TWI572650B - ０度單向長纖預浸材料、其製造方法及藉以製造多軸預浸材料組成物的方法 - Google Patents

０度單向長纖預浸材料、其製造方法及藉以製造多軸預浸材料組成物的方法 Download PDF

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TWI572650B
TWI572650B TW105116471A TW105116471A TWI572650B TW I572650 B TWI572650 B TW I572650B TW 105116471 A TW105116471 A TW 105116471A TW 105116471 A TW105116471 A TW 105116471A TW I572650 B TWI572650 B TW I572650B
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Taiwan
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prepreg
unidirectional
long fiber
fiber
long
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TW105116471A
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TW201643209A (zh
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尹浚榮
李賢哲
曹銀靜
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可隆工業股份有限公司
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Description

0度單向長纖預浸材料、其製造方法及藉以製造多軸預浸材料組成物的方 法
本發明係關於一種0度單向長纖預浸材料、其製造方法及藉以製造多軸預浸材料組成物的方法。
更具體而言，本發明係關於單向長纖預浸材料(於下文中又稱為「0度單向長纖預浸材料」)，其中於該單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，高強度長纖彼此平行排列，及一樹脂浸透該預浸材料，以及連續製造其之方法。
此外，本發明係關於製造一組成物的方法，該組成物係由二片單向長纖預浸材料所形成，該二片單向長纖預浸材料具有不同排列方向的高強度長纖且彼此相疊(於下文中又稱為「多軸預浸材料組成物」)，包含：同時並連續地進料(一)依據上述方法所製備之該0度單向長纖預浸材料及(二)另一單向長纖預浸材料(於下文中又稱為「90度單向長纖預浸材料」)，其中於垂直另一單向長纖預浸材料所捲繞之捲繞滾筒的軸向X之方向Y上，以任何習知的整經方式所製得之高強度長纖彼此平行排列，進入一熱壓滾筒；續對其進行熱壓，藉以製造依據上述之組成物。
在習知的製造單向長纖預浸材料的方法中，高強度長纖係以 單向排列，及一樹脂浸透該預浸材料，使用一整經機將該高強度長纖排列為平行其捲繞方向，以樹脂將其浸透，續將其捲繞於一捲繞捲繞滾筒1之製程，係已用於此技術領域之中。
然而，如第1圖所示，上述習知的方法僅可以用於連續製造90度單向長纖預浸材料B以形成一卷狀，其中於垂直該單向長纖預浸材料所捲繞之捲繞滾筒的軸向X之方向Y上，該高強度長纖彼此平行排列。另一方面，上述習知的方法具有一問題，即0度單向長纖預浸材料A無法被連續地製造以形成一卷狀，其中於該單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，該高強度長纖彼此平行排列，如第2圖所示。
