JP6839193B2 - 繊維強化複合材を製造するための樹脂注入法 - Google Patents
繊維強化複合材を製造するための樹脂注入法 Download PDFInfo
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- JP6839193B2 JP6839193B2 JP2018531494A JP2018531494A JP6839193B2 JP 6839193 B2 JP6839193 B2 JP 6839193B2 JP 2018531494 A JP2018531494 A JP 2018531494A JP 2018531494 A JP2018531494 A JP 2018531494A JP 6839193 B2 JP6839193 B2 JP 6839193B2
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/36—Means for plasticising or homogenising the moulding material or forcing it through the nozzle or die
- B29C48/375—Plasticisers, homogenisers or feeders comprising two or more stages
- B29C48/388—Plasticisers, homogenisers or feeders comprising two or more stages using a screw extruder and a ram or piston
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/78—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling
- B29C48/875—Thermal treatment of the extrusion moulding material or of preformed parts or layers, e.g. by heating or cooling for achieving a non-uniform temperature distribution, e.g. using barrels having both cooling and heating zones
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2027/00—Use of polyvinylhalogenides or derivatives thereof as moulding material
- B29K2027/12—Use of polyvinylhalogenides or derivatives thereof as moulding material containing fluorine
- B29K2027/18—PTFE, i.e. polytetrafluorethene, e.g. ePTFE, i.e. expanded polytetrafluorethene
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2063/00—Use of EP, i.e. epoxy resins or derivatives thereof, as moulding material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/0005—Condition, form or state of moulded material or of the material to be shaped containing compounding ingredients
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- Chemical & Material Sciences (AREA)
- Composite Materials (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Reinforced Plastic Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
- Extrusion Moulding Of Plastics Or The Like (AREA)
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Description
(a)供給原料として冷凍樹脂のブロックの形態の硬化性樹脂組成物を提供する工程であって、冷凍樹脂のブロックが、繊維予備成形物を完全に注入するために十分な樹脂組成物の量を提供する工程と、
(b)冷凍樹脂のブロックを加熱押出機の入口孔に結合する工程と、
(c)冷凍樹脂のブロックを入口孔において徐々に溶融すると同時に、溶融した樹脂を、押出機を通って供給して樹脂注入のために適した粘度を有する液体樹脂を製造する工程と、
(d)繊維予備成形物を保有する型に、押出機から液体樹脂を連続的に供給する工程と、
(e)液体樹脂を繊維予備成形物中に導入する工程を包含する。
本明細書に開示される樹脂注入法における繊維予備成形物は、樹脂注入または射出によって液体樹脂を受容するために構成され、すなわち、それは液体樹脂に対して透過性である。予備成形物は、連続した、一方向に整列された(または「一方向性」)繊維またはトウ、織布、不織布ベールまたはマット、多軸布(例えば非けん縮布またはNCF)、またはそれらの組合せの形態であってもよい、乾燥強化繊維の集成体からなる。連続したトウは、複数繊維フィラメント、例えば、3000〜24,000フィラメントから構成される。集成体は、積層配置においてレイアップされた乾燥強化繊維の層を含んでもよい。
