KR20040060017A - Method for manufacturing the preform of high temperature refractory, using needle-punching process - Google Patents
Method for manufacturing the preform of high temperature refractory, using needle-punching process Download PDFInfo
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- KR20040060017A KR20040060017A KR1020020086529A KR20020086529A KR20040060017A KR 20040060017 A KR20040060017 A KR 20040060017A KR 1020020086529 A KR1020020086529 A KR 1020020086529A KR 20020086529 A KR20020086529 A KR 20020086529A KR 20040060017 A KR20040060017 A KR 20040060017A
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- preform
- fabric
- needle
- strength
- needle punching
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- 238000004080 punching Methods 0.000 title claims abstract description 59
- 238000000034 method Methods 0.000 title claims description 35
- 238000004519 manufacturing process Methods 0.000 title claims description 33
- 239000000835 fiber Substances 0.000 claims abstract description 75
- 239000004744 fabric Substances 0.000 claims abstract description 65
- 239000002131 composite material Substances 0.000 claims abstract description 33
- 229920002239 polyacrylonitrile Polymers 0.000 claims description 31
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 23
- 239000004917 carbon fiber Substances 0.000 claims description 23
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 13
- 239000000919 ceramic Substances 0.000 claims description 5
- 239000002759 woven fabric Substances 0.000 claims description 4
- 239000010410 layer Substances 0.000 abstract description 66
- 239000011229 interlayer Substances 0.000 abstract description 4
- 238000010030 laminating Methods 0.000 abstract description 3
- 238000002360 preparation method Methods 0.000 abstract 2
- 239000000463 material Substances 0.000 description 9
- 238000010438 heat treatment Methods 0.000 description 5
- 229910052580 B4C Inorganic materials 0.000 description 3
- 229910052581 Si3N4 Inorganic materials 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 3
- 238000003763 carbonization Methods 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 239000002657 fibrous material Substances 0.000 description 3
- 239000002243 precursor Substances 0.000 description 3
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 3
- 238000009941 weaving Methods 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 239000004372 Polyvinyl alcohol Substances 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- CREMABGTGYGIQB-UHFFFAOYSA-N carbon carbon Chemical compound C.C CREMABGTGYGIQB-UHFFFAOYSA-N 0.000 description 2
- 239000011203 carbon fibre reinforced carbon Substances 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000009970 fire resistant effect Effects 0.000 description 2
- 238000005087 graphitization Methods 0.000 description 2
- 238000003780 insertion Methods 0.000 description 2
- 230000037431 insertion Effects 0.000 description 2
- 229920002451 polyvinyl alcohol Polymers 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 238000000197 pyrolysis Methods 0.000 description 2
- 239000012779 reinforcing material Substances 0.000 description 2
- 229920002994 synthetic fiber Polymers 0.000 description 2
- 239000004753 textile Substances 0.000 description 2
- NLHHRLWOUZZQLW-UHFFFAOYSA-N Acrylonitrile Chemical compound C=CC#N NLHHRLWOUZZQLW-UHFFFAOYSA-N 0.000 description 1
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 238000003491 array Methods 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 238000009954 braiding Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000000280 densification Methods 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 239000013305 flexible fiber Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 238000009940 knitting Methods 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 238000010526 radical polymerization reaction Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000011208 reinforced composite material Substances 0.000 description 1
- 230000002787 reinforcement Effects 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/06—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer characterised by a fibrous or filamentary layer mechanically connected, e.g. by needling to another layer, e.g. of fibres, of paper
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/024—Woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0246—Acrylic resin fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/10—Inorganic fibres
- B32B2262/105—Ceramic fibres
Landscapes
- Engineering & Computer Science (AREA)
- Textile Engineering (AREA)
- Nonwoven Fabrics (AREA)
- Woven Fabrics (AREA)
Abstract
Description
본 발명은 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 관한 것으로서, 보다 상세하게는 니들펀칭 기술을 이용하여 평면으로 다층 배열된 섬유의 일부를 두께방향으로 배열함으로써 각 층간 결속력을 증대시킬 수 있는 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 관한 것이다.The present invention relates to a method for manufacturing a preform for high-temperature composites using needle punching, and more particularly, a needle that can increase the binding force between layers by arranging a part of fibers arranged in a plane in the thickness direction by using a needle punching technique. It relates to a method for producing a preform for a high temperature composite using punching.
일반적으로, 복합재 제조에 이용되는 프리폼(Preform)이란 섬유상의 강화재료를 일정형태로 형상화한 것으로서, 일정형태로 형상화한 다음 기지재료를 프리폼의 공극으로 증착하거나 침투시키어 최종적으로 복합재료를 제조하기 위한 것이다.In general, a preform used in the manufacture of a composite material is a shape of a fibrous reinforcement material in a shape, and the shape is formed in a shape, and then the base material is deposited or penetrated into the pores of the preform to finally manufacture the composite material. will be.
