WO2013094706A1 - ランダムマット、および強化繊維複合材料 - Google Patents
ランダムマット、および強化繊維複合材料 Download PDFInfo
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- WO2013094706A1 WO2013094706A1 PCT/JP2012/083146 JP2012083146W WO2013094706A1 WO 2013094706 A1 WO2013094706 A1 WO 2013094706A1 JP 2012083146 W JP2012083146 W JP 2012083146W WO 2013094706 A1 WO2013094706 A1 WO 2013094706A1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
- B29C70/10—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres
- B29C70/12—Fibrous reinforcements only characterised by the structure of fibrous reinforcements, e.g. hollow fibres using fibres of short length, e.g. in the form of a mat
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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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
- B29C70/465—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating by melting a solid material, e.g. sheets, powders of fibres
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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
- B32B25/00—Layered products comprising a layer of natural or synthetic rubber
- B32B25/12—Layered products comprising a layer of natural or synthetic rubber comprising natural rubber
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4242—Carbon fibres
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4326—Condensation or reaction polymers
- D04H1/4334—Polyamides
- D04H1/4342—Aromatic polyamides
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/70—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres
- D04H1/72—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres characterised by the method of forming fleeces or layers, e.g. reorientation of fibres the fibres being randomly arranged
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H5/00—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length
- D04H5/02—Non woven fabrics formed of mixtures of relatively short fibres and yarns or like filamentary material of substantial length strengthened or consolidated by mechanical methods, e.g. needling
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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
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
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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
- B29K2069/00—Use of PC, i.e. polycarbonates or derivatives thereof, as moulding material
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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
- B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
- B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
- B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
- B29K2105/0854—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns in the form of a non-woven mat
- B29K2105/0863—SMC, i.e. sheet moulding compound
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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
- B29K2307/00—Use of elements other than metals as reinforcement
- B29K2307/04—Carbon
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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
- B29K2995/00—Properties of moulding materials, reinforcements, fillers, preformed parts or moulds
- B29K2995/0037—Other properties
- B29K2995/0045—Isotropic
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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
- B32B2471/00—Floor coverings
- B32B2471/04—Mats
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
- Y10T442/2008—Fabric composed of a fiber or strand which is of specific structural definition
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
- Y10T442/60—Nonwoven fabric [i.e., nonwoven strand or fiber material]
- Y10T442/608—Including strand or fiber material which is of specific structural definition
Definitions
- the present invention relates to a random mat used as a preform for a reinforced fiber composite material molded body, a molded body obtained therefrom, a reinforced fiber composite material using the random mat of the present invention, and a method for producing the same.
- the present invention relates to a random mat suitable for a preform of a molded body having an upright portion such as a rib.
- Reinforced fiber composite materials using carbon fibers, aramid fibers, glass fibers, etc. as reinforcing fibers make use of their high specific strength and specific elastic modulus to make structural materials such as aircraft and automobiles, tennis rackets, golf shafts, fishing rods. It has been widely used in general industries such as sports and sports applications.
- the form of the reinforcing fiber used for these includes a woven fabric made using continuous fibers, a UD sheet in which fibers are aligned in one direction, a random sheet made using cut fibers, a nonwoven fabric, and the like.
- woven fabrics and UD sheets using continuous fibers are laminated at various angles such as 0 / + 45 / -45 / 90 due to the anisotropy of the fibers, and warping of the molded product
- a complicated lamination process such as lamination on a surface object has been one of the causes of increasing the cost of the reinforced fiber composite material.
- a relatively inexpensive reinforcing fiber composite material can be obtained by using a random mat that is isotropic in advance.
- This random mat is a method of making paper by adding a cut reinforcing fiber alone or a spray-up method (dry type) in which a thermosetting resin is simultaneously sprayed on a mold, or adding a pre-cut reinforcing fiber to a slurry containing a binder. Although it can be obtained by (wet) etc., since the apparatus is relatively small, a random mat can be obtained at a lower cost by using a dry production method.
- the reinforcing fiber composite material is obtained by heating and pressurizing a material called a prepreg in which a reinforcing fiber base material is impregnated with a thermosetting resin in advance using an autoclave for 2 hours or more.
- a prepreg in which a reinforcing fiber base material is impregnated with a thermosetting resin in advance using an autoclave for 2 hours or more.
- an RTM molding method in which a thermosetting resin is poured after a reinforcing fiber base not impregnated with resin is set in a mold has been proposed, and the molding time has been greatly reduced.
- the RTM molding method it takes 10 minutes or more to mold one part.
- thermoplastic resin generally has a higher viscosity than the thermosetting resin, and therefore, there is a problem that the time for impregnating the fiber base material with the resin is long, and as a result, the tact time until molding becomes long. .
- thermoplastic stamping molding TP-SMC
- TP-SMC thermoplastic stamping molding
- Patent Documents 1 and 2 relating to a method of manufacturing a chopped fiber bundle and a molding material, and these are methods for forming a molding material called SMC or a stampable sheet.
- SMC thermoplastic stamping molding
- the viscosity is higher due to the difference in the molecular weight of the resin compared to the reinforced fiber composite material using a thermosetting resin as a matrix, and because it is molded by flowing, especially ribs, bosses, etc.
- a relatively high molding pressure is required to fill a complex shape with fibers and resin, and a large amount of capital investment and maintenance costs are required to mold a large molded body.
- An object of the present invention is a random mat that can be used as a preform for a reinforced fiber composite material molded body and that can obtain a complicated three-dimensional shape having a raised portion such as a rib and a boss by a single molding even under low pressure conditions. It is an object of the present invention to provide a molded body, a reinforcing fiber composite material using the random mat of the present invention, and a method for producing the same. Furthermore, it is providing the random mat which can obtain the molded object excellent in isotropic property.
- the present invention suitably controls the fluidity at the time of molding by forming a random mat composed of a thermoplastic resin and a reinforcing fiber that satisfies a specific convergence or opening condition and has a specific range of fiber lengths.
- the present invention has been found to be possible. That is, the present invention includes a random mat containing reinforcing fibers having a fiber length of 3 to 50 mm and satisfying the following i) to v), a molded product obtained therefrom, a reinforcing fiber composite material using the random mat of the present invention, and a method for producing the same It is.
- reinforcing fiber having a fiber length of 3 to 15 mm with respect to the total amount of reinforcing fibers contained in the random mat, and reinforcing fiber having a fiber length of 15 to 50 mm in the random mat 0 to 50% by mass with respect to the total amount of fiber, ii) the basis weight of the reinforcing fiber is 25 to 10,000 g / m 2 ; iii) The reinforcing fiber bundle (A) composed of a single yarn less than the critical number of single yarns defined by the following formula (1) and the critical single yarn number or more is present at the same time for the reinforcing fibers.
- the ratio of the mat to the total amount of fibers is 50 Vol% or more and less than 99 Vol%.
- the average number of fibers (N) in the reinforcing fiber bundle (A) satisfies the following formula (2).
- Critical number of single yarns 600 / D (1) 1.5 ⁇ 10 4 / D 2 ⁇ N ⁇ 3 ⁇ 10 5 / D 2 (2) (Where D is the average fiber diameter ( ⁇ m) of the reinforcing fibers)
- the random mat of the present invention is preferably used as a preform for molding a reinforced fiber composite material, and has excellent fluidity during molding. Therefore, a random three-dimensional shape such as a rib or a boss extending in the vertical direction with respect to a horizontal portion is formed. The upper part can be easily molded at a relatively low pressure. Therefore, from the random mat according to the present invention, the product shape can be formed using the minimum necessary material, and it can be expected that the trimming process is eliminated and the waste material is significantly reduced and the cost is reduced accordingly. Moreover, the random mat of the present invention can be used as a preform for various structural members, for example, an inner plate, an outer plate, a structural member of an automobile, various electric products, a frame of a machine, a casing, and the like.
- the random mat of the present invention includes reinforcing fibers having a fiber length of 3 to 50 mm and satisfies the following i) to v).
- the basis weight of the reinforcing fiber is 25 to 10,000 g / m 2 ;
- the reinforcing fiber bundle (A) composed of a single yarn less than the critical number of single yarns defined by the following formula (1) and the critical single yarn number or more is present at the same time for the reinforcing fibers.
- the ratio to the total amount of reinforcing fibers contained in the random mat is 50 Vol% or more and less than 99 Vol%.
- the average number of fibers (N) in the reinforcing fiber bundle (A) satisfies the following formula (2).
- Critical number of single yarns 600 / D (1) 1.5 ⁇ 10 4 / D 2 ⁇ N ⁇ 3 ⁇ 10 5 / D 2 (2) (Where D is the average fiber diameter ( ⁇ m) of the reinforcing fibers)
- the ratio (Vol%) to the total amount of reinforcing fibers contained in the random mat may be referred to as a volume ratio (Vol%) to the entire mat fiber.
- the reinforcing fibers are not oriented in a specific direction and are dispersed in a random direction.
- the random mat of the present invention is a material excellent in in-plane isotropy.
- the isotropy of the reinforcing fibers in the random mat is maintained in the molded body.
- the basis weight of the reinforcing fibers in the random mat is in the range of 25 to 10,000 g / m 2 . Random mat is useful as a prepreg, various basis weight can be selected according to the desired molding, basis weight is preferably 25 ⁇ 4500g / m 2, more preferably 25 ⁇ 3000g / m 2.
- the reinforcing fibers included in the random mat are discontinuous, and examples of the reinforcing fibers include reinforcing fibers having a fiber length of 3 mm or more and less than 15 mm (hereinafter sometimes referred to as reinforcing fibers (B)).
- the reinforcing fiber (B) is a group that greatly contributes to the fluidity during molding, and the fiber length range of the reinforcing fiber (B) is preferably 5 to 15 mm, more preferably 7 to 13 mm, and even more preferably 7 to 10 mm. preferable.
- the reinforcing fiber (B) is 50 to 100% by mass, preferably 70 to 100% by mass, and more preferably 90 to 100% by mass with respect to the total amount of reinforcing fibers contained in the random mat.
- the average fiber length is substantially equal to the cut fiber length.
- the mass% with respect to the total amount of reinforcing fibers contained in the random mat may be referred to as a mass ratio (%) with respect to the entire mat fiber.
- a reinforcing fiber having a fiber length of 15 mm or more and 50 mm or less may be used in combination. it can.
- the reinforcing fiber (C) has a relatively long fiber length, so that mechanical properties (especially long-term fatigue strength) can be ensured. However, an extremely long fiber inhibits the fluidity, so that the reinforcing fiber (C ) Is preferably 17 to 40 mm, more preferably 20 to 30 mm.
- the ratio of the reinforcing fibers (C) to the total amount of mat fibers is 0 to 50% by mass, and more preferably 0 to 10% by mass. More preferably, it is 2 to 10% by mass.
- the method for obtaining such fiber length distribution is not particularly limited, but in a preferable method for producing a random mat, which will be described later, a method of adjusting the pitch of blades for cutting a fiber bundle can be mentioned.
- a method of adjusting the pitch of blades for cutting a fiber bundle can be mentioned.
- the fiber length is expressed as a fiber length distribution obtained by measuring the fiber length of the reinforcing fiber in the obtained random mat.
- a method for measuring the fiber length there is a method of measuring the fiber length of 100 randomly extracted fibers up to 1 mm using calipers or the like, and obtaining the distribution. Further, by adopting a preferable reinforcing fiber cutting method to be described later, the length of the reinforcing fibers contained in the random mat can be controlled to a fixed length or a predetermined length distribution.
- the reinforcing fibers contained in the random mat are preferably at least one selected from the group consisting of carbon fibers, aramid fibers, and glass fibers. These can be used in combination, and among these, carbon fibers are preferable in that they can provide a composite material that is lightweight and excellent in strength.
- a carbon fiber having a polyacrylonitrile-based fiber as a precursor (hereinafter sometimes abbreviated as a polyacrylonitrile-based carbon fiber or a PAN-based carbon fiber) is particularly preferable.
- the average fiber diameter is preferably 3 to 12 ⁇ m, more preferably 5 to 7 ⁇ m.
- the sizing agent is preferably 0 to 10 parts by mass with respect to 100 parts by mass of the reinforcing fiber.
- the average fiber diameter is preferably 3 to 20 ⁇ m, more preferably 10 to 15 ⁇ m.
- the reinforcing fiber bundle (A) composed of the number of critical single yarns or more defined in the above is characterized in that the ratio of the random mat to the total amount of fibers is 50 Vol% or more and less than 99 Vol%.
- the abundance of the reinforcing fiber bundle (A) composed of the critical number of single yarns or more defined depending on the average fiber diameter is set to 50 Vol% or more and less than 99 Vol%, that is, the reinforcing fibers are opened.
- the fiber degree is controlled, and the reinforcing fiber bundle (A) composed of a specific number or more of reinforcing fibers and other opened reinforcing fibers are included at a specific ratio.
- it can be controlled by, for example, the pressure of air blown in the opening process in a preferable manufacturing method described later.
- the size of the fiber bundle used in the cutting step for example, the width of the bundle and the number of fibers per width.
- a method of expanding the width of the fiber bundle by opening the fiber and using it for the cutting process and a method of providing a slit process before the cutting process.
- a method of cutting a fiber bundle using a so-called splitting knife in which many short blades are arranged and a method of slitting simultaneously with cutting. Preferred conditions are described in the section of the opening process.
- the ratio of the reinforcing fiber bundle (A) to the total amount of the fibers is less than 50 Vol%, there is an advantage that a composite material having excellent surface quality can be obtained when the random mat of the present invention is molded, but the reinforcement has excellent mechanical properties. Not only is it difficult to obtain a fiber composite material, but the number of monofilaments increases, so that the fibers are entangled and fluidity is impaired.
- the ratio of the reinforcing fiber bundle (A) is 99 Vol% or more, the fiber entanglement is extremely small and the fluidity itself is good. However, since the binding force between the fibers is small, the fiber orientation advances in the flow direction. The isotropic property cannot be ensured and does not meet the purpose of the present invention.
