこれらの組み合わせが行われている、請求項16〜19のうちいずれか一に記載の3Dプリフォーム。
- 前記3Dプリフォームは、直交三次元織成プリフォーム、アングルインターロック三次元織成プリフォーム又は層間三次元織成プリフォームである、請求項16〜20のうちいずれか一に記載の3Dプリフォーム。
- 前記3Dプリフォームは、完全交絡織成プリフォーム、完全組成プリフォーム又は完全編成プリフォームである、請求項15記載の3Dプリフォーム。
- 前記SMAワイヤは、各々が別個独立に、所定の動作温度又は該所定動作温度範囲で構造体の耐衝撃性又は貫通抵抗を実質的に高める組成及び比率のものである、請求項15〜22のうちいずれか一に記載の3Dプリフォーム。
- 前記SMAは、Ti‐Ni、Ti‐Ni‐Cu、Ti‐Ni‐Nb、Ti‐Ni‐Hf、Cu‐Zn‐Al、Cu‐Al‐Ni、Cu‐Al‐Zn‐Mn、Cu‐Al‐Ni‐Mn、Cu‐Al‐Mn‐Ni、Fe‐Mn‐Si、Fe‐Cr‐Ni‐Mn‐Si‐Co、Fe‐Ni‐Mn、Fe‐Ni‐C及びFe‐Ni‐Co‐Ti合金から成る群から選択される、請求項15〜23のうちいずれか一に記載の3Dプリフォーム。
- 前記複合材料中の前記SMAワイヤの体積分率は、約2%から約25%までの範囲にある、請求項15〜24のうちいずれか一に記載の3Dプリフォーム。
- 前記SMAワイヤは、各々が別個独立に、第1の方向において前記第1の方向に垂直な第2の方向よりも実質的に長い断面を有しかつ前記長い方の寸法が前記層の平面に全体として平行であるように前記3Dプリフォーム中に位置決めされている、請求項15〜21又は請求項23〜25のうちいずれか一に記載の3Dプリフォーム。
- 前記強化用繊維は各々、別個独立に、50GPaを超え、例えば、200GPaを超える引張り弾性率を有する、請求項15〜26のうちいずれか一に記載の3Dプリフォーム。
- 前記強化用繊維は、各々が別個独立に、炭素繊維、ガラス繊維、アラミド繊維、ポリエチレン繊維及び硼素繊維から選択される、請求項15〜27のうちいずれか一に記載の3Dプリフォーム。
- 請求項1〜14のうちいずれか一に記載の複合材料を製造する方法であって、前記方法は、3Dプリフォームを形成するステップと、ポリマーマトリックスを前記3Dプリフォームに塗布するステップと、前記3Dプリフォームが埋め込まれた前記ポリマーマトリックスを硬化させるステップとを含む、方法。
- 請求項15〜28のうちいずれか一に記載の3Dプリフォームを製造する方法であって、前記方法は、前記強化用繊維及び前記SMAワイヤを用意するステップと、織成、組成、編成、ステッチング、タフティング及びzピンニングのうちの1つ又は2つ以上によって3Dプリフォームを作製するステップとを含む、方法。
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