고온용 복합재를 제조하기 위한 내화성(Refractory) 섬유는 탄소섬유 및 세라믹계 섬유이다.Refractory fibers for producing high temperature composites are carbon fibers and ceramic fibers.
상기 세라믹계 섬유로는 탄화물계(Carbide) 섬유, 질화물계(Nitride) 섬유 또는 산화물계(Oxide) 섬유 등이 있으며, 그 예로는 실리콘 나이트라이드(Silicon Nitride; Si3N4), 보론 카바이드(Born Carbide; BN), 알루미나(Alumina; Al2O3) 등이 있다.The ceramic fibers include carbide fibers, nitride fibers or oxide fibers, and examples thereof include silicon nitride (Si3N4) and boron carbide (BN). ), Alumina (Alumina; Al 2 O 3), and the like.
내화성 섬유의 전단계 재료(Precursor)는 열처리에 의한 내화상태 이전의 섬유로서, 탄소섬유의 대표적인 전단계 재료로는 폴리아크릴로니트릴(Polyacrylonitrile; PAN)이 있다.Precursor of the refractory fiber (precursor) is a fiber before the refractory state by heat treatment, a typical pre-stage material of the carbon fiber is polyacrylonitrile (PAN).
상기 PAN은 분자식이 CH2=CHCN인 아크릴로니트릴을 라디칼(Radical) 중합시켜 얻는 비닐중합체로서, 주용도는 아크릴계 합성섬유에 이용되며, 연화점(軟化點)이 300℃ 이상이고, 제조된 그대로 섬유재료로 사용하는 경우는 없고, 고온처리하여 이용하고 있으며, 탄소강화 복합재료 분야에서는 고온 탄화처리된 PAN을 펠트(Felt) 또는 섬유직물상으로 제작하여 복합체의 강화재료로 이용하고 있으며, 연성을 주기 위하여 산화된 oxi-PAN(Oxidized Polyacrylonitrile)를 이용하고 있다.The PAN is a vinyl polymer obtained by radical polymerization of acrylonitrile having a molecular formula of CH 2 = CHCN, and its main purpose is to be used for acrylic synthetic fibers, with a softening point of 300 ° C. or higher, and as a manufactured fiber material. It is not used, but it is used by high temperature treatment. In the field of carbon-reinforced composite materials, high temperature carbonized PAN is made of felt or fiber fabric and used as reinforcing material of composites. Oxi-PAN (Oxidized Polyacrylonitrile) is used.
펠트(Felt) 조직이란 섬유상이 서로 얽혀서 축융되는 성질을 이용하여 비벼서 일정한 두께로 굳어지게 한 것으로서, 불규칙배열(Rnadom Chopped) 섬유조직을 일컫는 것이다.Felt (Felt) tissue by using the property that the fibers are entangled with each other and rubbed to harden to a certain thickness, refers to the randomly arranged (Rnadom Chopped) fiber tissue.
내화성 섬유 프리폼의 제조와 관련된 종래 기술은 불규칙배열(Random Chopped)인 펠트조직이나 평직 및 주자직직물인 2차원 섬유배열구조가 대부분이었으며, 이러한 2차원적 구조에서는 평면방향의 기계적 특성은 우수하나 두께방향으로는 섬유가 보강(Reinforcement)되지 않기 때문에 밀도화 공정에서 층과 층 사이가 쉽게 분리되는 취약함을 나타내었다.Conventional techniques related to the manufacture of fire resistant fiber preforms are mostly random chopped felt or two-dimensional fiber arrays of plain and runner fabrics. In the direction, the fibers were not reinforced, indicating a weak separation between layers in the densification process.
상기한 층간 전단강도를 향상시키기 위해서는 두께방향으로 섬유가 보강되어있는 3차원적 섬유배열구조의 프리폼이 필요한데, 3차원적 프리폼 제조로 많이 적용되고 있는 기술로는 유기 바인더(Organic Binder)를 사용한 인발 성형된 봉(Rod)을 3축 혹은 4축 이상으로 입체 구성하여 열분해(Pyrolysis) 처리하는 방법이 있다.In order to improve the interlaminar shear strength, a preform of a three-dimensional fiber array structure in which fibers are reinforced in a thickness direction is required. As a technique that is widely applied in the manufacture of three-dimensional preforms, a drawing using an organic binder is used. There is a method of three-dimensionally forming the formed rod (Rod) in three or four axes or more pyrolysis treatment.
대부분이 수작업으로 이루어지는 이 열분해(Pyrolysis) 처리공정은 제조시간이 길고, 기공이 크게 존재하여 기지재료의 균일한 증착이나 침투가 일어나지 않는단점이 있다.This pyrolysis treatment process, which is mostly made by hand, has a long manufacturing time and large pores, so that uniform deposition or penetration of the base material does not occur.