- the ratio of the reinforcing fiber bundle (A) is more preferably 60 Vol% or more and less than 95 Vol%.
- the average number of fibers (N) in the reinforcing fiber bundle (A) composed of the number of critical single yarns or more is represented by the following formula (2). 1.5 ⁇ 10 4 / D 2 ⁇ N ⁇ 3 ⁇ 10 5 / D 2 (2) (Where D is the average fiber diameter ( ⁇ m) of the reinforcing fibers) It is characterized by satisfying.
- the size of the fiber bundle to be subjected to the cutting step for example, the width of the bundle and the number of fibers per width are set. It can also be controlled by adjusting. Specifically, there are a method of expanding the width of the fiber bundle by opening the fiber and using it for the cutting process, and a method of providing a slit process before the cutting process. Further, the fiber bundle may be slit simultaneously with the cutting.
- the average number of fibers (N) in the reinforcing fiber bundle (A) can be controlled by adjusting the dispersion of the cut fiber bundle by the pressure of the air to be blown in the opening process. Preferred conditions are described in the section of the opening process and the cutting process. Specifically, when the average fiber diameter of the reinforcing fibers contained in the random mat is 5 to 7 ⁇ m, the critical single yarn number is 86 to 120, and when the average fiber diameter of the reinforcing fibers is 5 ⁇ m, the average number of fibers in the fiber bundle Is in the range of 600 to 12,000, with 1000 to 9000 being particularly preferred. When the average fiber diameter of the reinforcing fibers is 7 ⁇ m, the average number of fibers in the fiber bundle is in the range of 306 to 6122, preferably 500 to 4900.
- the average number of fibers (N) in the reinforcing fiber bundle (A) is 1.5 ⁇ 10 4 / D 2 or less, it is difficult to obtain a high fiber volume content (Vf).
- Vf fiber volume content
- the average number of fibers (N) in the reinforcing fiber bundle (A) is 3 ⁇ 10 5 / D 2 or more, a thick portion is locally generated, which tends to cause voids, and has different physical properties after flow. It tends to have a directivity and is not suitable for the purpose of the present invention.
- the density is large and good physical properties cannot be obtained.
- the reinforcing fiber bundle (A B ) having a fiber length of 3 mm or more and less than 15 mm and having a critical single yarn number or more as defined in the formula (1). It is preferable that the average number of fibers (N B ) in () satisfy the following formula (2B).
- Reinforcing fiber (C) is a component having a relatively long fiber length, and a relatively large number of fibers constituting a bundle makes it easier to ensure the linearity of the fibers in the random mat, and the mechanical properties become higher. In addition, the entanglement between the fibers is suppressed, so that the fluidity is improved.
- the average fiber diameter D B of the reinforcing fiber (reinforcing fiber (B)) having a fiber length of 3 mm or more and 50 mm or less, and the average fiber diameter D C of the reinforcing fibers (reinforcing fiber (C)) fiber length is 15mm or more 50mm or less are of course the same as the average fiber diameter D in the formula (1) or (2).
- a length ratio of 1.5 to 10 is preferable because a molded article having particularly excellent moldability and strength can be obtained, and a length ratio of 1.5 to 5 is more preferable.
- the random mat of the present invention is particularly suitable for forming a molded body having raised portions such as ribs and bosses described later.
- the random mat of the present invention can have various thicknesses.
- a thin molded article having a thickness of about 0.2 to 1 mm can be suitably obtained. That is, according to the present invention, a random mat can be prepared in accordance with the thickness of a molded article for various purposes, and is particularly useful as a preform for a thin molded article such as a skin of a sandwich material.
- the average number of fibers in the reinforcing fiber bundle (A) can be controlled by a cutting step and a fiber opening step of a preferable manufacturing method as described later.
- the sandwich material refers to a member in which a plurality of materials are laminated in three or more layers, typically three layers.
- a typical example of a sandwich material is a laminate of different materials (face materials) on the front and back of the center layer material (core material) like a food sandwich, but in a broad sense, A laminate having four or more layers and a laminate in which the core material and the face material are the same are also included.
- the random mat of the present invention further contains a thermoplastic resin and becomes a preform for obtaining a reinforced fiber composite material.
- the thermoplastic resin is preferably present in the form of fibers and / or particles.
- the presence of a mixture of reinforced fiber and fibrous and / or particulate thermoplastic resin eliminates the need to flow the fiber and resin in the mold and allows easy impregnation of the thermoplastic resin during molding.
- the thermoplastic resin is preferably configured in a fibrous or particulate form. Two or more types of thermoplastic resins can be used, and fibrous and particulate resins may be used in combination.
- a cylindrical shape such as a spherical shape, a fine piece shape, or a pellet is preferable.
- a spherical shape a perfect circular or elliptical rotating body or an egg-like shape is preferable.
- a preferable average particle diameter in the case of a sphere is 0.01 to 1000 ⁇ m. More preferably, the average particle size is 0.1 to 900 ⁇ m, and still more preferably the average particle size is 1 to 800 ⁇ m.
- the particle size distribution is not particularly limited, but a sharp distribution is more preferable for the purpose of obtaining a thinner molded product, but can be used as a desired particle size distribution by an operation such as classification.
- a columnar shape such as a pellet, a prismatic shape, and a flake shape are preferable examples.
- it may have a certain aspect ratio, but the preferred length is about the same as that of the above fibrous form.
- thermoplastic resin examples include vinyl chloride resin, vinylidene chloride resin, vinyl acetate resin, polyvinyl alcohol resin, polystyrene resin, acrylonitrile-styrene resin (AS resin), acrylonitrile-butadiene-styrene resin (ABS resin), acrylic resin, Methacrylic resin, polyethylene resin, polypropylene resin, polyamide 6 resin, polyamide 11 resin, polyamide 12 resin, polyamide 46 resin, polyamide 66 resin, polyamide 610 resin, polyacetal resin, polycarbonate resin, polyethylene terephthalate resin, polyethylene naphthalate resin, boribylene Terephthalate resin, polybutylene naphthalate resin, polyarylate resin, polyphenylene ether resin, polyphenylene sulfide resin, poly Sulfone resins, polyether sulfone resins, polyether ether ketone resins, such as polylactic acid resins. These thermoplastic resins may be used alone or in combination.
- the abundance of the thermoplastic resin in the random mat is preferably 50 to 1000 parts by mass with respect to 100 parts by mass of the reinforcing fibers. More preferably, the thermoplastic resin is 55 to 500 parts by mass with respect to 100 parts by mass of the reinforcing fiber, and further preferably 60 to 300 parts by mass with respect to 100 parts by mass of the reinforcing fiber.
- various fibrous or non-fibrous fillers such as glass fibers and organic fibers, flame retardants, UV-resistant agents, pigments, mold release agents, softeners, and the like within a range that does not impair the purpose of the present invention.
- Plasticizers and surfactant additives may be included.
- the random mat of the present invention is preferably produced from the following steps 1 to 3. 1. Cutting the reinforcing fibers, 2. Introducing the cut reinforcing fiber into the tube and opening the fiber bundle; 3. Step of forming random mat from reinforcing fiber and thermoplastic resin. That is, the present invention includes a method for producing a random mat, which includes the above steps 1 to 3. Hereinafter, each step will be described in detail.
- the method for cutting reinforcing fibers in the method of the present invention is specifically a step of cutting reinforcing fibers using a knife.
- a knife used for cutting a rotary cutter or the like is preferable.
- the rotary cutter it is preferable to provide a spiral knife having a prescribed angle or a so-called splitting knife in which a large number of short blades are arranged.
- FIG. 2 An example of a rotary cutter having a spiral knife is shown in FIG. 2, and an example of a rotary cutter having a separating knife is shown in FIG.
- the size of the fiber bundle used for the cutting step for example, the width of the bundle and the number of fibers per width. It is preferable to control.
- a fiber bundle in which the number of fiber bundles of reinforcing fibers is in the range of formula (2) as a fiber bundle used for cutting.
- the smaller the number of fiber bundles the more expensive the fiber. Therefore, when a reinforcing fiber bundle having a large number of fiber bundles that can be obtained at low cost is used, it is preferable to adjust the width of the fiber bundle used for the cutting step and the number of fibers per width for use in the cutting step.
- the width of the fiber bundle is thinned by opening or the like and used for the cutting step, or a slitting step is provided before the cutting step. In the method of providing the slit process, since the fiber bundle is thinned in advance and used for the cutting process, a normal flat blade, a spiral blade or the like having no special mechanism can be used as the cutter.
- the method of cutting a fiber bundle using a splitting knife and the method of slitting simultaneously with cutting using the cutter which has a slit function are mentioned.
- the average fiber number (N) can be reduced by using a narrow knife width, and conversely, the average fiber number (N) can be increased by using a wide knife width. I can do things.
- FIG. 4 shows an example of a splitting cutter having a blade having a slit function parallel to the fiber direction in addition to a blade perpendicular to the fiber direction.
- short blades perpendicular to the fiber direction are spirally provided at a certain interval, and at the same time, the fibers can be cut with the blade perpendicular to the fiber direction.
- the angle ⁇ formed by the circumferential direction of the rotary cutter and the arrangement direction of the knife is also constant.
- a blade parallel to the fiber direction may be provided between the splitting knives.
- the density of fibers is greatly affected.
- the knife angle for continuously cutting the reinforcing fibers is geometrically calculated by the width of the reinforcing fibers to be used and the pitch of the blades, and the relationship between them is preferably the following formula (3).
- the pitch of the circumferential blade is directly reflected in the fiber length of the reinforcing fiber.
- Reinforcing fiber length (blade pitch) reinforcing fiber strand width ⁇ tan (90 ⁇ ) (3)
- ⁇ is an angle formed by the circumferential direction and the arrangement direction of the knife.
- FIGS. 2 to 4 are examples of knives that define the angles as described above, and an angle ⁇ formed by the circumferential direction and the arrangement direction of the knives in these cutter examples is shown in the drawings.
- a plurality of the above-described cutting devices are prepared, and the fibers cut by each of the cutting devices are separated by a fiber opening device or a coating device described later. Each can be mixed.
- the degree of opening by the opening device, the abundance of the reinforcing fiber bundle (A), and the average number of fibers (N) in the reinforcing fiber bundle (A) are appropriately determined depending on the pressure of air or the like.
- the average number of fibers (N) in the reinforcing fiber bundle (A) appropriate for each fiber length is not particularly limited, but the reinforcing fiber (C) having a fiber length of 15 to 50 mm has a fiber length of 3 to 15 mm.
- the average number of fibers in the reinforcing fiber bundle composed of single yarns of the number of critical single yarns or more as shown by the above formula (2C) is large, that is, the average number of fibers (N C ) is preferably larger than the average number of fibers (N B ). Since the reinforcing fiber (C) tends to have a larger aspect ratio than the reinforcing fiber (B), the reinforcing fiber (C) tends to be bent and entangled more easily as a fiber bundle, which may impair fluidity.
- the fiber can be cut by continuously changing the fiber length.
- the fiber-opening step in the method of the present invention is a step of introducing cut reinforcing fibers into a tube to open the fiber bundle.
- the fiber can be appropriately opened by blowing air onto the fiber.
- the degree of opening, the abundance of the reinforcing fiber bundle (A), and the average number of fibers (N) in the reinforcing fiber bundle (A) can be appropriately controlled by air pressure or the like.
- the reinforcing fibers can be opened by blowing air directly from the compressed air blowing holes at a wind speed of 1 to 1000 m / sec.
- the wind speed is more preferably 5 to 500 m / sec, and more preferably the wind speed is more than 50 to 500 m / sec.
- Step of forming random mat In this step, the cut and opened reinforcing fibers are diffused in the air, and at the same time, a granular or short fiber thermoplastic resin (hereinafter collectively referred to as “thermoplastic resin particles etc.”). And spraying the reinforcing fiber together with the thermoplastic resin particles and the like on a breathable support provided below the opening device, and in a state where the reinforcing fibers and the thermoplastic resin particles are mixed on the support. In this process, a random mat is formed by depositing and fixing to a thickness of 2 mm.
- thermoplastic resin particles etc. granular or short fiber thermoplastic resin
- the reinforcing fibers opened with gas and the thermoplastic resin particles supplied from another route are sprayed onto the breathable support at the same time, and the breathable support is in a state where they are almost uniformly mixed. It is deposited on the body in a mat shape and fixed in that state.
- the air-permeable support is constituted by a conveyor made of a net and is continuously moved in one direction and deposited thereon, a random mat can be continuously formed.
- the reinforcing fibers and the thermoplastic resin particles are dispersed so as to be two-dimensionally oriented.
- a tapered pipe having a conical shape or the like that is expanded downstream.
- the gas blown to the reinforcing fiber diffuses and the flow velocity in the tube is reduced, so that a rotational force is applied to the reinforcing fiber at this time.
- the opened reinforcing fibers can be evenly sprayed together with the thermoplastic resin particles and the like.
- a movable ventilation support such as a net conveyor having a suction mechanism below and deposit it in a random mat shape.
- the supply amount of the thermoplastic resin particles and the like is preferably 50 to 1000 parts by mass with respect to 100 parts by mass of the reinforcing fibers. More preferably, the thermoplastic resin particles and the like are 55 to 500 parts by mass, and still more preferably the thermoplastic resin particles and the like are 60 to 300 parts by mass with respect to 100 parts by mass of the reinforcing fiber.
- This random mat forming step includes a step of fixing reinforced fibers and thermoplastic resin particles. That is, this fixing step is a step of fixing the accumulated reinforcing fibers and thermoplastic resin particles.
- the reinforcing fibers are fixed by sucking air from the lower part of the breathable support.
- the thermoplastic resin sprayed at the same time as the reinforcing fiber is also mixed, and if it is fibrous, it is fixed with the reinforcing fiber even if it is particulate by air suction.
- thermoplastic resin particles and the like are uniformly present in the gaps and the vicinity of the reinforcing fibers contained therein, so that the resin moving distance is short and relatively short in the heating impregnation and pressurization step described later.