另一方面，為了製造一多軸預浸材料組成物C，其中(一)至少二片單向長纖預浸材料彼此相疊；及(二)於彼此緊密相疊的二片單向長纖預浸材料中，一單向長纖預浸材料所包含的高強度長纖係與另一單向長纖預浸材料所包含的高強度長纖之方向呈90度角排列，藉由僅使用上所述習知的方法所製得之該90度單向長纖預浸材料B，必須使用一種典型製程，包含：將第1圖所示之90度單向長纖預浸材料B的一剪切部份旋轉90度，其係剪切為與該90度單向長纖預浸材料B之寬度相等的長度，續沿該90度單向長纖預浸材料B的長軸方向將其疊於該90度單向長纖預浸材料B；及熱壓該疊層物。因此，上述製造一多軸預浸材料組成物C的方法變得複雜且具有一問題，即該多軸預浸材料組成物C無法經由連續製程製備以形成一卷狀。
本發明之一目的係提供0度單向長纖預浸材料，其中於單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，高強度長纖彼此平行排列，及一樹脂浸透該預浸材料，以及藉由一簡單製程，將其連續製造以形成一卷狀之方法。
本發明之另一目的係提供一方法，以連續製造一多軸預浸材料組成物C形成一卷狀，其中0度單向長纖預浸材料A及90度單向長纖預浸材料B彼此相疊。
為了達成上述目的，提供0度單向長纖預浸材料，係以如下述方法製備：(一)使用寬度為5至60mm之熱塑薄膜帶(thermoplastic film tape)作為經紗，及一高強度長纖作為緯紗，編織一織物；及(二)於該經紗之熔融溫度熱壓該編織織物，其中於單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，該高強度長纖彼此平行排列，及一樹脂浸透該預浸材料。
另一方面，依據本發明，提供一多軸預浸材料組成物，藉由同時且連續地進料依據上述方法所製備之0度單向長纖預浸材料A及以習知的整經方式所製備之90度單向長纖預浸材料B，進入一熱壓捲繞滾筒2，及對其進行熱壓，使其具有一結構，其中：(一)至少二片單向長纖預浸材料彼此相疊；及(二)於彼此緊密相疊的二片單向長纖預浸材料中，一單向長纖預浸材料所包含的高強度長纖係與另一單向長纖預浸材料所包含的高強度長纖之排列方向呈90度角排列。
依據本發明，能夠連續製造0度單向長纖預浸材料A，其中於該單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，該高強度長纖彼此平行排列，且該樹脂浸透該預浸材料。
此外，依據本發明，能夠連續製造該多軸預浸材料組成物C，其中：(一)至少二片單向長纖預浸材料彼此相疊，及(二)於彼此緊密相疊的二片單向長纖預浸材料中，一單向長纖預浸材料所包含的高強度長纖係與另一單向長纖預浸材料所包含的高強度長纖之排列方向呈90度角排列，經由一簡單製程，藉此提升產量同時降低生產成本。
本申請案針對韓國專利申請第10-2015-0077258號專利案主張優先權，該專利案係於2015年6月1日送交韓國智慧財產局，其所有揭 露內容係作為參考資料併入本案之中。
1‧‧‧單向長纖預浸材料所捲繞之捲繞滾筒
A‧‧‧0度單向長纖預浸材料
B‧‧‧90度單向長纖預浸材料
X‧‧‧捲繞滾筒1之軸向
Y‧‧‧垂直捲繞滾筒1之軸向的方向
2‧‧‧熱壓滾筒
C‧‧‧多軸預浸材料組成物
3‧‧‧多軸預浸材料組成物之捲繞滾筒
F‧‧‧高強度長纖
於後續之實施方式中，配合所附之圖示，將可以更清楚地理解本發明之上述及其他目的、特徵及其他優點，其中：第1圖係為一示意圖，繪示以習知的方法製造之90度單向長纖預浸材料B，自一捲繞滾筒1解卷的狀態。
第2圖係為一示意圖，繪示以本發明製造之0度單向長纖預浸材料A，自該捲繞滾筒1解卷的狀態。
第3圖係為一示意圖，繪示製造一多軸預浸材料組成物C的製程。
在下文中，將參照所附之圖示，更詳細描述本發明。
本發明揭露0度單向長纖預浸材料，係以如下述方法製備：(一)使用寬度為5至60mm之熱塑薄膜帶作為經紗，及一高強度長纖作為緯紗，編織一織物；及(二)於該經紗之熔融溫度熱壓該編織織物，其中於單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，該高強度長纖彼此平行排列，及一樹脂浸透該預浸材料。