또한, 연속 섬유다발을 사용하여 완전한 3차원 섬유배열구조의 프리폼을 생산하는 방법으로는 3차원 위빙(3D Weaving), 3차원 브레이딩(3D Braiding) 이나 다층 니팅(Multi-Layer Knitting) 등의 방법이 있으나, 생산성이 낮아 대량 생산하는데 한계가 있다.In addition, a method of producing a preform of a complete three-dimensional fiber array structure using a continuous fiber bundle method, such as 3D weaving, 3D braiding or multi-layer knitting There is, however, low productivity, there is a limit to mass production.
3차원 섬유배열구조를 가지면서 대량생산에 가장 적합한 프리폼을 제조하는 방법은 니들펀칭(Needle Punching) 기술이다. 이 기술은 바늘의 상하운동에 의해 평면상으로 배열된 섬유의 일부를 두께방향으로 배열시키기 위해서 고인성의 oxi-PAN계 탄소섬유로 구성된 펠트(Felt)를 주로 사용하고 있다.Needle Punching is a method of manufacturing a preform that has a three-dimensional fiber array structure and is most suitable for mass production. This technique mainly uses felt made of highly tough oxi-PAN carbon fiber to arrange a part of the fibers arranged in the plane by the vertical movement of the needle in the thickness direction.
펠트는 섬유가 연속적이지 않고 불규칙(Random)하게 배열되어 있기 때문에 니들펀칭에 의하여 두께방향으로 쉽게 섬유가 배열되어 펀칭은 잘되지만 섬유배열의 방향성이 없고 펠트 자체가 부풀러진 상태이므로 밀집시키는데는 한계가 있었다.Since the felt is not continuous but randomly arranged, the felt is easily arranged in the thickness direction by needle punching, so the punching is good, but the orientation of the fiber is not oriented and the felt itself is inflated. there was.
또한, 탄화 전처리단계인 oxi-PAN 섬유는 열처리 흑연화공정에서 20% 이상의 부피수축을 발생하기 때문에 제품치수가 불안정하거나, 생산공정 및 시간이 늘어나는 단점이 있다.In addition, the oxi-PAN fiber, which is a carbonization pretreatment step, has a volume shrinkage of 20% or more in the heat treatment graphitization process, and thus has an unstable product dimension or an increase in production process and time.
이러한 단점을 해결하기 위하여, 흑연화된 고강도 탄소섬유를 사용할 수 있으나, 이 섬유는 취성이 높기 때문에 펀칭에 의하여 섬유가 절단되어 두께방향으로 배열되지 않으므로 탄소섬유를 일정 길이로 절단(Stretch-Breaking)하여 그 주위를 폴리비닐 알코올(PVA) 섬유로 감아(Wrapping) 직조한 직물형태가 있다.In order to solve this drawback, graphitized high strength carbon fibers may be used, but since the fibers are brittle, the fibers are cut by punching so that the fibers are not arranged in the thickness direction, thus cutting the carbon fibers to a predetermined length (Stretch-Breaking). There is a form of woven fabric wrapped around with polyvinyl alcohol (PVA) fibers.
상기와 같은 방법은 고강도 탄소섬유를 사용하므로 흑연화공정이 필요치 않고 균일한 공극을 제공하기 때문에 고품질의 탄소-탄소 복합재를 얻을 수 있으나, 이런 형태의 직물로만 중첩하는 경우 섬유가 절단되어 있기 때문에 기계적 특성이 떨어지는 단점이 있다.Since the above method uses high strength carbon fiber, it does not require graphitization process and provides uniform voids, so that a high quality carbon-carbon composite can be obtained. However, when overlapping only with this type of fabric, the fiber is cut and thus mechanically There is a disadvantage of falling characteristics.
상기한 문제점들을 해결하기 위하여, 본 발명은 열처리 공정이 필요치 않는 평직, 주자직 등과 같은 연속 고강도 탄소섬유직물과, 고인성 탄소섬유직물이나 비연속 고강도 섬유직물을 이용하여 여러 층의 직물이 서로 결속되도록 하는 니들 펀칭함으로써 단위층 자체도 결속이 되며, 중첩된 단위층 사이에도 밀집도와 결속력이 높은 다층 구조를 구성하기 위한 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법을 제공한다.In order to solve the above problems, the present invention is a continuous high-strength carbon fiber fabrics such as plain weave, runner weaving, etc. that do not require a heat treatment process, and a plurality of layers of the fabric is bound to each other using a high toughness carbon fiber fabric or a discontinuous high strength fiber fabric. The unit layer itself is also bound by needle punching to provide a high-temperature composite preform manufacturing method using needle punching to form a multi-layer structure having high density and binding force even between overlapping unit layers.