- the resin can be impregnated into the random mat over time.
- thermoplastic resin particles In order to prevent this, if the openings of the sheets, nets, etc. constituting the breathable support are small, if some of the thermoplastic resin particles pass through the support and do not remain in the mat, It is also possible to set a non-woven fabric or the like on the surface of the body and spray and fix the reinforcing fibers and thermoplastic resin particles on the non-woven fabric. In this case, if the nonwoven fabric is made of the same resin as the thermoplastic resin particles or the like, it is not necessary to peel the nonwoven fabric from the deposited mat, and the nonwoven fabric constituting fiber becomes a matrix of the composite material by heating and pressurizing as it is in the next step. It can be used as part of a thermoplastic resin.
- the strand piece and the reinforcing fiber separated into a single yarn state at the time of cutting are supplied to the transport path for sucking and transporting, and the middle or the end of the transport path Gas is blown to the reinforcing fibers from the gas blowing nozzle installed in the section, and the cut strand pieces are separated and opened into reinforcing fiber bundles of a desired size (thickness), and at the same time, the reinforcing fibers are made of thermoplastic resin particles.
- a random mat is formed by spraying and depositing on the surface of a breathable support (hereinafter sometimes referred to as “fixing net”) that moves continuously or intermittently in a certain direction.
- the transport route is preferably constituted by a flexible tube such as a flexible tube or a hose and a tapered tube continuously provided at the tip thereof.
- a gas blowing nozzle may be installed at the connection between the flexible tube and the taper tube.
- the reinforced fiber composite material refers to a material in which a resin is reinforced with a reinforced fiber in a broad sense, but in a narrow sense, a molding intermediate (a base material for molding) made of the material, such as a prepreg. Point to.
- a molding intermediate a base material for molding
- the reinforced fiber composite material in a narrow sense in the present invention will be described.
- the reinforcing fiber composite material of the present invention can also be referred to as a plate-like molded body.
- the random mat of the present invention has a characteristic that it is easily impregnated with a thermoplastic resin
- a reinforced fiber composite material can be efficiently obtained by a method such as hot press molding. Specifically, it is preferable to melt the thermoplastic resin in the random mat under pressure, impregnate the thermoplastic resin in the reinforcing fiber bundle and between the reinforcing yarns, and then cool and heat and press. This heating and pressurizing operation is preferably performed in a mold.
- the pressurizing condition for obtaining the reinforcing fiber composite material is preferably less than 10 MPa, more preferably 8 MPa or less, and further preferably 5 MPa or less.
- the molding pressure is less than 10 MPa, a cheaper or general molding apparatus can be used, and even when a large molded body is molded, it is preferable because capital investment and maintenance costs can be suppressed.
- the thermoplastic resin contained in the random mat is crystalline when the crystalline resin is crystalline or above the decomposition temperature, and when it is amorphous, the glass transition
- the thermoplastic resin is crystalline, it is preferably at least the melting point and below the decomposition temperature, and when amorphous, it is more preferably at the glass transition temperature and below the decomposition temperature.
- the decomposition temperature of the thermoplastic resin is preferably the heat decomposition temperature in air.
- a plate-like reinforcing fiber composite material (molded plate) can be obtained efficiently in a short time.
- the plate-like reinforcing fiber composite material is further useful as a prepreg for three-dimensional molding, particularly as a prepreg for press molding.
- the plate-like reinforcing fiber composite material is heated to its melting point or higher if the thermoplastic resin contained therein is crystalline, or to its glass transition temperature or higher if the thermoplastic resin is amorphous.
- the molded product can be obtained by so-called cold pressing, in which the molded product is put into the interior, pressurized and then cooled.
- a plate-like reinforcing fiber composite material is introduced into the mold, and if the thermoplastic resin contained therein is crystalline, the melting point or higher, or if the thermoplastic resin is amorphous, the glass transition temperature or higher. Press molding while raising the temperature, and then the mold is cooled to below the melting point if the thermoplastic resin is crystalline, or to the glass transition temperature below if the thermoplastic resin is amorphous. To obtain a molded body.
- the present invention includes a reinforcing fiber composite material obtained from a random mat, and a molded body obtained by molding the same.
- the reinforcing fiber and the thermoplastic resin are mixed and exist in close proximity, so that it is not necessary to flow the fiber and the resin in the mold, and the thermoplastic resin can be easily impregnated.
- the reinforcing fiber composite material obtained from the random mat of the present invention and the molded body obtained by molding the same it is possible to maintain the form of the reinforcing fibers in the random mat, that is, the isotropic property.
- the reinforcing fiber having an average fiber length of 3 mm or more and less than 15 mm is 50 to 100% by mass with respect to the total amount of mat fibers
- the reinforcing fiber having an average fiber length of 15 to 50 mm is 0 to 50% by mass with respect to the total amount of mat fibers.
- a reinforcing fiber bundle comprising a reinforcing fiber composed of% and a thermoplastic resin, wherein the reinforcing fiber is substantially two-dimensionally randomly oriented, and is composed of at least the critical single yarn number defined by the formula (1) ( Regarding A), the ratio of the reinforcing fiber bundle (A) to the total amount of fibers is 50 Vol% or more and less than 99 Vol%, and the average number of fibers (N) in the reinforcing fiber bundle (A) satisfies the following formula (2). It is a characteristic composite material.
- Critical number of single yarns 600 / D (1) 1.5 ⁇ 10 4 / D 2 ⁇ N ⁇ 3 ⁇ 10 5 / D 2 (2) (Where D is the average fiber diameter ( ⁇ m) of the reinforcing fibers)
- the melting temperature at the time of molding is increased, or the resin flows into a narrow flow path, that is, the melt viscosity is lowered by a shear flow, so ribs, bosses, etc. Can be formed to be thinner and higher.
- it is a resin-only flow, it is also possible to shape it into a complicated shape, making the best use of the effects of bosses and ribs while reducing the overall thickness of the molded body, with a smaller amount of resin, A large reinforcing effect can be imparted to the molded body.
- the molded body is a composite material, the fiber as the reinforcing material tends to hinder the fluidity.
- the reinforcing fiber composite material has a large aspect ratio of the reinforcing fiber, the fluidity of the material tends to be remarkably lowered. If the length of the reinforcing fiber is shortened and the aspect ratio is reduced, the fluidity of the material is increased, but the mechanical properties of the entire molded body are lowered. Conventionally, in the case of a composite material with high fluidity, the reinforcing fiber tends to be oriented in the flow direction, and even if the material flow direction has high strength, the strength does not increase in the direction orthogonal to the flow, and the molded body.
- the molded body obtained from the random mat of the present invention uses a random mat that flows isotropically as a constituent material, so that it is easier to form upright portions such as ribs and bosses.
- a reinforcing effect can be imparted to the entire molded body with a smaller amount of material.
- the molded object which has an upright part by this invention can be provided preferably.
- An upright part means the site
- the height of the upright portion is not particularly limited, but is preferably 1 to 300 mm, more preferably 5 to 100 mm.
- the height of the upright portion does not need to be uniform and can be increased or decreased locally. There is no particular limitation on the increase / decrease width of the upright height, preferably 10 to 90% of the maximum height, more preferably 20 to 80%.
- the plate thickness of the erected portion is preferably 0.2 to 100 mm, and more preferably 1 to 50 mm.
- the plate thickness of the upright portion does not need to be uniform, and can be locally increased or decreased.
- the increase / decrease width is not particularly limited, but is preferably 20 to 500%, more preferably 50 to 200%, of the base rising plate thickness.
- the plate thickness can be changed stepwise, and can be continuously changed with a taper or a curvature, but it is preferably changed continuously from the viewpoint of avoiding stress concentration.
- the upright portion extends in the vertical direction at an arbitrary angle from the horizontal portion of the molded body, and the rising angle from the horizontal portion is preferably 30 to 90 degrees, and more preferably 40 to 85 degrees. If the angle from the horizontal portion of the upright portion is smaller than 30 degrees, it is advantageous for releasing from the mold, but more material is required. Moreover, it is also possible to add arbitrary chamfering and curvature to the upright part to such an extent that the intention of the present invention is not impaired. There are no particular restrictions on the dimensions of chamfering and curvature, but C0.2 to 10 mm is preferable for chamfering, and R0.2 to 10 mm is preferable for curvature.
- the draft of the mold is preferably 1 to 45 degrees, more preferably 5 to 10 degrees.
- the upright portion may have partial unevenness and beads, but in this case, it should be noted that the draft angle of the mold can be secured.
- Ribs are used to increase the strength and rigidity of molded products without increasing the thickness of the molded product, for example, the edges and side walls of electronic and electrical equipment casings, or to warp or twist the molded product with a wide flat surface.
- the boss is used to reinforce a part of the molded body, such as to reinforce the periphery of the hole in the molded body, the fitting allowance when combined with other molded bodies or parts, and the purpose of stabilizing the sitting of the molded body.
- the protrusion part to provide is pointed out.
- the shape, length, and height of the rib are not particularly limited, and can be appropriately set according to the purpose.
- the edge or the side wall of the molded body it is installed in a shape such as a rectangular parallelepiped or a triangular prism at a portion to be reinforced, with a length or height of several mm to several hundred mm.
- the height is usually preferably 1 to 300 mm, and more preferably 5 to 100 mm. If the height is too low, it may be difficult to obtain a reinforcing effect.
- a continuous rib from one end to the other end of the molded body may be provided.
- the height may be constant or may be increased or decreased along the way.
- the increase / decrease width is preferably 10 to 90% of the maximum height, and more preferably 20 to 80%.
- the thickness of a rib It may be the same as a horizontal part, and may differ. Since the rib has a more complicated shape than the horizontal portion, the thickness is preferably 0.2 to 100 mm, and more preferably 1 to 50 mm. If the thickness is less than 0.2 mm, a sufficient reinforcing effect may not be exhibited. On the contrary, if it is thicker than 50 mm, it is not preferable in terms of economy and weight reduction.
- the rib thickness need not be uniform, and can be locally increased or decreased.
- the increase / decrease width is not particularly limited, but is preferably 20 to 500%, more preferably 50 to 200% of the base thickness.
- the thickness can be changed in stages, and can be continuously changed with a taper or curvature, but from the viewpoint of avoiding stress concentration when a load is applied. It is preferable to change.
- the shape, length, height, and thickness of the rib influence the reinforcement and deformation prevention of the molded body, respectively.
- the rib is larger, longer, taller, and thicker, and the reinforcing effect is higher. However, doing so is disadvantageous in terms of economy and weight reduction because more materials are required. Therefore, the shape and each size are set in a well-balanced manner according to the required reinforcement and deformation prevention level.
- the rib may have a through-hole for ventilation, etc., and may be opened with a shear or the like in the mold at the time of molding, and may be opened by drilling, punching or cutting as post-processing. May be.
- the shape of the boss is not particularly limited, and any shape such as a prism or a cylinder may be used, but a cylinder is more preferable in terms of reinforcing effect.
- the height is preferably 0.1 to 300 mm, more preferably 0.2 to 100 mm, depending on the size of the molded body. When the height is lower than 0.1 mm, it is difficult to obtain a reinforcing effect. When the height is higher than 300 mm, many materials are required, which is disadvantageous in terms of economy and weight reduction.
- the thickness is appropriately set according to the target reinforcement level, and may be the same as or different from the horizontal portion.
- the boss has a more complicated shape than the horizontal part, 0.5 to 100 mm is preferred when the shape is solid when the purpose of installing the boss is to stabilize the sitting of the molded body, etc., and 1 to 50 mm. Is more preferable.
- a hollow shape is formed.
- the thickness is preferably 0.2 to 50 mm, and more preferably 1 to 20 mm. If the thickness in the case of a solid body or the thickness in the case of a hollow body is too thin, it may be difficult to obtain a reinforcing effect. If it is too thick, more materials are required, which is disadvantageous in terms of economy and weight reduction.
- the thickness and thickness of the boss need not be uniform, and can be locally increased or decreased.
- the increase / decrease width is not particularly limited, but the difference between the thickest part and the thinnest part is preferably within 5 times, more preferably within 2 times.
- the thickness can be changed in stages, and can be continuously changed with a taper or curvature, but from the viewpoint of avoiding stress concentration when a load is applied. It is preferable to change.
- the boss may be insert-molded with a metal part such as a nutsert inside. As the molded body of the present invention, as illustrated in FIG.
- bosses and a plurality of ribs are preferable because they are practical, and are substantially rectangular parallelepiped boxes, It is more preferable to have bosses at least at the four corners of the box-like material and rib portions in an arrangement that partitions the inside of the box-like portion into two or more sections.
- molding method of the molded object using the random mat of this invention is not specifically limited, the following methods can be illustrated. That is, the impregnation / molding is performed by including the following steps A-1) to A-3) or the impregnation / molding is performed by including the steps B-1) to B-4).
- A-1) When the thermoplastic resin is crystalline, the random mat is heated above the melting point and below the decomposition temperature, and when amorphous, it is heated above the glass transition temperature and below the decomposition temperature, and pressurized to reinforce the thermoplastic resin.
- the prepreg obtained is below the melting point, and if it is amorphous, the glass transition Step of placing and pressurizing in a mold whose temperature is adjusted to below the temperature so that the charge rate represented by the following formula (4) is 5 to 100% or less A-3)
- the thermoplastic resin is crystalline Step of completing molding by adjusting the mold temperature below the melting point or below the glass transition temperature in the case of non-crystalline B-1) Charge rate 5-100% or less represented by the following formula (3)
- the mold is to a temperature not lower than the melting point of the thermoplastic resin and not higher than the thermal decomposition temperature, and in the case of amorphous, to a temperature not lower than the glass transition temperature of the thermoplastic resin and not higher than the thermal decomposition temperature.
- thermoplastic resin When the thermoplastic resin is crystalline, it can be preferably produced by a step of completing the molding by adjusting the mold temperature below the melting point, and when it is amorphous, below the glass transition temperature.
- the method of impregnating to forming including the steps A-1) to A-3) is a so-called cold press method.