該高強度長纖可以包含一芳香族聚醯胺(aramid)長纖或一碳纖(carbon fiber)長纖，且該芳香族聚醯胺長纖或碳纖長纖可以單獨用以作為編織一織物之經紗。此外，該高強度長纖可以以一形式使用，其中彼此具有不同強度之相異的高強度長纖交錯排列。
該熱塑薄膜帶可以包含，例如一聚丙烯(polypropylene)薄膜帶、一聚乙烯(polyethylene)薄膜帶、一聚亞醯胺(polyimide)薄膜帶、一聚酯(polyester)薄膜帶、一聚二醚酮(polyetheretherketone，簡稱PEEK)薄膜帶、一聚氨酯(polyurethane)薄膜帶，或其類似物。然而，該熱塑薄 膜帶之種類未特定限制於本發明之中。
相較於習知的織物預浸材料，本發明製造之0度單向長纖預浸材料不具有介於經紗及緯紗之間的交叉點，故可以解決強度降低之問題。
依據本發明，能夠連續製造0度單向長纖預浸材料A以形成一卷狀，其無法藉由習知的連續製程製得。
另一方面，本發明可以製造一多軸預浸材料組成物C，藉由同時且連續地進料依據上述方法所製備且如第2圖所示之0度單向長纖預浸材料A；及以習知的整經方式所製備且如第1圖所示之90度單向長纖預浸材料B，進入如第3圖所示之熱壓滾筒2，續對其進行熱壓，使所製得之多軸預浸材料組成物捲繞於多軸預浸材料組成物之一捲繞滾筒3。
該多軸預浸材料組成物C具有一結構，其中：(一)至少二片單向長纖預浸材料彼此相疊，及(二)於彼此緊密相疊的二片單向長纖預浸材料中，一單向長纖預浸材料所包含的高強度長纖係與另一單向長纖預浸材料所包含的高強度長纖之排列方向呈90度角排列。
本發明可以實現連續製造該多軸預浸材料組成物C以形成一卷狀，藉由相較於相關技術更簡單的製程。
於下文中，藉由下述之實施例及比較例，可以更具體地理解本發明。
下述之實施例僅供說明本發明之較佳實施例，然而，本發明之範圍應不受此處所描述之內容限制。
實施例1
使用密度為0.9的聚丙烯薄膜帶作為經紗，並以芳香族聚醯胺長纖作為緯紗，以編織一平面紋理之織物。而後，將該編織織物於140℃進行熱壓，以融化該聚丙烯薄膜帶。據此，如第2圖所繪示，可以製備0度單向長纖預浸材料A以形成一卷狀，其中該芳香族聚醯胺長纖於一捲 繞滾筒之軸向X上彼此平行排列。
另一方面，同時且連續地進料依據上述方法所製備之0度單向長纖預浸材料A；及以習知的整經方法所製備且如第1圖所示之90度單向長纖預浸材料B，其中該芳香族聚醯胺長纖於垂直該捲繞滾筒之軸向X的方向Y上彼此平行排列，進入如第3圖所示之熱壓滾筒2，續對其進行熱壓，藉以連續製造一多軸預浸材料組成物C形成一卷狀。
實施例2
使用一聚氨酯薄膜帶作為經紗，並以碳纖長纖作為緯紗，以編織一平面紋理之織物。而後，將該編織織物於200℃進行熱壓，以融化該聚氨酯薄膜帶。據此，如第2圖所繪示，可以製備0度單向長纖預浸材料A以形成一卷狀，其中該碳纖長纖於一捲繞滾筒之軸向X上彼此平行排列。
另一方面，同時且連續地進料依據上述方法所製備之0度單向長纖預進料胚A；及以習知的整經方法所製備且如第1圖所示之90度單向長纖預浸材料B，其中該碳纖長纖於垂直該捲繞滾筒之軸向X的方向Y上彼此平行排列，進入如第3圖所示之熱壓滾筒2，續對其進行熱壓，藉以連續製造一多軸預浸材料組成物C形成一卷狀。
實施例3
使用一聚乙烯薄膜帶作為經紗，並以比例為2：2之芳香族聚醯胺長纖及碳纖長纖作為緯紗，以編織一平面紋理之織物。而後，將該編織織物於140℃進行熱壓，以融化該聚乙烯薄膜帶。據此，如第2圖所繪示，可以製備0度單向長纖預浸材料A以形成一卷狀，其中該緯紗於一捲繞滾筒之軸向X上彼此平行排列。
另一方面，同時且連續地進料依據上述方法所製備之0度單向長纖預進料胚A；及以習知的整經方法所製備且如第1圖所示之90度單 向長纖預浸材料B，其中該碳纖長纖於垂直該捲繞滾筒之軸向X的方向Y上彼此平行排列，進入如第3圖所示之熱壓滾筒2，續對其進行熱壓，藉以連續製造一多軸預浸材料組成物C形成一卷狀。
比較例1