도 1은 본 발명에 이용되는 니들펀칭 장비의 일례를 도시한 장치 개략도;1 is a device schematic diagram showing an example of a needle punching equipment used in the present invention;
도 2는 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 이용되는 니들의 형상도;Figure 2 is a shape of the needle used in the preform manufacturing method for high temperature composite using needle punching according to the present invention;
도 3은 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 따라 제작되는 프리폼 단위층의 모사도;3 is a schematic view of a preform unit layer manufactured according to the preform manufacturing method for a high temperature composite using needle punching according to the present invention;
도 4는 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 따라 제작된 프리폼 단위층을 적층하는 방법을 도시한 개념도;4 is a conceptual diagram illustrating a method of laminating a preform unit layer manufactured according to a preform manufacturing method for a high temperature composite using needle punching according to the present invention;
도 5는 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 의하여 제조된 프리폼의 형상 사진도이다.Figure 5 is a photograph of the shape of the preform manufactured by the preform manufacturing method for a high temperature composite using needle punching according to the present invention.
♣도면의 주요부분에 대한 부호의 설명♣♣ Explanation of symbols for main part of drawing ♣
10:니들 11:펀칭헤드 12:가이드 평판 20:인발용 롤러10: needle 11: punching head 12: guide plate 20: drawing roller
21:프리폼 30:재료층 31:가이드 롤러 40:바브21: preform 30: material layer 31: guide roller 40: barb
70:제1단위층 71:제2단위층 72:제3단위층70: first unit layer 71: second unit layer 72: third unit layer
상기한 목적을 달성하기 위하여, 본 발명은 고연성 섬유직물 또는 불연속 고강도 섬유직물의 1개층을 최상부에 위치시키고, 연속 고강도 섬유직물의 다수 층을 상기 고연성 섬유직물 또는 불연속 고강도 섬유직물 층의 하부에 위치시킨 다음, 상부에서 다수개의 바브가 형성된 니들을 펀칭하여 프리폼 단위층을 제조하는 단계와; 상기 제조된 프리폼 단위층을 다수 적층시키면서 다시 니들 펀칭하여 결속시키는 단계로 구성되는 특징으로 하는 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법을 제공한다.In order to achieve the above object, the present invention places one layer of a high ductile fabric or a discontinuous high strength fibrous fabric on top, and a plurality of layers of continuous high strength woven fabric is placed at the bottom of the high ductile fabric or the discontinuous high strength fibrous layer. Positioning a plurality of barbs at the top to prepare a preform unit layer; The present invention provides a method for manufacturing a preform for a high temperature composite using needle punching, wherein the preform unit layer is laminated with a plurality of the preform unit layers.
또한, 본 발명은 상기 고연성 섬유직물은 부피%로서 55~65% 탄화된 산화 폴리아크릴로니트릴(oxi-PAN)계 섬유로 제작된 펠트 또는 평직이나 주자직 직물인 것을 특징으로 하는 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법을 제공하게 되며,In addition, the present invention is a needle punching, characterized in that the high ductile fabric is a felt or plain or main fabric fabric made of 55 to 65% carbonized polyacrylonitrile (oxi-PAN) based fibers as the volume% It will provide a preform manufacturing method for high temperature composite using
또한, 본 발명은 상기 불연속 고강도 섬유직물은 부피%로서 99% 이상 탄화된 폴리아크릴로니트릴(PAN)계 탄소섬유를 잡아당겨 절단(Stretch-Broken)한 섬유를 직조한 다축경편 직물(Multiaxial Warp Knit)인 것을 특징으로 하는 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법을 제공하게 되고,In addition, the present invention, the discontinuous high-strength fibrous fabric is a multi% warp knitted fabric weaving a fiber (Stretch-Broken) by pulling the carbonized polyacrylonitrile (PAN) -based carbon fibers in volume% or more (Multiaxial Warp Knit) To provide a method for producing a preform for high-temperature composites using a needle punching, characterized in that
또한, 본 발명은 상기 연속 고강도 섬유직물은 부피%로서 99% 이상 탄화된 폴리아크릴로니트릴(PAN)계 연속 탄소섬유 또는 고강도 세라믹계 섬유를 직조한 평직 또는 주자직물인 것을 특징으로 하는 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법을 제공한다.In addition, the present invention is a needle punching, characterized in that the continuous high-strength fiber fabric is a woven or runner fabric woven from polyacrylonitrile (PAN) -based continuous carbon fibers or high-strength ceramic fibers carbonized more than 99% by volume% It provides a preform manufacturing method for high temperature composite material using.
이하, 본 발명의 구성을 상세하게 설명한다.EMBODIMENT OF THE INVENTION Hereinafter, the structure of this invention is demonstrated in detail.
도 1은 본 발명에 이용되는 니들펀칭 장비의 일례를 도시한 장치 개략도이고, 도 2는 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 이용되는 니들의 형상도이다.1 is a schematic view showing an example of the needle punching equipment used in the present invention, Figure 2 is a shape diagram of the needle used in the method for manufacturing a preform for high temperature composite using the needle punching according to the present invention.