- the method of impregnating to forming including the steps B-1) to B-4) is a so-called hot press method.
- Steps A-2) and B-3) are steps for applying a pressure to a substrate such as a prepreg or a random mat to obtain a desired molded body, but the molding pressure at this time is not particularly limited. It is preferably less than 10 MPa, more preferably 8 MPa or less, and even more preferably 5 MPa or less with respect to the mold cavity projected area. A molding pressure of 10 MPa or more is not preferable because a large amount of capital investment and maintenance costs are required particularly for molding a large molded body.
- the charge rate is a value defined by the following equation (4).
- Charge rate 100 ⁇ base material area (mm 2 ) / mold cavity projected area (mm 2 ) (4) (Here, the base material area is the projected area of all the arranged random mats or prepregs in the removal direction, and the mold cavity projected area is the projected area in the removal direction.)
- the charge rate is not particularly limited, but the substrate is more easily filled into a complicated shape by molding at a relatively low charge rate. Specifically, 5 to 100% is preferable, and 20 to 95% is more preferable. A more preferable base material charge rate is 50 to 90%. If the charge rate of the base material is lower than 5%, the base material may be cooled in the process of flowing during molding, and a molded product having a desired thickness may not be obtained. On the contrary, when the charge rate of the base material exceeds 100%, the feature of the present invention that the material is made to flow to some extent is not realized. Further, if the charge rate of the base material exceeds 100%, not only the loss of the base material is increased, but also post-processing such as trimming is required, which is disadvantageous in terms of productivity and cost.
- the carbon fibers used in this example are all PAN-based carbon fibers.
- the thermoplastic resin used by the Example and the comparative example is shown below.
- Polycarbonate glass transition temperature 150 ° C, thermal decomposition temperature (in air) 350 ° C
- Polyamide 66 melting point 265 ° C., thermal decomposition temperature (in air) 300 ° C.
- Polyamide 6 melting point 225 ° C, thermal decomposition temperature (in air) 300 ° C)
- the method for obtaining the average number of fibers (N) of the reinforcing fiber bundle (A) is as follows.
- the number of fibers (Ni) in each reinforcing fiber bundle is obtained by the following equation from the fineness (F) of the reinforcing fibers used.
- Ni Wi / (Li ⁇ F)
- the average number of fibers (N) in the reinforcing fiber bundle (A) is obtained from the number of bundles (I) of the reinforcing fiber bundle (A) by the following formula.
- the ratio (VR) of the reinforcing fiber bundle (A) to the total amount of fibers of the mat can be obtained by the following equation using the density ( ⁇ ) of the reinforcing fibers.
- VR ⁇ (Wi / ⁇ ) ⁇ 100 / ((Wk + ⁇ Wi) / ⁇ )
- Example 1 As the reinforcing fiber, carbon fiber “Tenax” (registered trademark) STS40-24KS (average fiber diameter: 7 ⁇ m, fiber width: 10 mm) manufactured by Toho Tenax Co., Ltd. was widened to a fiber width of 20 mm.
- the cutting device a rotary cutter using a cemented carbide and a spiral knife arranged on the surface was used.
- Reinforcing fiber length (blade pitch) reinforcing fiber strand width ⁇ tan (90 ⁇ ) (3) (Here, ⁇ is the angle between the circumferential direction and the knife.) ⁇ was 68 degrees, the blade pitch was 8 mm, and the reinforcing fiber was cut to a fiber length of 8 mm.
- nipples made of SUS304 having different diameters were welded to produce a double pipe. A small hole was provided in the inner tube, and compressed air was supplied to the outer tube using a compressor. At this time, the wind speed from the small hole was 150 m / sec. This pipe was placed directly under the rotary cutter, and a tapered pipe was welded to the lower part thereof.
- Matrix resin is supplied from the side of the taper tube, and as this matrix resin, polycarbonate “Panlite” (registered trademark) L-1225L pellets made by Teijin Chemicals Ltd. are frozen and ground, and further at 20 mesh and 100 mesh Classified particles were used. The average particle size of the polycarbonate powder was about 710 ⁇ m.
- a table movable in the XY directions was installed at the lower part of the taper tube outlet, and suction was performed from the lower part of the table with a blower.
- the reinforcing fiber supply rate is set to 180 g / min and the matrix resin supply rate is set to 480 g / min, and the apparatus is operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin (polycarbonate powder) are mixed. It was.
- the average fiber length of the reinforcing fibers of the obtained random mat was 8 mm, and the basis weight of the reinforcing fibers was 200 g / m 2 .
- the critical single yarn number defined by the formula (1) was 86, and the reinforcing fiber bundle (A)
- the ratio of the mat to the total amount of fibers was 61%
- the average number of fibers (N B ) in the bundle of reinforcing fibers ( B ) was 1500
- the average number of fibers (N) of the reinforcing fiber bundle (A) was 1500.
- the surface of the obtained random mat was observed, it was not oriented in a specific direction in the plane and was randomly dispersed. Further, the polycarbonate powder was dispersed in the reinforcing fiber without any large spots.
- the obtained random mats were stacked 8 times and heated at 4 MPa for 3 minutes with a press apparatus heated to 300 ° C. to obtain a reinforced fiber composite material (molded plate) having a thickness of 4.8 mm.
- molded plate When the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- E ⁇ elastic modulus
- the ratio of elastic modulus (E ⁇ ) was 1.03, and there was almost no fiber orientation, and a material that maintained isotropy was obtained. I was able to get it.
- this molded plate was heated in a furnace at 500 ° C. for about 1 hour to remove the resin, and then the ratio of the reinforcing fiber bundle (A) and the average number of fibers (N) were examined. There was no difference from the measurement results.
- the molded plate obtained was heated to 300 ° C. using an IR oven made by NGK Kiln Tech, and placed at a horizontal portion of the mold shown in FIG. Cold pressing was performed at a pressure of 5 MPa for 60 seconds to obtain a molded body having bosses and ribs as shown in FIG.
- each part has Horizontal part (9) is 400mm long, 200mm wide, 2mm thick Side wall (10) is 50mm high and 2mm thick Rib 1 (11A) is 50mm high and 2mm thick Rib 2 (11B) is 30-50mm high and 2mm thick Rib 3 (11C) is 30-50mm high and 1mm thick
- Boss 1 (12A) has a height of 50 mm, a hollow part diameter of 5 mm, and a wall thickness of 2 mm.
- Boss 2 (12B) has a height of 40 mm, a hollow part diameter of 5 mm, and a wall thickness of 2 mm.
- Boss 3 (12C) has a height of 50 mm, a hollow part diameter of 5 mm, and a wall thickness of 1 mm.
- the boss 4 (12D) had a height of 40 mm, a hollow part diameter of 5 mm, and a wall thickness of 1 mm.
- the strip-shaped test piece was cut out from the horizontal part and the rib part, the tension test was done, and the evaluation result was described in Table 1.
- Example 2 As the reinforcing fiber, carbon fiber “Tenax” (registered trademark) IMS 60-12K (average fiber diameter 5 ⁇ m, fiber width 6 mm) manufactured by Toho Tenax Co., Ltd. was used.
- As the cutting device a rotary cutter having a blade pitch of 8 mm as in Example 1 was used. This rotary cutter was provided with blades parallel to the fiber direction at 0.8 mm intervals for the purpose of reducing the fiber bundle.
- the opening device used was the same as in Example 1, and the wind speed from the small hole was 100 m / sec. This pipe was placed directly under the rotary cutter, and a tapered pipe was welded to the lower part thereof.
- Matrix resin was supplied from the side surface of the tapered tube, and PA66 fiber (T5 nylon fineness 1400 dtex made by Asahi Kasei Fiber) dry-cut to 2 mm was used as the matrix resin.
- a table movable in the X and Y directions similar to that in Example 1 was installed at the lower part of the taper tube outlet, and suction was performed from the lower part of the table with a blower.
- the supply amount of the reinforcing fibers was set to 270 g / min and the supply amount of the matrix resin was set to 550 g / min.
- the apparatus was operated to obtain a random mat in which the reinforcing fibers and the polyamide (PA66 fiber) were mixed.
- the basis weight of the reinforcing fiber was 300 g / m 2 .
- the critical single yarn number defined by the formula (1) was 120, and the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers was 93%, the average number of fibers (N B ) in the bundle of reinforcing fibers ( B ) was 1900, and the average number of fibers (N) of the reinforcing fiber bundle (A) was 1900.
- Nylon fiber (PA66 fiber) was dispersed in the reinforcing fiber without any large spots. Eight random mats obtained were stacked and heated at 4.0 MPa for 3 minutes with a press apparatus heated to 280 ° C.
- a reinforced fiber composite material (molded plate) having a thickness of 5.9 mm.
- the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- the ratio of elastic modulus (E ⁇ ) was 1.07, and there was almost no fiber orientation, and a material that maintained isotropy was obtained. I was able to get it.
- this molded plate was heated in a furnace at 500 ° C. for about 1 hour to remove the resin, and then the ratio of the reinforcing fiber bundle (A) and the average number of fibers (N) were examined. There was no difference from the measurement results.
- the molded plate obtained was heated to 300 ° C. using an IR oven made by NGK Kiln Tech, and placed at a horizontal portion of the mold shown in FIG. Cold pressing was performed at a pressure of 5 MPa for 60 seconds to obtain a molded body having bosses and ribs as shown in FIG. Table 1 shows the results of evaluating the obtained molded plate and molded body in the same manner as in Example 1.
- Example 3 As a reinforcing fiber, a carbon fiber “TENAX” (registered trademark) STS40-24KS (average fiber diameter: 7 ⁇ m, fiber width: 10 mm) manufactured by Toho Tenax Co., Ltd. was widened to a fiber width of 20 mm as in Example 1. did.
- As the cutting device two rotary cutters (cutting devices a and b) using a cemented carbide and having a spiral knife arranged on the surface were used. In the cutting device a, ⁇ in the formula (3) is 45 degrees, the blade pitch is 20 mm, and the reinforcing fiber is cut to a fiber length of 20 mm.
- ⁇ in the formula (3) is 68 degrees
- the pitch of the blade was 8 mm
- the reinforcing fiber could be cut to a fiber length of 8 mm.
- the opening device two double tubes similar to those in Example 1 were prepared, and each was arranged immediately below the cutting devices a and b. At this time, the wind speed from the small holes was 150 m / sec.
- the same tapered pipe as in Example 1 was welded to the lower part of the double pipe immediately below the cutting device a.
- another hole is formed on the side of the tapered pipe of Example 3 and the lower part of the double pipe just below the cutting device b and this hole has an inner diameter of 1.5 mm.
- the reinforcing fiber supply amount from the cutting device a is set to 81 g / min
- the reinforcing fiber supply amount from the cutting device b is set to 189 g / min
- the matrix resin supply amount is set to 550 g / min.
- the critical single yarn number defined by the formula (1) was 86, and the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers is 86%, and the average number of fibers in the bundle of reinforcing fibers (B) and (C) (respectively N B and N C ) is 1500 and 2200, respectively, and the reinforcing fiber bundle (A) The average number of fibers (N) was 1800.
- the polyamide powder (PA6 powder) was dispersed in the reinforcing fiber without any large spots.
- the obtained random mats were stacked eight times and heated at 4.0 MPa for 3 minutes with a press apparatus heated to 260 ° C. to obtain a reinforced fiber composite material (molded plate) having a thickness of 5.9 mm.
- molded plate When the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- the ratio of elastic modulus (E ⁇ ) was 1.05, there was almost no fiber orientation, and a material that maintained isotropy was used. I was able to get it. Furthermore, this molded plate was heated in a furnace at 500 ° C.
- Example 1 shows the results of evaluating the obtained molded plate and molded body in the same manner as in Example 1.
- Example 4 As the reinforcing fiber, glass fiber EX-2500 (average fiber diameter 15 ⁇ m, fiber width 9 mm) manufactured by Nippon Electric Glass Co., Ltd. was used.
- As the cutting device a rotary cutter in which a fiber and a short blade in a 90-degree direction are arranged obliquely using a cemented carbide and having a separating knife arranged on the surface thereof was used. The width of the knife was 1 mm, and a blade parallel to the fiber direction was provided between the knives for the purpose of miniaturizing the fiber bundle. At this time, ⁇ in the above formula (3) was 42 degrees, the blade pitch was 10 mm, and the reinforcing fiber was cut to a fiber length of 10 mm.
- Example 2 An apparatus similar to that in Example 1 was used as the opening apparatus. By reducing the pressure of the compressor, the wind speed from the small hole was 250 m / sec. This pipe was placed directly under the rotary cutter, and a tapered pipe was welded to the lower part thereof. A matrix resin is supplied from the side of the taper tube, and as this matrix resin, polycarbonate “Panlite” (registered trademark) L-1225L pellets made by Teijin Chemicals Ltd. are freeze-ground and further, 30 mesh and 200 mesh are used. Classified powder was used. At this time, the average particle size was about 360 ⁇ m.
- the reinforcing fiber supply rate is set to 300 g / min and the matrix resin supply rate is set to 600 g / min, and the apparatus is operated to obtain a random mat in which the reinforcing fibers and the thermoplastic resin (polycarbonate powder) are mixed. It was.
- the basis weight of the reinforcing fiber was 300 g / m 2 .
- the critical single yarn number defined by the formula (1) was 40, and the reinforcing fiber bundle (A)
- the ratio of the mat to the total amount of fibers was 63%
- the average number of fibers (N B ) in the bundle of the 63% reinforcing fibers (B) was 300
- the average number of fibers (N) of the reinforcing fiber bundle (A) was 300.
- the polycarbonate powder was dispersed in the reinforcing fiber without any large spots.
- the molded plate obtained was heated to 300 ° C. using an IR oven made by NGK Kiln Tech, and placed at a horizontal portion of the mold shown in FIG. Cold pressing was performed at a pressure of 5 MPa for 60 seconds to obtain a molded body having bosses and ribs as shown in FIG.
- the results of evaluating the obtained molded body in the same manner as in Example 1 are shown in Table 1.