本明細書に開示される樹脂注入またはRTMプロセスのための硬化性樹脂組成物は、1つまたは複数の熱硬化樹脂と少なくとも1つの硬化剤を含有する。さらに、硬化性樹脂組成物は熱硬化性である。樹脂組成物は、180℃未満、より具体的には、約80℃〜約130℃の範囲の温度で粘度が5ポアズ未満であるように調合される。また、樹脂組成物は、サブミクロン粒度の強化用粒子を含有してもよく、しかしながら、粒子があまり小さくないなら、粒子は、予備成形物中の繊維によって効果的に濾過されて除去され、粒子の不均一な分布をもたらし、いくつかの場合、型をさらなる樹脂注入から完全に阻む。このように、存在しているとき、強化用粒子は800nm以下、例えば、約2nm〜約800nm、または約50nm〜約200nmの範囲の粒度を有する。
Claims (17)
- (a)冷凍樹脂のブロックの形態の硬化性樹脂組成物を提供する工程と、
(b)加熱バレル内に収容される少なくとも1つの回転スクリューを含む、加熱押出機の入口孔に冷凍樹脂の前記ブロックを結合する工程と、
(c)冷凍樹脂の前記ブロックを前記入口孔において徐々に溶融すると同時に、溶融した樹脂を、前記加熱バレルを通して供給し、樹脂注入のために適した粘度を有する液体樹脂を製造する工程と、
(d)繊維予備成形物を保有する型に、前記押出機から出る前記液体樹脂を連続的に供給する工程と、
(e)前記液体樹脂を前記繊維予備成形物中に導入する工程と、を含む樹脂注入法であって、
冷凍樹脂の前記ブロックが、繊維予備成形物全体を注入するために十分な樹脂組成物の量を提供する、樹脂注入法。 - 冷凍樹脂の前記ブロックが、工程(a)の前に再利用可能なケーシング内に貯蔵され、前記ケーシングが管状壁、トップキャップおよびボトムキャップを含み、
前記トップキャップおよびボトムキャップが、冷凍樹脂の前記ブロックを前記加熱押出機の前記入口孔に結合する前に前記管状壁から除去される、請求項1に記載の方法。 - 前記再利用可能なケーシングの前記管状壁が、冷凍樹脂の前記ブロックが滑り出すことができるようにする低摩擦材料から製造される、請求項2に記載の方法。
- 前記低摩擦材料がポリテトラフルオロエチレンである、請求項3に記載の方法。
- (b)において、冷凍樹脂の前記ブロックが、前記押出機の前記入口孔に機械的に接続されている受け器内に置かれて、冷凍樹脂の前記ブロックの一方の端部が、前記押出機の前記入口孔内にあり、圧力が冷凍樹脂の前記ブロックの反対側の端部に適用されてそれが溶融するときに前記冷凍樹脂を前記受け器から移動させるようにする、請求項1〜3のいずれか一項に記載の方法。
- 冷凍樹脂の前記ブロックが円筒形状を有し、前記受け器が、冷凍樹脂の前記ブロックの前記円筒形状を収容する管状または円筒壁を有する、請求項5に記載の方法。
- 圧力が、機械的または油圧で駆動されるピストンによって冷凍樹脂の前記ブロックの前記反対側の端部に適用される、請求項5または6に記載の方法。
- 前記押出機が、前記バレルの長さに沿って複数の加熱領域をさらに含む、請求項1〜7のいずれか一項に記載の方法。
- 前記押出機の前記加熱領域が、30℃〜300℃の範囲の温度勾配を生成するために設定される、請求項8に記載の方法。
- 前記押出機を出る前記液体樹脂が、80℃〜130℃の範囲の温度において5ポアズ未満の粘度を有する、請求項1〜9のいずれか一項に記載の方法。
- (a)においての前記硬化性樹脂組成物が、1つまたは複数の熱硬化樹脂と硬化剤を含む、請求項1〜10のいずれか一項に記載の方法。
- (a)においての前記硬化性樹脂組成物が、1つまたは複数のエポキシ樹脂とアミン硬化剤を含む、請求項11に記載の方法。
- 前記繊維予備成形物が、積層配置においてレイアップされる強化繊維の複数の層を含む、請求項1〜12のいずれか一項に記載の方法。
- 圧力が、冷凍樹脂の前記ブロックの前記反対側の端部に消耗ピストンによって適用され、それが、前記冷凍樹脂が溶融するときに前記冷凍樹脂を前記受け器から移動させる請求項5または6に記載の方法であって、
前記消耗ピストンが、前記押出機の前記バレルを通って押出され得る非反応性押出可能ポリマーから製造され、前記冷凍樹脂の全てが移動させられたときに前記冷凍樹脂によって占められたスペースを充填するように大きさを定められる、方法。 - 前記消耗ピストンが、周囲温度(20℃〜25℃)および圧力(1気圧)において実質的に硬質であるが加熱されるときに変形するかまたは半液体状態を形成し得る押出可能ポリマーから形成される、請求項14に記載の方法。
- 前記消耗ピストンがポリプロピレンから形成される、請求項15に記載の方法。
- 樹脂注入した予備成形物を形成する請求項1〜16のいずれか一項に記載の樹脂注入法と、その後に、
前記樹脂注入した予備成形物を硬化して固化複合構造物を形成する工程を含む、複合構造物を製造するための方法。
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US201562267947P | 2015-12-16 | 2015-12-16 | |
US62/267,947 | 2015-12-16 | ||
PCT/US2016/067011 WO2017106550A1 (en) | 2015-12-16 | 2016-12-15 | Resin infusion process for manufacturing fiber-reinforced composites |
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RU2686919C1 (ru) * | 2018-07-02 | 2019-05-06 | Акционерное общество "Препрег-Современные Композиционные Материалы" (АО "Препрег-СКМ") | Эпоксидное клеевое связующее, пленочный клей и клеевой препрег на его основе |
WO2020144625A1 (en) * | 2019-01-11 | 2020-07-16 | Air Design, S.A. De C.V. | Carbon fiber shell having elastomer inner overmold, and method to fabricate a carbon fiber shell having elastomer inner overmold |
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