본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법은 종래에 확립된 니들 펀칭(Needle Punching) 기술을 이용하여 섬유층간의 결속을 가능하게 하는 것이다.The method for manufacturing a preform for a high temperature composite using needle punching according to the present invention is to enable binding between fiber layers using a needle punching technique established in the prior art.
즉, 본 발명에 니들펀칭 기술의 원리는 도 1에 도시된 바와 같이, 니들 펀칭하고자 하는 다수의 재료층(30)이 가이드 롤러(31)에 의하여 일방향으로 공급되며,상하왕복 운동하는 펀칭헤드(11)에 고정되어 있는 다수의 니들(10)이 가이드 평판(12)을 통과하여 상기 재료층(30)의 최상층을 통과하게 된다.That is, the principle of the needle punching technique according to the present invention, as shown in Figure 1, the plurality of material layers 30 to be punched needle is supplied in one direction by the guide roller 31, the punching head ( A plurality of needles 10 fixed to 11 pass through the guide plate 12 and pass through the top layer of the material layer 30.
상기 최상층을 통과하는 니들(10)은, 도 2에 도시된 바와 같이, 하향 경사지도록 돌출된 바브(Barb; 40)에 섬유가 걸리어 아래로 내려가고, 상기 니들(10)이 상승할 때에는 상기 바브(40)가 하향 경사지도록 형성되어 있기 때문에 니들(10)만 섬유 재료층(30)으로부터 빠져나오게 됨으로써 섬유 재료층(30)이 두께방향으로 배열된 프리폼(21)으로 제조되어지는 것이다.Needle 10 passing through the top layer, as shown in Figure 2, the bar (40) protruding downwardly obliquely caught the fiber down, when the needle 10 is raised Since the barb 40 is formed to be inclined downward, only the needle 10 is pulled out of the fibrous material layer 30 so that the fibrous material layer 30 is made of the preform 21 arranged in the thickness direction.
상기와 같은 니들펀칭시 제조되는 프리폼(21)을 압축하기 위하여, 가이드 평판(12)이 제공되는 것이며, 원하는 압축력을 니들 펀칭되는 재료층(30)에 가할 수 있다.In order to compress the preform 21 manufactured during needle punching as described above, a guide plate 12 is provided, and a desired compressive force may be applied to the material layer 30 to be needle punched.
또한, 길이방향의 이송은 인발용 롤러(20)에 의하여 이루어지며, 인발속도와 펀칭헤드(11)의 속도 및 펀칭헤드(11)의 니들(10)의 설치밀도를 적절히 조절함으로써 단위면적당 펀칭회수를 제어할 수 있다.In addition, the conveyance in the longitudinal direction is made by the drawing roller 20, by appropriately adjusting the drawing speed, the speed of the punching head 11 and the installation density of the needle 10 of the punching head 11, the number of punches per unit area Can be controlled.
도 3은 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 따라 제작되는 프리폼 단위층의 모사도이고, 도 4는 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 따라 제작된 프리폼 단위층을 적층하는 방법을 도시한 개념도이며, 도 5는 본 발명에 따른 니들 펀칭을 이용한 고온 복합재용 프리폼 제조방법에 의하여 제조된 프리폼의 형상 사진도이다.3 is a schematic view of a preform unit layer manufactured according to the method for manufacturing a high temperature composite using needle punching according to the present invention, and FIG. 4 is a preform manufactured according to the method for manufacturing a preform for high temperature composite using needle punching according to the present invention. FIG. 5 is a conceptual view illustrating a method of laminating unit layers, and FIG. 5 is a shape photograph of a preform manufactured by a preform manufacturing method for a high temperature composite using needle punching according to the present invention.
고강도 섬유로 구성된 직물은 펀칭에 의해 두께방향으로 섬유가 배열되지 않기 때문에 그 직물 위층에 고연성의 섬유로 구성된 직물, 혹은 비연속 고강도 섬유직물을 사용하여 이 두 종류의 직물로 구성된 단위층을, 도 3에 도시된 바와 같이, 서로 중첩시키게 된다.Since fabrics composed of high strength fibers are not arranged in the thickness direction by punching, a fabric layer composed of high-ductile fibers on top of the fabric, or a unit layer composed of these two types of fabrics using discontinuous high-strength textile fabrics, As shown in FIG. 3, they overlap each other.
펀칭니들(10)의 삽입은 최상위층에 적층된 고연성 섬유직물 혹은 비연속 고강도 섬유직물(50)에서 아래층으로 연속 고강도 섬유직물(51) 방향으로 일어나며, 이 때 최상층에 적재된 고연성 섬유직물 혹은 비연속 고강도 섬유직물(50)은 연신율이 높거나 이미 절단된 섬유이기 때문에 니들(10)의 삽입작용에 의하여 아래층의 고강도 섬유직물(51)의 섬유사이로 두께방향 배열이 일어난다.Insertion of the punching needle 10 takes place in the direction of the continuous high-strength fibrous fabric (51) from the highly flexible fibrous fabric or the non-continuous high-strength fibrous fabric (50) laminated on the uppermost layer to the lower layer, wherein the high-flexible fibrous fabric or Since the discontinuous high strength fibrous fabric 50 is a high elongation or already cut fibers, the thickness direction arrangement occurs between the fibers of the high strength fibrous fabric 51 of the lower layer by the insertion of the needle 10.