- Example 5 A random mat was prepared in the same manner as in Example 1 except that the reinforcing fiber supply rate was 315 g / min and the matrix resin supply rate was 390 g / min.
- the average fiber length of the reinforcing fibers of the obtained random mat was 8 mm, and the basis weight of the reinforcing fibers was 350 g / m 2 .
- the critical single yarn number defined by the formula (1) was 86, and the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers was 66%, the average number of fibers (N B ) in the bundle of reinforcing fibers ( B ) was 1600, and the average number of fibers (N) of the reinforcing fiber bundle (A) was 1600. .
- the surface of the obtained random mat was observed, it was not oriented in a specific direction in the plane and was randomly dispersed. Further, the polycarbonate powder was dispersed in the reinforcing fiber without any large spots.
- the obtained random mats were stacked 8 times and heated at 4 MPa for 3 minutes with a press apparatus heated to 300 ° C. to obtain a reinforced fiber composite material (molded plate) having a thickness of 4.8 mm.
- molded plate When the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- the ratio of elastic modulus (E ⁇ ) was 1.05, there was almost no fiber orientation, and a material that maintained isotropy was used. I was able to get it. Furthermore, this molded plate was heated in a furnace at 500 ° C.
- Example 1 shows the results of evaluating the obtained molded plate and molded body in the same manner as in Example 1.
- Example 6 In Example 3, the supply amount of the reinforcing fiber (fiber length 20 mm) from the cutting device a is 450 g / min, the supply amount of the reinforcing fiber from the cutting device b (fiber length 8 mm) is 450 g / min, and the supply amount of the matrix resin was set to 1830 g / min, and the apparatus was operated to obtain a random mat in which reinforcing fibers and polyamide 6 were mixed. The basis weight of the reinforcing fiber was 1000 g / m 2 .
- the critical single yarn number defined by the formula (1) was 86, and the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers is 87%, and the average number of fibers in the bundle of reinforcing fibers (B) and (C) (respectively N B and N C ) is 1700 and 2300, respectively, and the reinforcing fiber bundle (A) The average number of fibers (N) was 2000.
- the surface of the obtained random mat was observed, it was not oriented in a specific direction in the plane and was randomly dispersed.
- the polyamide powder was dispersed in the reinforcing fiber without any large spots.
- Three random mats obtained were stacked and heated at 4 MPa for 3 minutes with a press apparatus heated to 260 ° C. to obtain a reinforced fiber composite material (molded plate) having a thickness of 6.0 mm.
- molded plate When the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- the ratio of elastic modulus (E ⁇ ) was 1.02, there was almost no fiber orientation, and a material that maintained isotropy was obtained. I was able to get it.
- this molded plate was heated in a furnace at 500 ° C. for about 1 hour to remove the resin, and then the ratio of the reinforcing fiber bundle (A) and the average number of fibers (N) were examined. There was no difference from the measurement results. Further, the molded plate obtained was heated to 300 ° C. using an IR oven made by NGK Kiln Tech, and placed at a horizontal portion of the mold shown in FIG. Cold pressing was performed at a pressure of 5 MPa for 60 seconds to obtain a molded body having bosses and ribs as shown in FIG. Table 1 shows the results of evaluating the obtained molded plate and molded body in the same manner as in Example 1.
- Example 7 In Example 3, a splitting knife as used in Example 4 and a rotary cutter having blades parallel to the fiber direction and the splitting knife used in Example 4 were used for both of the two cutting devices.
- ⁇ in the above formula (3) is 45 degrees
- the blade pitch is 20 mm
- the reinforcing fiber is cut to a fiber length of 20 mm.
- ⁇ was 68 degrees
- the blade pitch was 8 mm
- the reinforcing fiber could be cut to a fiber length of 8 mm.
- the opening device two double tubes similar to those in Example 1 were prepared, and each was arranged immediately below the cutting devices a and b.
- the wind speed from the small holes was 150 m / sec.
- the same tapered pipe as in Example 1 was welded to the lower part of the double pipe immediately below the cutting device a.
- another hole is formed on the side of the tapered pipe of Example 3 and the lower part of the double pipe just below the cutting device b and this hole has an inner diameter of 1.5 mm.
- Connected with rubber hose As a result, the fibers cut by the cutting device b are moved through the hose and supplied to the tapered tube, and the fibers cut by the cutting devices a and b are mixed by the tapered tube.
- PA6 powder (A1030FP manufactured by Unitika) was used as a matrix resin supplied from the side surface of the tapered tube.
- a table movable in the X and Y directions similar to that in Example 1 was installed at the lower part of the taper tube outlet, and suction was performed from the lower part of the table with a blower.
- the supply amount of the reinforcing fiber from the cutting device a was set to 81 g / min
- the supply amount of the reinforcing fiber from the cutting device b was set to 189 g / min
- the supply amount of the matrix resin was set to 550 g / min.
- a random mat in which reinforcing fibers and polyamide were mixed was obtained.
- the basis weight of the reinforcing fiber was 300 g / m 2 .
- the critical single yarn number defined by the formula (1) was 86, and the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers is 80%, the average number of fibers in the bundle of reinforcing fibers (B) and (C) (respectively N B and N C ) is 500 and 800, respectively, and the reinforcing fiber bundle (A) The average number of fibers (N) was 600. Further, the polyamide powder was dispersed in the reinforcing fiber without any large spots. The obtained random mats were stacked eight times and heated at 4.0 MPa for 3 minutes with a press apparatus heated to 260 ° C.
- a reinforced fiber composite material (molded plate) having a thickness of 5.9 mm.
- the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- the ratio of elastic modulus (E ⁇ ) was 1.03, and there was almost no fiber orientation, and a material that maintained isotropy was obtained. I was able to get it.
- this molded plate was heated in a furnace at 500 ° C. for about 1 hour to remove the resin, and then the ratio of the reinforcing fiber bundle (A) and the average number of fibers (N) were examined. There was no difference from the measurement results.
- the molded plate obtained was heated to 300 ° C. using an IR oven made by NGK Kiln Tech, and placed at a horizontal portion of the mold shown in FIG. Cold pressing was performed at a pressure of 5 MPa for 60 seconds to obtain a molded body having bosses and ribs as shown in FIG. Table 1 shows the results of evaluating the obtained molded plate and molded body in the same manner as in Example 1.
- Example 1 a random mat was prepared in the same manner except that the wind speed from the small hole was set to 450 m / sec.
- the critical single yarn number defined by the formula (1) was 86
- the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers was 43%
- the average number of fibers in the bundle of reinforcing fibers (B) (N B ) was 800
- the average number of fibers (N) of the reinforcing fiber bundle (A) was 800. .
- the fiber bundles present in the obtained random mat were thin, not oriented in a specific direction in the plane, and randomly dispersed. Further, the polycarbonate powder was dispersed in the reinforcing fiber without any large spots. Heating was performed at 4 MPa for 3 minutes using a press machine in which eight random mats obtained in the same manner as in Example 1 were stacked and heated to 300 ° C. to obtain a reinforcing fiber composite material (molded plate) having a thickness of 4.8 mm. It was. When the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- Example 1 shows the results of evaluating the obtained molded plate and molded body in the same manner as in Example 1.
- Example 2 In Example 1, a random mat was obtained by the same method except that the angle ⁇ of the spiral blade of the rotary cutter was 45 degrees and the pitch of the blade was 20 mm.
- the critical single yarn number defined by the formula (1) was 86
- the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers was 71%
- the average number of fibers (N C ) in the bundle of reinforcing fibers ( C ) was 2200
- the average number of fibers (N) of the reinforcing fiber bundle (A) was 2200.
- the obtained random mats were stacked 8 times and heated at 4 MPa for 3 minutes with a press apparatus heated to 300 ° C. to obtain a reinforced fiber composite material (molded plate) having a thickness of 4.8 mm.
- molded plate When the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- Example 3 the supply amount of the reinforcing fiber (fiber length 20 mm) from the cutting device a is 216 g / min, the supply amount of the reinforcing fiber (fiber length 8 mm) from the cutting device b is 54 g / min, and the supply amount of the matrix resin was set to 550 g / min, and the apparatus was operated. As a result, a random mat in which reinforcing fibers and polyamide 6 were mixed was obtained. The basis weight of the reinforcing fiber was 300 g / m 2 .
- the critical single yarn number defined by the formula (1) was 86, and the reinforcing fiber bundle (A) The ratio of the mat to the total amount of fibers is 85%, the average number of fibers in the bundle of reinforcing fibers (B) and (C) (respectively N B and N C ) is 1500 and 2200, respectively, and the reinforcing fiber bundle (A) The average number of fibers (N) was 2100.
- the surface of the obtained random mat was observed, it was not oriented in a specific direction in the plane and was randomly dispersed. Further, the polyamide powder was dispersed in the reinforcing fiber without any large spots.
- Polyamide 6 resin (manufactured by Ube Industries, 1013B) is supplied as a matrix resin to a hopper of a screw type extruder whose temperature is adjusted to 260 ° C., and a predetermined amount of molten resin is measured at the number of revolutions of the gear pump to 260 ° C.
- a temperature-controlled extruder (Ikegai, FS50) was supplied to the impregnation crosshead die.
- carbon fiber “Tenax” (registered trademark) STS40-24KS (average fiber diameter: 7 ⁇ m, fiber width: 10 mm) manufactured by Toho Tenax Co., Ltd.
- a reinforcing fiber is widened to have a fiber width of 20 mm.
- the volume content of the reinforcing fiber in the tape prepreg was 30%.
- the obtained tape prepreg was slit to 10 mm in width, then cut to 10 mm, randomly distributed in a flat plate mold, and heated at 4.0 MPa for 3 minutes in a press apparatus heated to 260 ° C.
- a 5.8 mm reinforcing fiber composite material (molded plate) was obtained.
- the obtained molded plate was subjected to an ultrasonic flaw detection test, no unimpregnated portion or void was found.
- the elastic modulus ratio (E ⁇ ) was 1.13, and there was almost no fiber orientation, and a material that maintained isotropy was obtained. I was able to get it.
- the molded plate was heated in a furnace at about 500 ° C. for about 1 hour to remove the resin, and then the ratio of the reinforcing fiber bundle (A) and the average number of fibers (N) were examined.
- the number of critical single yarns defined by is 86, with respect to the reinforcing fiber bundle (A), the ratio of the mat to the total amount of fibers is 97%, and the average number of fibers in the bundle of reinforcing fibers (B) (N B ) is 11000, The average fiber number (N) of the reinforcing fiber bundle (A) was 11,000. Further, the molded plate obtained was heated to 300 ° C. using an IR oven made by NGK Kiln Tech, and placed at a horizontal portion of the mold shown in FIG. Cold pressing was performed at a pressure of 5 MPa for 60 seconds to obtain a molded body having bosses and ribs. The evaluation results of the obtained molded body are shown in Table 1. The tensile modulus ratio between the horizontal portion and the rib portion was 1.53, and the isotropic property was slightly inferior.
- the random mat of the present invention is preferably used as a preform for molding a reinforced fiber composite material, and has excellent fluidity during molding. Therefore, a random three-dimensional shape such as a rib or a boss extending in the vertical direction with respect to a horizontal portion is formed. The upper part can be easily molded at a relatively low pressure. Therefore, from the random mat according to the present invention, the product shape can be formed using the minimum necessary material, and it can be expected that the trimming process is eliminated and the waste material is significantly reduced and the cost is reduced accordingly. Moreover, the random mat of the present invention can be used as a preform for various structural members, for example, an inner plate, an outer plate, a structural member of an automobile, various electric products, a frame of a machine, a casing, and the like.