如第1圖所示，90度單向長纖預浸材料B，其中芳香族聚醯胺長纖於垂直該捲繞滾筒之軸向X的方向Y上彼此平行排列，係依據習知的整經方法製備以形成一卷狀。
另一方面，將該90度單向長纖預浸材料B剪切為與該90度單向長纖預浸材料B之寬度相等的長度後，將其旋轉90度，而後，將其疊於另一90度單向長纖預浸材料B，該疊層物經熱壓，藉以經由一非連續方法製造一多軸預浸材料組成物C。
依據實施例1~3，於連續地製備該0度單向長纖預浸材料A以形成一卷狀後，將其連續地疊於以習知的整經方法所製備形成一卷狀之90度單向長纖預浸材料B，續對其進行熱壓，藉以連續地製造一多軸預浸材料組成物C。然而，比較例1不能達成依據上述之連續性製程。
本發明之0度單向長纖預浸材料組成物可以應用於製造一多軸預浸材料組成物之材料、製造安全帽之材料、製造高爾夫球桿之材料、製造用於交通工具之車門防撞樑之材料，或其類似物。
本發明之多軸預浸材料組成物可以應用於製造安全帽之材料、製造高爾夫球桿之材料、製造用於交通工具之車門防撞樑之材料，或其類似物。
1‧‧‧單向長纖預浸材料所捲繞之捲繞滾筒
A‧‧‧0度單向長纖預浸材料
X‧‧‧捲繞滾筒1之軸向
F‧‧‧高強度長纖

Claims (9)

  1. 一種0度單向長纖預浸材料，包含：於單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，彼此呈平行排列之高強度長纖，其中一樹脂浸透該預浸材料。
  2. 如申請專利範圍第1項所述之0度單向長纖預浸材料，其中，該高強度長纖係選自一芳香族聚醯胺(aramid)長纖及一碳纖(carbon fiber)長纖的一者。
  3. 一種製造0度單向長纖預浸材料的方法，包含：(一)使用寬度為5至60mm之熱塑薄膜帶作為經紗，及一高強度長纖作為緯紗，編織一織物；及(二)於該經紗之熔融溫度熱壓該編織織物，其中於單向長纖預浸材料所捲繞之捲繞滾筒的軸向X上，該高強度長纖彼此平行排列，及一樹脂浸透該預浸材料。
  4. 如申請專利範圍第3項所述之方法，其中，該高強度長纖係選自一芳香族聚醯胺長纖及一碳纖長纖的一者。
  5. 如申請專利範圍第3項所述之方法，其中，該織物所包含之緯紗係由相異的高強度纖維彼此交錯排列而形成。
  6. 如申請專利範圍第3項所述之方法，其中，該熱塑薄膜帶係選自一聚丙烯(polypropylene)薄膜帶、一聚乙烯(polyethylene)薄膜帶、一聚亞醯胺(polyimide)薄膜帶、一聚酯(polyester)薄膜帶、一聚二醚酮(polyetheretherketone)薄膜帶及一聚氨酯(polyurethane)薄膜帶的一者。
  7. 一種製造多軸預浸材料組成物的方法，包含：同時且連續地進料：0度單向長纖預浸材料A，其中於單向長纖預浸材料所捲繞之捲繞滾筒 的軸向X上，高強度長纖F彼此平行排列；及90度單向長纖預浸材料B，其中於垂直該單向長纖預浸材料所捲繞之捲繞滾筒的軸向X之方向Y上，高強度長纖F彼此平行排列，進入一熱壓滾筒2，及對其進行熱壓，以製備該多軸預浸材料組成物，該多軸預浸材料組成物具有一結構，其中：(一)至少二片單向長纖預浸材料彼此相疊，及(二)於彼此緊密相疊的二片單向長纖預浸材料中，一單向長纖預浸材料所包含的高強度長纖係與另一單向長纖預浸材料所包含的高強度長纖之排列方向呈90度角排列。
  8. 如申請專利範圍第7項所述之方法，其中，該0度單向長纖預浸材料A係以如下述之方法製得：(一)使用寬度為5至60mm之熱塑薄膜帶作為經紗，及一高強度長纖作為緯紗，編織一織物；及(二)於該經紗之熔融溫度熱壓該編織織物。
  9. 如申請專利範圍第7項所述之方法，其中，該90度單向長纖預浸材料B係以使用一整經機之整經方式製得。
TW105116471A 2015-06-01 2016-05-26 ０度單向長纖預浸材料、其製造方法及藉以製造多軸預浸材料組成物的方法 TWI572650B (zh)

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