상기와 같이 두께방향으로 배열된 고연성 섬유직물 혹은 비연속 고강도 섬유직물(51)은 여러층으로 적층된 연속 고강도 섬유직물(51)을 관통하게 되면서 각각의 층들이 결속되어짐으로써 프리폼의 단위층(55)을 형성하게 된다.As described above, the highly flexible fibrous fabric or the discontinuous high-strength fibrous fabric 51 arranged in the thickness direction passes through the continuous high-strength fibrous fabric 51 stacked in several layers, and the respective layers are bound to form a unit layer of the preform ( 55).
도 3에 도시된 중첩된 프리폼 단위층(55)의 구성에 있어서, 연속 고강도 섬유직물(51)은 다층으로 하고, 고연성 섬유직물 혹은 비연속 고강도 섬유직물(50)은 단층으로 조합한다.In the configuration of the superimposed preform unit layer 55 shown in FIG. 3, the continuous high-strength fibrous fabric 51 is made of multiple layers, and the high soft fibrous fabric or the discontinuous high strength fibrous fabric 50 is combined in a single layer.
일반적으로, 고연성 섬유직물(50)은 전단계 재료(Precursor)를 사용함으로써 강도향상을 위한 열처리 공정을 거치는데, 이 때 부피수축으로 인한 잔류응력이나 치수불안정 등을 고려하여 고연성 섬유직물층(50)이 차지하는 부피는 가능한 한 적도록 한다. 또한, 비연속 고강도 섬유직물(50)을 사용하는 경우에도 절단된 형태이므로 강도 저하를 되도록 적게 하기 위하여 이 직물이 차지하는 부피도 가능한 한 적도록 한다.In general, the high ductile fabric 50 is subjected to a heat treatment process for improving the strength by using a pre-stage material (Precursor), at this time the high ductile fabric fabric layer in consideration of residual stress or dimensional instability due to volume shrinkage ( The volume occupied by 50) should be as small as possible. In addition, even when using the discontinuous high-strength fibrous fabric 50 is cut form so that the volume occupied by the fabric is as small as possible in order to reduce the strength decrease.
이러한 단위층(55)을 다시 중첩하여 펀칭하면, 최종 제조되는 프리폼의 두께를 원하는 치수로 증가시킬 수 있다. 즉, 하나의 단위층(55)을 펀칭한 다음, 니들펀칭된 다른 단위층(55)을 그 위에 적재 중첩시켜 펀칭하는 단위층간의 펀칭방법에 의하면 단위층 내부 및 단위층 층간의 결속을 형성할 수 있을 뿐 아니라, 프리폼의 밀집도를 향상시킬 수 있는 것이다.If the unit layer 55 is overlapped and punched again, the thickness of the final preform to be manufactured may be increased to a desired dimension. That is, according to the punching method between the unit layers in which one unit layer 55 is punched, and then the other punched unit layers 55 are stacked and superimposed thereon to form a bond between the unit layers and the unit layer layers. Not only can it improve the density of the preforms.
이하, 바람직한 실시예를 통하여 본 발명의 작용을 상세하게 설명한다.Hereinafter, the operation of the present invention in detail through the preferred embodiment.
[실시예 1]Example 1
본 발명의 실시예에서는 탄소-탄소 복합재용으로서 탄소섬유로 구성되는 프리폼의 제조에 대하여 설명한다.In the embodiment of the present invention will be described for the production of a preform composed of carbon fibers for the carbon-carbon composite.
고연성의 섬유직물로서는 파손변형율이 PAN계의 탄소섬유보다 수십 배 높은 oxi-PAN계 섬유로 제조된 펠트(Felt) 혹은 평직 또는 주자직을 사용하며, 고강도 섬유직물로서는 탄소섬유 8매 주자직 직물을 사용한다.As the soft ductile fabric, felt or plain weave fabric is made of oxi-PAN fiber which has several tens of times higher damage strain than PAN carbon fiber. Use
즉, 상기 고연성의 섬유직물인 oxi-PAN계 직물은 탄화율이 무게%로 55~65%인 oxi-PAN계 탄소섬유를 이용하는데, 그 이유는 55% 미만으로 탄화된 섬유조직을 복합재료의 강화재료로 이용하면 최종 제조되는 복합재료의 기계적 물성이 크게 개선되지 않으며, 65%를 초과하는 탄화율을 가지는 탄소섬유를 이용하면 연신율이 크게 저하되어 본 발명에 따른 니들 펀칭공정 수행시 취성이 강하여 부서지는 경향이 강하여 층간 결속력이 현저히 저하하기 때문이다.In other words, oxi-PAN-based fabrics of the highly flexible fiber fabrics use oxi-PAN-based carbon fibers having a carbonization rate of 55 to 65% by weight, because the composite material is a carbonized fiber structure less than 55% When used as a reinforcing material of the final composite material does not significantly improve the mechanical properties, carbon fiber having a carbonization rate of more than 65% elongation is greatly reduced and brittleness during the needle punching process according to the present invention This is because the tendency to be strong and brittle is such that the interlayer binding strength is significantly lowered.