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Abstract
Description
i)繊維長が3mm以上15mm未満である強化繊維がランダムマットに含まれる強化繊維全量に対し50~100質量%であり、繊維長が15mm以上50mm以下である強化繊維がランダムマットに含まれる強化繊維全量に対し0~50質量%である、
ii)強化繊維の目付けが25~10000g/m2である、
iii)強化繊維について下記式(1)で定義される臨界単糸数未満の単糸と、臨界単糸数以上で構成される強化繊維束(A)が同時に存在する、
iv)強化繊維束(A)について、マットの繊維全量に対する割合が50Vol%以上99Vol%未満である、
v)強化繊維束(A)中の平均繊維数(N)が下記式(2)を満たす、
臨界単糸数=600/D (1)
1.5×104/D2<N<3×105/D2(2)
(ここでDは強化繊維の平均繊維径(μm)である)
本発明のランダムマットは、繊維長3~50mmの強化繊維を含み、下記i)~v)を満たす。
i)繊維長が3mm以上15mm未満である強化繊維がランダムマットに含まれる強化繊維全量に対し50~100質量%であり、繊維長が15mm以上50mm以下である強化繊維がランダムマットに含まれる強化繊維全量に対し0~50質量%である、
ii)強化繊維の目付けが25~10000g/m2である、
iii)強化繊維について下記式(1)で定義される臨界単糸数未満の単糸と、臨界単糸数以上で構成される強化繊維束(A)が同時に存在する、
iv)強化繊維束(A)について、ランダムマットに含まれる強化繊維全量に対する割合が50Vol%以上99Vol%未満である、
v)強化繊維束(A)中の平均繊維数(N)が下記式(2)を満たす、
臨界単糸数=600/D (1)
1.5×104/D2<N<3×105/D2 (2)
(ここでDは強化繊維の平均繊維径(μm)である)
なお、本発明において、強化繊維束(A)について、ランダムマットに含まれる強化繊維全量に対する割合(Vol%)を、マット繊維全体に対する体積比(Vol%)と記することがある。
本発明のランダムマットは面内等方性に優れた材料である。ランダムマットより成形体を得た場合に、ランダムマット中の強化繊維の等方性は、成形体においても維持される。ランダムマットより成形体を得て、互いに直交する二方向の引張弾性率の比を求めることで、ランダムマットおよびそれからの成形体の等方性を定量的に評価できる。ランダムマットから得られた成形体における2方向の弾性率の値のうち大きいものを小さいもので割った比が2を超えないときに等方性であるとする。比が1.3を超えないときは等方性に優れているとする。
ランダムマットにおける強化繊維の目付けは25~10000g/m2の範囲である。ランダムマットはプリプレグとして有用であり、所望の成形に合わせて各種目付けが選択でき、目付けは好ましくは25~4500g/m2であり、より好ましくは25~3000g/m2である。
ランダムマットに含まれる強化繊維は不連続であり、強化繊維としては、繊維長が3mm以上15mm未満の強化繊維(以下、強化繊維(B)と称することがある)が含まれる。強化繊維(B)は成形時の流動性に大きく寄与する群であり、強化繊維(B)の繊維長の範囲としては5~15mmが好ましく、7~13mmがより好ましく、7~10mmがより一層好ましい。また、強化繊維(B)はランダムマットに含まれる強化繊維全量に対し50~100質量%であり、70~100質量%が好ましく、90~100質量%がより好ましい。後述する好ましい強化繊維のカット方法において、強化繊維を固定長にカットしてランダムマットを製造した場合、平均繊維長はカットした繊維長とほぼ等しくなる。
なお、本発明において、特定の強化繊維について、ランダムマットに含まれる強化繊維全量に対する質量%を、マット繊維全体に対する質量比(%)と記することがある。
強化繊維はサイジング剤が付着されたものを用いることが好ましく、サイジング剤は強化繊維100質量部に対し、0~10質量部であることが好ましい。
ガラス繊維の場合、平均繊維径は好ましくは3~20μmであり、より好ましくは10~15μmである。
本発明のランダムマットは、式(1)
臨界単糸数=600/D (1)
(ここでDは強化繊維の平均繊維径(μm)である)
で定義する臨界単糸数以上で構成される強化繊維束(A)について、ランダムマットの繊維全量に対する割合が50Vol%以上99Vol%未満であることを特徴とする。ランダムマット中には、強化繊維束(A)以外の強化繊維として、単糸の状態または臨界単糸数未満で構成される繊維束が存在する。
1.5×104/D2<N<3×105/D2(2)
(ここでDは強化繊維の平均繊維径(μm)である)
を満たすことを特徴とする。
具体的にはランダムマットに含まれる強化繊維の平均繊維径が5~7μmの場合、臨界単糸数は86~120本となり、強化繊維の平均繊維径が5μmの場合、繊維束中の平均繊維数は600~12000本の範囲となるが、なかでも1000~9000本であることが好ましい。強化繊維の平均繊維径が7μmの場合、繊維束中の平均繊維数は306~6122本の範囲となるが、なかでも500~4900本であることが好ましい。
1.5×104/DB 2<NB<3×105/DB 2 (2B)
(ここでDBは強化繊維の平均繊維径(μm)である)
本発明において、繊維長が15mm以上50mm以下である強化繊維(C)が存在しない場合、当然、上記の平均繊維数(NB)は前記の平均繊維数(N)にひとしい。
更に、繊維長が15mm以上50mm以下である強化繊維(C)について、前記式(1)に定義される臨界単糸数以上で構成される強化繊維束(AC)中の平均繊維数(NC)が下記式(2C)を満たすことが好ましい。
5.0×104/DC 2<NC<3×105/DC 2 (2C)
(ここでDCは繊維長が15mm以上50mm以下である強化繊維の平均繊維径(μm)である)
強化繊維(C)は比較的繊維長が長い成分であり、比較的束を構成する繊維本数が多いほうが、ランダムマット中で繊維の直線性を担保することが容易となり、機械的物性が高くなるだけでなく、繊維同士の絡合も抑制されるため、流動性が向上する。
なお、本発明において、一種類の強化繊維のみが用いられている場合などは、上記の、繊維長が3mm以上50mm以下である強化繊維(強化繊維(B))の平均繊維径DB、および繊維長が15mm以上50mm以下である強化繊維(強化繊維(C))の平均繊維径DCは、前記式(1)や(2)における平均繊維径Dと当然同じである。
本発明においては、繊維長が3mm以上15mm未満である強化繊維(強化繊維(B))の平均繊維長に対する、繊維長が15mm以上50mm以下である強化繊維(強化繊維(C))の平均繊維長の比が1.5~10であると、成形性と強度の双方が特に優れた成形体とすることができるので好ましく、1.5~5であるとより好ましい。
ここでサンドイッチ材とは、複数の素材を3層以上、代表的なものとしては3層、が積層された部材のことを言う。サンドイッチ材として特に代表的なものは、食品のサンドイッチのように、中心層の材料(芯材)の表裏に、これとは異なる材料(面材)を積層したものであるが、広義には、4層以上の積層体であるものや、芯材と面材とが同一素材の積層体も含まれる。
本発明のランダムマットは、さらに熱可塑性樹脂を含み、強化繊維複合材料を得るためのプリフォームとなる。ランダムマットにおいては、熱可塑性樹脂が、繊維状および/または粒子状で存在することが好ましい。強化繊維と繊維状および/または粒子状の熱可塑性樹脂が混合して存在していることにより、型内で繊維と樹脂を流動させる必要がなく、成形時に熱可塑性樹脂を容易に含浸できることを特徴とする。熱可塑性樹脂は、繊維状又は粒子状で構成されることが好ましい。熱可塑性樹脂の種類を2種以上とすることもでき、また繊維状と粒子状のものを併用してもよい。
これらの熱可塑性樹脂は単独で使用しても良いし、複数を併用して用いても良い。
本発明のランダムマット中には、本発明の目的を損なわない範囲で、ガラス繊維や有機繊維等の各種繊維状または非繊維状フィラー、難燃剤、耐UV剤、顔料、離型剤、軟化剤、可塑剤、界面活性剤の添加剤を含んでいてもよい。
以下本発明のランダムマットを好ましく得る方法について述べる。本発明のランダムマットは以下の工程1~3より、好ましく製造される。
1.強化繊維をカットする工程、
2.カットされた強化繊維を管内に導入し、繊維束を開繊させる工程、
3.強化繊維と熱可塑性樹脂からランダムマットを形成する工程
すなわち本発明は、上記の工程1~3を含む、ランダムマットの製造方法を包含する。
以下、各工程について詳細に述べる。
本発明方法における強化繊維のカット方法は、具体的にはナイフを用いて強化繊維をカットする工程である。カットに用いるナイフとしてはロータリーカッター等が好ましい。ロータリーカッターとしては、角度を規定した螺旋状ナイフ、あるいは短い刃を多数並べたいわゆる分繊ナイフを設けたものが好ましい。カット工程の具体的な模式図を図1に示す。螺旋状ナイフを有するロータリーカッターの一例を図2に、分繊ナイフを有するロータリーカッターの一例を図3に示す。
強化繊維束(A)中の平均繊維数(N)を本発明における好ましい範囲とするために、カット工程に供する繊維束の大きさ、例えば束の幅や幅当たりの繊維数を調整することでコントロールすることが好ましい。
分繊ナイフを用いる場合、ナイフ幅が狭いものを用いる事で平均繊維数(N)を小さくする事ができ、逆にナイフの幅が広いものを用いる事で平均繊維数(N)を大きくする事ができる。
強化繊維の繊維長(刃のピッチ)=強化繊維ストランド幅×tan(90-θ) (3)
ここで、θは周方向とナイフの配置方向のなす角である。
また、ランダムマットをに含まれる強化繊維の繊維長を2種類以上とする場合は、上述のカット装置を複数用意し、各々のカット装置で切断した繊維を、後述する開繊装置もしくは塗布装置により各々を混合することができる。その際、後述するように開繊装置によって開繊の度合い、強化繊維束(A)の存在量、および強化繊維束(A)中の平均繊維数(N)については、空気の圧力等により適宜コントロールする事が出来、複数のカット装置各々にそれぞれ開繊装置を設置し、各々の開繊装置について空気の圧力を変え、各々の繊維長について適正な強化繊維束(A)の存在量、および強化繊維束(A)中の平均繊維数(N)を得ることができる。各繊維長に対して適正な強化繊維束(A)中の平均繊維数(N)は特に限定はしないが、繊維長が15以上50mm以下の強化繊維(C)は、繊維長が3mm以上15mm未満の強化繊維(B)に対し、上記式(2C)で示すように臨界単糸数以上の数の単糸よりなる強化繊維束中の平均繊維数が多い、つまり、前記の平均繊維数(NC)が、平均繊維数(NB)より大きいことが好ましい。強化繊維(C)は強化繊維(B)よりもアスペクト比が大きい傾向にあるため、繊維束としてより屈曲しやすく、交絡しやすい傾向となり、流動性を阻害する可能性がある。
さらに、ランダムマットをに含まれる強化繊維の繊維長に比較的広い長さ分布を持たせる場合は、例えば、図5に示すような刃のピッチが連続的に変化しているロータリーカッターを用いることで、連続的に繊維長を変化させて繊維を切断することができる。
本発明方法における開繊工程はカットされた強化繊維を管内に導入し、繊維束を開繊させる工程である。空気を繊維に吹き付ける事により適宜開繊させることができる。開繊の度合い、強化繊維束(A)の存在量、および強化繊維束(A)中の平均繊維数(N)については、空気の圧力等により適宜コントロールする事が出来る。開繊工程において好ましくは圧縮空気吹き付け孔より、風速1~1000m/secにて空気を直接繊維束に吹き付ける事により、強化繊維を開繊させることができる。より好ましくは風速5~500m/secであり、より好ましくは風速50超~500m/secである。具体的には強化繊維の通る管内にΦ1~2mm程度の孔を数箇所あけ、外側より0.01~1.0MPa、より好ましくは0.2~0.8MPa程度の圧力をかけ、圧縮空気を繊維束に直接吹き付ける。風速を下げる事により、より多くの繊維束を残す事が可能であり、逆に、風速を上げる事により、繊維束を単糸状まで開繊させる事ができる。
この工程は、カットし開繊させた強化繊維を、空気中に拡散させると同時に、粉粒体状又は短繊維状の熱可塑性樹脂(以下、これらを「熱可塑性樹脂粒子等」と総称する)を供給し、強化繊維を熱可塑性樹脂粒子等とともに、開繊装置下方に設けた通気性支持体上に散布し、該支持体上に強化繊維と熱可塑性樹脂粒子等が混在した状態で、所定の厚さに堆積・定着させてランダムマットを形成させる工程である。
本発明において、強化繊維複合材料とは、広義には、樹脂が強化繊維により強化された素材を指すが、狭義には、当該素材からなる、プリプレグなどの成形中間体(成形用の基材)を指す。以下、本発明における狭義の強化繊維複合材料について述べる。
本発明のランダムマットをプリフォームとして加熱および加圧することにより、強化繊維と、熱可塑性樹脂とからなる強化繊維複合材料を得ることができる。ここで、加熱および加圧する方法としては、加熱と加圧を別々に行っても良いが、プレス成形および/または熱成形などの方法により成形することが好ましい。この場合、本発明の強化繊維複合材料は板状の成形体ということもできる。本発明のランダムマットは熱可塑性樹脂を容易に含浸しやすい特徴を持つため、ホットプレス成形などの方法により強化繊維複合材料を効率よく得ることができる。具体的には加圧下でランダムマット中の熱可塑性樹脂を溶融し、強化繊維束内および強化繊維の単糸間に熱可塑性樹脂を含浸させた後、冷却して加熱および加圧することが好ましい。この加熱及び加圧操作は、金型内で行われると好ましい。
強化繊維複合材料を得る際の加圧条件としては、10MPa未満であると好ましく、8MPa以下であるとより好ましく、5MPa以下であると更に好ましい。成形圧力が10MPa未満であると、より安価または一般的な成形装置を使用でき、大型成形体を成形する場合でも、設備投資や維持費を抑制でき好ましい。
本発明のランダムマットを強化繊維複合材料とするために加熱する際の温度としては、ランダムマットに含まれる熱可塑性樹脂が結晶性の場合は融点以上分解温度以下、非晶性の場合はガラス転移温度以上分解温度以下であると好ましく、熱可塑性樹脂が結晶性の場合は融点以上分解温度未満、非晶性の場合はガラス転移温度以上分解温度未満であるとより好ましい。なお、本発明において、熱可塑性樹脂の分解温度としては、空気中の熱分解温度であると好ましい。
または、金型内に板状の強化繊維複合材料を投入し、その含有する熱可塑性樹脂が結晶性であればその融点以上、あるいは熱可塑性樹脂が非晶性であればそのガラス転移温度以上まで昇温しつつ、プレス成形を行い、次いで金型を熱可塑性樹脂が結晶性であればその融点未満あるいは熱可塑性樹脂が非晶性であればそのガラス転移温度未満まで冷却する、いわゆるホットプレスにて成形体を得る事ができる。
臨界単糸数=600/D (1)
1.5×104/D2<N<3×105/D2(2)
(ここでDは強化繊維の平均繊維径(μm)である)