또한, 고연성의 섬유직물의 형태로서 펠트조직을 이용하는 이유는 섬유형태가 연속섬유가 아닌 단섬유로 되어 있어서 니들 펀칭공정에 의하여 두께방향으로 배열이 용이하므로 층간 결속력을 증가시킬 수 있기 때문이다.In addition, the reason why the felt structure is used as the form of the high ductile fabric is because the fiber form is made of short fibers rather than continuous fibers, so that the interlayer binding force can be increased because the arrangement is easy in the thickness direction by the needle punching process.
한편, 고강도 섬유직물로서는 PAN계 탄소섬유를 이용하는데, 그 이유는, 탄소 수량(Yield)이 oxi-PAN계의 섬유보다 현저히 높기 때문에(약 99% 이상) 고온 열처리과정에서 부피수축이 상기 oxi-PAN계 섬유보다 현저히 적음과 동시에 최종 제조되는 복합재료의 강도도 더욱 증대되기 때문이며, 이러한 고강도 섬유직물은 탄소섬유 뿐 아니라, 강도가 높고 내화성이 좋은 세라믹계(알루미나, 실리콘 나이트라이드, 보론 카바이드 등) 섬유도 이용될 수 있는 것이다.On the other hand, PAN-based carbon fiber is used as the high-strength fiber fabric because the carbon yield is significantly higher than that of the oxi-PAN fiber (more than about 99%). This is because it is significantly less than PAN-based fibers and at the same time, the strength of the final composite is further increased. This high-strength textile fabric is not only carbon fiber, but also high strength and fire-resistant ceramics (alumina, silicon nitride, boron carbide, etc.). Fiber can also be used.
따라서, 본 발명의 실시예에서는 가능한 한 oxi-PAN 섬유량을 최소로 하기 위하여, 8매 주자직 탄소섬유 직물 6장에 oxi-PAN 펠트를 1장 중첩한 것을 단위층으로 구성한다.Therefore, in the embodiment of the present invention, in order to minimize the amount of oxi-PAN fibers as much as possible, one sheet of oxi-PAN felt is superimposed on six sheets of eight carbon fiber fabrics.
도 4에 도시된 바와 같이, 제1단위층(70)은 전체 프리폼의 중심면에 위치하도록 하기 위하여 펠트-8주자직-펠트의 순서로 구성하여 상하면 모두 니들 펀칭을 한다.As shown in FIG. 4, the first unit layer 70 is needle-punched on both the upper and lower surfaces in the order of felt-8 woven fabric-felt in order to be located at the center surface of the entire preform.
이 때 평면에 배열된 고연성 섬유펠트의 일부는 두께방향으로 배열되어 이 두께방향으로 배열된 섬유가 각 층간결속을 주게 되는 것이다. 본 실시예에서는 니들펀칭이 한 면에서만 일어나는 단면펀칭을 적용하였다.At this time, a part of the high ductile fiber felt arranged in the plane is arranged in the thickness direction so that the fibers arranged in the thickness direction give each interlayer bond. In this embodiment, the needle punching is applied to the end face punching occurs only on one side.
상기 제1단위층(70) 위에서 제2단위층(71)을 중첩시키고, 같은 방법으로 니들 펀칭을 수행하며, 니들의 펀칭깊이는 두 층(70,71)을 관통하는 길이가 되도록 한다.The second unit layer 71 is superimposed on the first unit layer 70, needle punching is performed in the same manner, and the punching depth of the needle is such that the length penetrates the two layers 70 and 71.
상기 니들 펀칭이 수행된 프리폼은 그 상하면을 바꾸어 반대면에서 제3단위층(72)을 중첩시켜 니들펀칭한다.The needle punched preforms are needle punched by overlapping the third unit layer 72 on the opposite side by changing the upper and lower surfaces thereof.
상기와 같은 니들 펀칭과정을 프리폼의 전체 두께가 50㎜가 될 때까지 반복한 것이 도 5에 도시되어 있다.The needle punching process described above is repeated in FIG. 5 until the total thickness of the preform becomes 50 mm.