上記のとおり本発明により立上部を有する成形体が好ましく提供できる。立上部とは、前述の水平部に対して縦方向に伸びた部位のことを言い、筐体もしくはパネル状部材の側壁、リブ、ボス、マウント、ヒンジが一例として挙げられる。立上部の高さは特に制限はないが、1~300mmが好ましく、5~100mmが更に好ましい。立上部の高さは均一である必要はなく、局所的に増減させることも可能である。立上部高さの増減幅に特に制限はなく、最大高さの10~90%が好ましく、20~80%がさらに好ましい。立上部の板厚に特に制限は無く、水平部と同じであってもよく、異なっていても良い。立上部は水平部と比較して、より複雑な形状を求められることが多いことから、立上部の板厚は0.2~100mmが好ましく、1~50mmがさらに好ましい。立上部の板厚は均一である必要はなく、局所的に増減させることも可能である。この場合、増減幅に特に制限はないが、基礎となる立上板厚の20~500%が好ましく、50~200%がさらに好ましい。板厚は段階的に変化させることも可能であり、テーパーや曲率を持たせて連続的に変化させることも可能であるが、応力集中を回避するという観点から連続的に変化させるのが好ましい。
本発明の成形体としては、図7に例示するように、複数部のボス、および複数のリブを有するものは、実用性のあるものが多いため好ましく、略直方体の箱状物であり、該箱状物の少なくとも四隅にボスを有し、かつ箱状部の内部を2つ以上の区間に仕切る配置にてリブ部を有するものであるとより好ましい。
また、本発明のランダムマットを用いた成形体の成形方法は特に限定はしないが、次の様な方法が例示できる。
すなわち、以下の工程A-1)~A-3)を含んで含浸~成形を行うか、工程B-1)~B-4)を含んで含浸~成形を行う方法である。
A-1) ランダムマットを、熱可塑性樹脂が結晶性の場合は融点以上分解温度以下、非晶性の場合はガラス転移温度以上分解温度以下に加温し、加圧して熱可塑性樹脂を強化繊維束内に含浸させ強化繊維複合材料であるプリプレグを得る工程
A-2) A-1)で得られたプリプレグを、熱可塑性樹脂が結晶性の場合は融点以下、非晶性の場合はガラス転移温度以下に温度調節された金型に、下記式(4)で表されるチャージ率5~100%以下となるように配置し、加圧する工程
A-3) 熱可塑性樹脂が結晶性の場合は融点以下、非晶性の場合はガラス転移温度以下に金型温度を調節することにより成形を完結させる工程
B-1) ランダムマットを下記式(3)で表されるチャージ率5~100%以下となるように金型に配置する工程
B-2) 金型を熱可塑性樹脂が結晶性の場合は熱可塑性樹脂の融点以上熱分解温度以下の温度まで、非晶性の場合は熱可塑性樹脂のガラス転移温度以上熱分解温度以下の温度まで昇温しつつ、加圧する工程(第1プレス工程)
B-3) 1段以上であり、最終段の圧力が第1プレス工程の圧力の1.2倍~100倍となるように加圧する工程(第2プレス工程)
B-4) 熱可塑性樹脂が結晶性の場合は融点以下、非晶性の場合はガラス転移温度以下に金型温度を調節することにより成形を完結させる工程により好ましく製造できる。
尚、ここでチャージ率とは、次の下記式(4)で定義される値である。
チャージ率=100×基材面積(mm2)/金型キャビティ投影面積(mm2) (4)
(ここで基材面積とは配置した全てのランダムマットまたはプリプレグの抜き方向への投影面積であり金型キャビティ投影面積とは抜き方向への投影面積である)
なお、実施例、比較例で用いられた熱可塑性樹脂は以下に示すものである。
・ポリカーボネート(ガラス転移温度150℃、熱分解温度(空気中)350℃)
・ポリアミド66(融点265℃、熱分解温度(空気中)300℃)
・ポリアミド6(融点225℃、熱分解温度(空気中)300℃)
1)ランダムマットにおける強化繊維束の分析
ランダムマットを100mm×100mm程度に切り出す。切り出したマットより、繊維束をピンセットで全て取り出し、強化繊維束(A)の束の数(I)および繊維束の長さ(Li)と質量(Wi)を測定し、記録する。ピンセットにて取り出す事ができない程度に繊維束が小さいものについては、まとめて最後に質量を測定する(Wk)。質量の測定には、1/100mgまで測定可能な天秤を用いる。ランダムマットに使用している強化繊維の繊維径(D)より、臨界単糸数を計算し、臨界単糸数以上の強化繊維束(A)と、それ以外に分ける。なお、2種類以上の強化繊維が使用されている場合には、繊維の種類毎に分け、各々について測定及び評価を行う。
強化繊維束(A)の平均繊維数(N)の求め方は以下の通りである。
各強化繊維束中の繊維本数(Ni)は使用している強化繊維の繊度(F)より、次式により求められる。
Ni=Wi/(Li×F)
強化繊維束(A)中の平均繊維数(N)は、強化繊維束(A)の束の数(I)より、次式により求められる。
N=ΣNi/I
強化繊維束(A)のマットの繊維全量に対する割合(VR)は、強化繊維の密度(ρ)を用いて次式により求められる。
VR=Σ(Wi/ρ)×100/((Wk+ΣWi)/ρ)
ランダムマットまたは強化繊維複合材料より無作為に抽出した強化繊維100本の長さをノギスおよびルーペで1mm単位まで測定して記録し、測定した全ての強化繊維の長さ(Li)から、次式により平均繊維長(La)を求めた。複合材料の場合は500℃×1時間程度、炉内にて樹脂を除去した後、強化繊維を抽出した。
La=ΣLi/100
ランダムマットを加熱プレスして得られる強化繊維複合材料(成形板)については、500℃×1時間程度、炉内にて樹脂を除去した後、上記のランダムマットにおける方法と同様にして測定する。
成形体を500℃×1時間、炉内にて樹脂を燃焼除去し、処理前後の試料の質量を秤量することによって繊維分と樹脂分の質量を算出した。次に、各成分の比重を用いて、繊維体積含有率を算出した。
ランダムマットおよび複合材料の流動性や成形性を評価する目的で、成形体の外観、特にリブやボスの端部を目視評価した。
評価ではランダムマットを加熱プレスして得られる強化繊維複合材料(成形板)を所望の条件で加熱したものを120℃に設定した図5に示す金型の水平部にチャージ率80%となる様に配置して所望の圧力で60秒間コールドプレスした。
リブやボスの端部まで材料が充填され、成形体に欠陥が見られない場合を○、わずかに欠陥が見られる場合を△、充填が不十分で成形体に明らかな欠陥がある場合を×とした。
リブ部分の繊維配向性を評価する目的で、図8のようにボス及びリブを有する成形体の水平部及びリブ部から短冊状の試験片を切り出し、引張り試験を行い、引張弾性率を測定し、測定した引張弾性率の値のうち大きいものを小さいもので割った比(Eδ)を測定した。弾性率の比が1に近いほど、等方性に優れる材料である。本実施例では弾性率の比が1.3以下の場合、等方性であると評価する。
強化繊維として、東邦テナックス社製の炭素繊維“テナックス”(登録商標)STS40-24KS(平均繊維径7μm、繊維幅10mm)を拡幅して、繊維幅20mmとしたものを使用した。カット装置には、超硬合金を用いて螺旋状ナイフを表面に配置したロータリーカッターを用いた。このとき、下記式(3)
強化繊維の繊維長(刃のピッチ)=強化繊維ストランド幅×tan(90-θ) (3)
(ここで、θは周方向とナイフのなす角である。)
におけるθは68度であり、刃のピッチを8mmとし、強化繊維を繊維長8mmにカットするようにした。開繊装置として、径の異なるSUS304製のニップルを溶接し、二重管を製作した。内側の管に小孔を設け、外側の管との間にコンプレッサーを用いて圧縮空気を送気した。この時、小孔からの風速は、150m/secであった。この管をロータリーカッターの直下に配置し、さらに、その下部にはテーパ管を溶接した。テーパ管の側面より、マトリックス樹脂を供給し、このマトリックス樹脂として、帝人化成社製のポリカーボネート“パンライト”(登録商標)L-1225Lペレットを冷凍粉砕し、更に、20メッシュ、及び100メッシュにて分級した粒子を用いた。ポリカーボネートパウダーの平均粒径は約710μmであった。次に、テーパ管出口の下部に、XY方向に移動可能なテーブルを設置し、テーブル下部よりブロワにて吸引を行った。そして、強化繊維の供給量を180g/min、マトリックス樹脂の供給量を480g/min、にセットし、装置を稼動して、強化繊維と熱可塑性樹脂(ポリカーボネートパウダー)が混合されたランダムマットを得た。得られたランダムマットの強化繊維の平均繊維長は8mmであり、強化繊維の目付け量は、200g/m2であった。
得られたランダムマットを8枚重ねて300℃に加熱したプレス装置にて、4MPaにて3分間加熱し、厚さ4.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.03であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
水平部(9)が、長さ400mm、幅200mm、厚み2mm
側壁(10)が、高さ50mm、厚み2mm
リブ1(11A)が、高さ50mm、厚み2mm
リブ2(11B)が、高さ30~50mm、厚み2mm
リブ3(11C)が、高さ30~50mm、厚み1mm
ボス1(12A)が、高さ50mm、中空部径5mm、肉厚2mm
ボス2(12B)が、高さ40mm、中空部径5mm、肉厚2mm
ボス3(12C)が、高さ50mm、中空部径5mm、肉厚1mm
ボス4(12D)が、高さ40mm、中空部径5mm、肉厚1mmであった。
得られた成形体について、図8に示すように水平部及びリブ部から短冊状の試験片を切り出し、引張り試験を行い、評価結果を表1に記載した。
強化繊維として、東邦テナックス社製の炭素繊維“テナックス”(登録商標)IMS60-12K(平均繊維径5μm、繊維幅6mm)を使用した。カット装置には、実施例1と同様の刃のピッチが8mmのロータリーカッターを用いた。このロータリーカッターには、繊維束を小型化する目的で、繊維方向に平行な刃を0.8mm間隔で設けた。開繊装置は実施例1と同様のものを用い、小孔からの風速は、100m/secとした。この管をロータリーカッターの直下に配置し、さらに、その下部にはテーパ管を溶接した。テーパー管の側面より、マトリックス樹脂を供給し、このマトリックス樹脂として、2mmにドライカットしたPA66繊維(旭化成せんい製 T5ナイロン 繊度1400dtex)を用いた。次に、テーパー管出口の下部に、実施例1と同様のXY方向に移動可能なテーブルを設置し、テーブル下部よりブロワにて吸引を行った。そして、強化繊維の供給量を270g/min、マトリックス樹脂の供給量を550g/min、にセットし、装置を稼動して、強化繊維とポリアミド(PA66繊維)が混合されたランダムマットを得た。強化繊維の目付け量は300g/m2であった。
得られたランダムマットを8枚重ねて280℃に加熱したプレス装置にて、4.0MPaにて3分間加熱し、厚さ5.9mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.07であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、実施例1と同様に図7に示すようなボス及びリブを有する成形体を得た。
得られた成形板、成形体について実施例1と同様に評価した結果を表1に記載した。
強化繊維として、実施例1と同様に東邦テナックス社製の炭素繊維“テナックス”(登録商標)STS40-24KS(平均繊維径7μm、繊維幅10mm)を拡幅して、繊維幅20mmとしたものを使用した。カット装置は、超硬合金を用いて螺旋状ナイフを表面に配置したロータリーカッターを2台(カット装置a、b)使用した。カット装置aにおいては、上記式(3)中のθは45度、刃のピッチを20mmとし、強化繊維を繊維長20mmにカットし、カット装置bにおいては、上記式(3)中のθは68度、刃のピッチを8mmとし、強化繊維を繊維長8mmにカットできるようにした。
開繊装置も実施例1と同様の二重管を2台準備し、カット装置a、bの直下にそれぞれ配置した。このとき小孔からの風速は、ともに150m/secとした。更に、実施例1と同様のテーパー管をカット装置a直下の二重管の下部に溶接した。尚、実施例3のテーパー管の側面には、マトリックス樹脂供給用の穴のほかに、その対面側にもう一つ穴を開けカット装置b直下の二重管の下部とこの穴を内径1.5mmのゴムホースで接続した。これによって、カット装置bで切断した繊維は、ホース内を移動してテーパー管に供給され、テーパー管内でカット装置a、bそれぞれで切断した繊維が混合される。テーパー管の側面より供給するマトリックス樹脂としてPA6パウダー(ユニチカ製 A1030FP)を用いた。次に、テーパー管出口の下部に、実施例1と同様のXY方向に移動可能なテーブルを設置し、テーブル下部よりブロワにて吸引を行った。そして、カット装置aからの強化繊維の供給量を81g/min、カット装置bからの強化繊維の供給量を189g/min、マトリックス樹脂の供給量を550g/min、にセットし、装置を稼動して、強化繊維とポリアミド(PA6パウダー)が混合されたランダムマットを得た。強化繊維の目付け量は300g/m2であった。
得られたランダムマットを8枚重ねて260℃に加熱したプレス装置にて、4.0MPaにて3分間加熱し、厚さ5.9mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.05であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、実施例1と同様に図7に示すようなボス及びリブを有する成形体を得た。
得られた成形板、成形体について実施例1と同様に評価した結果を表1に記載した。
強化繊維として、日本電気硝子社製のガラス繊維EX-2500(平均繊維径15μm、繊維幅9mm)を使用した。カット装置には、超硬合金を用いて、繊維と90度方向の短い刃が斜めに配置された、分繊ナイフを表面に配置したロータリーカッターを用いた。ナイフの幅は1mmであり、さらにナイフ間には繊維束を小型化する目的で、繊維方向に平行な刃を設けた。このとき、上記式(3)中のθは42度であり、刃のピッチを10mmとし、強化繊維を繊維長10mmにカットした。開繊装置として、実施例1と同様の装置を用いた。コンプレッサーの圧力を下げる事により、小孔からの風速は、250m/secとした。この管をロータリーカッターの直下に配置し、さらに、その下部にはテーパ管を溶接した。テーパ管の側面より、マトリックス樹脂を供給し、このマトリックス樹脂として、帝人化成社製のポリカーボネート“パンライト”(登録商標)L-1225Lペレットを冷凍粉砕し、更に、30メッシュ、及び200メッシュにて分級したパウダーを用いた。このとき、平均粒径は約360μmであった。次に、テーパ管出口の下部に、XY方向に移動可能なテーブルを設置し、テーブル下部よりブロワにて吸引を行った。そして、強化繊維の供給量を300g/min、マトリックス樹脂の供給量を600g/min、にセットし、装置を稼動して、強化繊維と熱可塑性樹脂(ポリカーボネートパウダー)が混合されたランダムマットを得た。強化繊維の目付け量は300g/m2であった。
このランダムマットを8枚重ねて300℃に加熱したプレス装置にて、4.0MPaにて3分間加熱し、厚さ5.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.14であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、実施例1と同様に図7に示すようなボス及びリブを有する成形体を得た。
得られた成形体について実施例1と同様に評価した結果を表1に記載した。
実施例1において、強化繊維の供給量を315g/minとし、マトリックス樹脂の供給量を390g/minとしたこと以外は同様の方法でランダムマットを作成した。得られたランダムマットの強化繊維の平均繊維長は8mmであり、強化繊維の目付け量は、350g/m2であった。