[실시예 2]Example 2
실시예 1에서처럼 탄소 수량(Yield)이 적은 oxi-PAN계의 섬유를 사용하는 경우, 고온(500~1000℃)의 열처리 과정에서 20~30%의 부피수축을 가져오기 때문에 이를 방지하기 위하여 PAN계나 피치(Pitch)계의 탄소섬유를 사용할 수 있다. 그러나 이런 고강도 섬유가 연속섬유 형태의 직물인 경우는 펀칭 작업에 의하여 섬유가 두께 방향으로 배열되지 않고 절단만 주로 일어나기 때문에 섬유 결속을 주기 어렵다.In the case of using the oxi-PAN-based fiber with a low carbon yield as in Example 1, 20-30% volumetric shrinkage is produced during the heat treatment at a high temperature (500-1000 ° C.). Pitch-based carbon fibers can be used. However, when such a high strength fiber is a woven fabric in the form of a continuous fiber, it is difficult to bind the fiber because the fiber is not mainly arranged in the thickness direction by the punching operation but only cutting occurs.
따라서, 고강도 섬유를 사용하는 경우에는 PAN계 의 연속 탄소 섬유를 잡아당겨 일정한 길이로 절단(Stretch-Broken)한 섬유를 직조한 다축경편 직물(Multiaxial Warp Knit)을 상부 직물로 사용하고 하부직물로는 연속 고강도 탄소섬유 8매 주자직 직물을 사용한다.Therefore, when using high-strength fibers, multiaxial warp knits, which are woven from PAN-based continuous carbon fibers and stretch-broken fibers, are used as the upper fabric. Eight continuous high strength carbon fiber runners are used.
따라서, 본 발명의 실시예에서는 가능한 한 불연속 고강도 섬유량을 최소로 하기 위하여, 다축경편 직물 1장에 8매 주자직 탄소섬유 직물 2장 중첩한 것을 단위층으로 구성한다.Therefore, in the embodiment of the present invention, in order to minimize the amount of discontinuous high strength fibers as much as possible, a unit layer is formed by superimposing two sheets of multi-axial warp knitted fabric with eight main carbon fiber fabrics.
도 4에 도시된 바와 같이, 첫 번째 단위층(70)은 전체 프리폼의 중심면에 위치하도록 하기 위하여 다축경편-8주자직-다축경편의 순서로 구성하여 상하면 모두 니들 펀칭을 한다.As shown in FIG. 4, the first unit layer 70 is needle-punched on both the upper and lower surfaces in the order of the multi-axis warp yarns-eight main shaft-multi-axis warp yarns so as to be located at the center plane of the entire preform.
실시예 1과 같은 방법으로 첫 번째 단위층(70) 위에서 두 번째 단위층(71)을중첩시키고, 같은 방법으로 니들 펀칭을 수행하며, 니들의 펀칭깊이는 두 층(70,71)을 관통하는 길이가 되도록 한다. 두 번째 단위 층은 다축경편-8주자직으로 구성한다.In the same manner as in Example 1, the second unit layer 71 is overlapped on the first unit layer 70, needle punching is performed in the same manner, and the punching depth of the needle penetrates the two layers 70 and 71. Length. The second unit layer consists of multiaxial warp-8 runners.
상기 니들 펀칭이 수행된 프리폼은 그 상하면을 바꾸어 반대면에서 세 번째 단위층(72)을 중첩시켜 니들펀칭한다.The preform on which needle punching is performed is needle punched by overlapping the third unit layer 72 on the opposite side by changing the upper and lower surfaces thereof.
상술한 바와 같이, 본 발명에 의하면 고강도 강화섬유를 사용하더라도 고연성의 직물 또는 비연속 고강도 섬유직물의 섬유가 니들 펀칭에 의하여 두께방향으로 배열되면서 고강도 연속 섬유층을 결속시켜주기 때문에 니들 펀칭공정이 용이함과 동시에 단위층별 니들 펀칭공정을 수행함으로서 섬유층의 밀집화가 가능하며 두께에 제한이 없는 복합재용 프리폼을 제조할 수 있는 공정상의 효과가 있다.As described above, the needle punching process is easy because the high-strength fabric or the fibers of the non-continuous high-strength fabric are bound in the thickness direction by needle punching to bind the high-strength continuous fiber layer even when the high-strength reinforced fiber is used. At the same time, by performing the needle punching process per unit layer, the fiber layer can be densified, and there is a process effect that can produce a preform for a composite without any limitation in thickness.
또한, 기존의 3차원적 직조형 섬유배열구조에 비하여 프리폼 제조시간 및 제조비용이 저감되어 대량생산이 적합하며, 복합재의 원재료인 프리폼을 수입에 의존하지 않고 국내 제작된 프리폼을 이용할 수 있으므로 수입대체 효과가 매우 크다.In addition, the preform manufacturing time and manufacturing cost are reduced compared to the existing three-dimensional woven fiber array structure, which is suitable for mass production, and it is possible to use the preform manufactured domestically without relying on importing the preform, which is the raw material of the composite material. The effect is very big.
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