得られたランダムマットについて、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、式(1)で定義される臨界単糸数は86であり、強化繊維束(A)について、マットの繊維全量に対する割合は66%、強化繊維(B)の束内平均繊維数(NB)は1600であり、強化繊維束(A)の平均繊維数(N)は1600であった。得られたランダムマットの表面を観察したところ、面内で特定の方向に配向しておらず、ランダムに、分散されていた。また、ポリカーボネートパウダーは、強化繊維中に大きな斑が無い状態で分散されていた。
得られたランダムマットを8枚重ねて300℃に加熱したプレス装置にて、4MPaにて3分間加熱し、厚さ4.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.05であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、実施例1と同様に図7に示すようなボス及びリブを有する成形体を得た。
得られた成形板、成形体について実施例1と同様に評価した結果を表1に記載した。
実施例3において、カット装置aからの強化繊維(繊維長20mm)の供給量を450g/min、カット装置b(繊維長8mm)からの強化繊維の供給量を450g/min、マトリックス樹脂の供給量を1830g/min、にセットし、装置を稼動して、強化繊維とポリアミド6が混合されたランダムマットを得た。強化繊維の目付け量は1000g/m2であった。
得られたランダムマットについて、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、式(1)で定義される臨界単糸数は86であり、強化繊維束(A)について、マットの繊維全量に対する割合は87%、強化繊維(B)及び(C)の束内平均繊維数(それぞれNB,NC)は、それぞれ1700、2300であり、強化繊維束(A)の平均繊維数(N)は2000であった。得られたランダムマットの表面を観察したところ、面内で特定の方向に配向しておらず、ランダムに、分散されていた。また、ポリアミドパウダーは、強化繊維中に大きな斑が無い状態で分散されていた。
得られたランダムマットを3枚重ねて260℃に加熱したプレス装置にて、4MPaにて3分間加熱し、厚さ6.0mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.02であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、実施例1と同様に図7に示すようなボス及びリブを有する成形体を得た。得られた成形板、成形体について実施例1と同様に評価した結果を表1に記載した。
実施例3において、2台のカット装置とも実施例4で使用したような分繊ナイフであって繊維カット長を変えた分繊ナイフ及び繊維方向に並行な刃を有するロータリーカッターを使用した。このときカット装置aにおいては、上記式(3)中のθは45度、刃のピッチを20mmとし、強化繊維を繊維長20mmにカットし、カット装置bにおいては、上記式(3)中のθは68度、刃のピッチを8mmとし、強化繊維を繊維長8mmにカットできるようにした。
開繊装置も実施例1と同様の二重管を2台準備し、カット装置a、bの直下にそれぞれ配置した。このとき小孔からの風速は、ともに150m/secとした。更に、実施例1と同様のテーパー管をカット装置a直下の二重管の下部に溶接した。尚、実施例3のテーパー管の側面には、マトリックス樹脂供給用の穴のほかに、その対面側にもう一つ穴を開けカット装置b直下の二重管の下部とこの穴を内径1.5mmのゴムホースで接続した。これによって、カット装置bで切断した繊維は、ホース内を移動してテーパー管に供給され、テーパー管でカット装置a、bそれぞれで切断した繊維が混合される。テーパー管の側面より供給するマトリックス樹脂としてPA6パウダー(ユニチカ製 A1030FP)を用いた。次に、テーパー管出口の下部に、実施例1と同様のXY方向に移動可能なテーブルを設置し、テーブル下部よりブロワにて吸引を行った。そして、カット装置aからの強化繊維の供給量を81g/min、カット装置bからの強化繊維の供給量を189g/min、マトリックス樹脂の供給量を550g/min、にセットし、装置を稼動したところ、強化繊維とポリアミドが混合されたランダムマットを得た。強化繊維の目付け量は300g/m2であった。
得られたランダムマットを8枚重ねて260℃に加熱したプレス装置にて、4.0MPaにて3分間加熱し、厚さ5.9mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.03であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、実施例1と同様に図7に示すようなボス及びリブを有する成形体を得た。
得られた成形板、成形体について実施例1と同様に評価した結果を表1に記載した。
実施例1において、小孔からの風速を、450m/secとした以外は同様にランダムマットを作成した。
得られたランダムマットについて、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、式(1)で定義される臨界単糸数は86であり、強化繊維束(A)について、マットの繊維全量に対する割合は43%、強化繊維(B)の束内平均繊維数(NB)は800であり、強化繊維束(A)の平均繊維数(N)は800であった。
得られたランダムマット中に存在する繊維束は細く、面内で特定の方向に配向しておらず、ランダムに分散されていた。また、ポリカーボネートパウダーは、強化繊維中に大きな斑が無い状態で分散されていた。
実施例1と同様に得られたランダムマットを8枚重ねて300℃に加熱したプレス装置にて、4MPaにて3分間加熱し、厚さ4.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.02であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし成形体を得たが、ボス及びリブ部への繊維及び樹脂の充填は不十分であった。得られた成形板、成形体について実施例1と同様に評価した結果を表1に記載した。
実施例1において、ロータリーカッターの螺旋刃の角度θを45度、刃のピッチを20mmとしたこと以外は同様の方法でランダムマットを得た。
得られたランダムマットについて、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、式(1)で定義される臨界単糸数は86であり、強化繊維束(A)について、マットの繊維全量に対する割合は71%、強化繊維(C)の束内平均繊維数(NC)は2200であり、強化繊維束(A)の平均繊維数(N)は2200であった。得られたランダムマットの表面を観察したところ、面内で特定の方向に配向しておらず、ランダムに、分散されていた。また、ポリカーボネートパウダーは、強化繊維中に大きな斑が無い状態で分散されていた。
得られたランダムマットを8枚重ねて300℃に加熱したプレス装置にて、4MPaにて3分間加熱し、厚さ4.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.03であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、成形体を得たが、ボス及びリブ部へは繊維及び樹脂がほとんど充填されていなかったので、実施例1と同様に引張弾性率とVfを評価しようとしたが、測定不可であった。
実施例3において、カット装置aからの強化繊維(繊維長20mm)の供給量を216g/min、カット装置bからの強化繊維(繊維長8mm)の供給量を54g/min、マトリックス樹脂の供給量を550g/min、にセットし、装置を稼動したところ、強化繊維とポリアミド6が混合されたランダムマットを得た。強化繊維の目付け量は300g/m2であった。
得られたランダムマットについて、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、式(1)で定義される臨界単糸数は86であり、強化繊維束(A)について、マットの繊維全量に対する割合は85%、強化繊維(B)及び(C)の束内平均繊維数(それぞれNB,NC)は、それぞれ1500、2200であり、強化繊維束(A)の平均繊維数(N)は2100であった。得られたランダムマットの表面を観察したところ、面内で特定の方向に配向しておらず、ランダムに、分散されていた。また、ポリアミドパウダーは、強化繊維中に大きな斑が無い状態で分散されていた。
得られたランダムマットを8枚重ねて260℃に加熱したプレス装置にて、4MPaにて3分間加熱し、厚さ4.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.02であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、上記ランダムマットの測定結果と差異は見られなかった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、成形体を得たが、ボス及びリブ部への繊維及び樹脂の充填は不十分であった。
得られた成形体について実施例1と同様に評価した結果を表1に記載した。
260℃に温度調節されたスクリュータイプ押出機のホッパーにマトリックス樹脂として、ポリアミド6樹脂(宇部興産製、1013B)を供給し、溶融樹脂をギアポンプの回転数にて所定量計量して、260℃に温度調節されたエクストルーダー(池貝製、FS50)にて含浸用クロスヘッドダイへ供給した。一方、強化繊維として、東邦テナックス社製の炭素繊維“テナックス”(登録商標)STS40-24KS(平均繊維径7μm、繊維幅10mm)を拡幅して、繊維幅20mmとしたものを下流先端に開口部を絞ったスリットダイを備えた含浸用クロスヘッドダイの上流に供給し、強化繊維に樹脂を含浸・脱泡させ、下流開口部から吐出された強化繊維とポリアミド6からなるテーププリプレグを冷却してかせに巻き取った。このときテーププリプレグにおける強化繊維の体積含有率は30%であった。
得られたテーププリプレグを幅10mmにスリットした後、10mmにカットし、平板金型内にランダムにばら撒き、260℃に加熱したプレス装置にて、4.0MPaにて3分間加熱し、厚さ5.8mmの強化繊維複合材料(成形板)を得た。得られた成形板について超音波探傷試験を行ったところ、未含浸部やボイドは確認されなかった。
得られた成形板の0度及び90度方向の引張り弾性率を測定したところ、弾性率の比(Eδ)は1.13であり、繊維配向は殆ど無く、等方性が維持された材料を得る事ができた。更に、この成形板を500℃×1時間程度炉内にて加熱し、樹脂を除去した後、強化繊維束(A)の割合と、平均繊維数(N)を調べたところ、式(1)で定義される臨界単糸数は86であり、強化繊維束(A)について、マットの繊維全量に対する割合は97%、強化繊維(B)の束内平均繊維数(NB)は11000であり、強化繊維束(A)の平均繊維数(N)は11000であった。
また、得られた成形板をNGKキルンテック製のIRオーブンを用いて300℃に加熱したものを120℃に設定した図6に示す金型の水平部にチャージ率80%となる様に配置して5MPaの圧力で60秒間コールドプレスし、ボス及びリブを有する成形体を得た。得られた成形体の評価結果を表1に記載した。水平部及びリブ部の引張り弾性率比は1.53であり、等方性がやや劣っていた。
本出願は、2011年12月22日出願の日本特許出願(特願2011-281509)に基づくものであり、その内容はここに参照として取り込まれる。
2.ピンチローラー
3.ゴムローラー
4.ロータリーカッター本体
5.刃
6.カットされた強化繊維
7.刃のピッチ
8.繊維方向に平行な刃
9.水平部
10.側壁
11A. リブ1
11B. リブ2
11C. リブ3
12A. ボス1
12B. ボス2
12C. ボス3
12D. ボス4
13. リブ部における引張弾性率測定用試料切り出し部分
14. 水平部における引張弾性率測定用試料切り出し部分
Claims (16)
- 繊維長3~50mmの強化繊維を含み、下記i)~v)を満たすランダムマット。
i)繊維長が3mm以上15mm未満である強化繊維が、ランダムマットに含まれる強化繊維全量に対し50~100質量%であり、繊維長が15mm以上50mm以下である強化繊維が、ランダムマットに含まれる強化繊維全量に対し0~50質量%である、
ii)強化繊維の目付けが25~10000g/m2である、
iii)強化繊維について下記式(1)で定義される臨界単糸数未満の繊維束および単糸と、臨界単糸数以上で構成される強化繊維束(A)が同時に存在する、
iv)強化繊維束(A)について、ランダムマットに含まれる強化繊維全量に対する割合が50Vol%以上99Vol%未満である、
v)強化繊維束(A)中の平均繊維数(N)が下記式(2)を満たす、
臨界単糸数=600/D (1)
1.5×104/D2<N<3×105/D2 (2)
(ここでDは強化繊維の平均繊維径(μm)である。) - 強化繊維が炭素繊維、アラミド繊維、およびガラス繊維からなる群から選ばれる少なくとも一種である請求項1に記載のランダムマット。
- 繊維長が3mm以上15mm未満である強化繊維が、ランダムマットに含まれる強化繊維全量に対し90~100質量%であり、繊維長が15mm以上50mm以下である強化繊維がランダムマットに含まれる強化繊維全量に対し0~10質量%である請求項1又は2に記載のランダムマット。
- 繊維長が3mm以上15mm未満である強化繊維について、臨界単糸数以上で構成される強化繊維束(AB)中の平均繊維数(NB)が下記式(2B)を満たす請求項1~3のいずれかに記載のランダムマット。
1.5×104/DB 2<NB<3×105/DB 2 (2B)
(ここでDBは強化繊維の平均繊維径(μm)である。) - 繊維長が15mm以上50mm以下である強化繊維について、臨界単糸数以上で構成される強化繊維束(AC)中の平均繊維数(NC)が下記式(2C)を満たす請求項1~4のいずれかに記載のランダムマット。
5.0×104/DC 2<NC<3×105/DC 2 (2C)
(ここでDCは強化繊維の平均繊維径(μm)である。) - 前記の平均繊維数(NC)が、平均繊維数(NB)より大きい請求項5記載のランダムマット。
- 繊維長が3mm以上15mm未満である強化繊維の平均繊維長に対する、繊維長が15mm以上50mm以下である強化繊維の平均繊維長の比が1.5~10である請求項1~6のいずれかに記載のランダムマット。
- さらに熱可塑性樹脂を含み、ランダムマットにおける熱可塑性樹脂の存在量が、強化繊維100質量部に対し、50~1000質量部である請求項1~7のいずれかに記載のランダムマット。
- 請求項8に記載のランダムマットを加熱および加圧して得られる強化繊維複合材料。
- 請求項8に記載のランダムマット又は請求項9に記載の強化繊維複合材料を成形して得られる成形体。
- 立上部を有する請求項10に記載の成形体。
- 請求項8に記載のランダムマットを用い、熱可塑性樹脂を含浸させて加熱および加圧する強化繊維複合材料の製造方法。
- 加圧する際の圧力が10MPa未満である請求項12に記載の強化繊維複合材料の製造方法。
- 請求項8に記載のランダムマット又は請求項9に記載の強化繊維複合材料を、10MPa未満の圧力にてプレス成形することを特徴とする成形体の製造方法。
- 成形体が複数部のボス、および複数のリブを有するものである請求項14記載の製造方法。
- 成形体が、略直方体の箱状物であり、該箱状物の少なくとも四隅にボスを有し、かつ箱状部の内部を2つ以上の区間に仕切る配置にてリブ部を有するものである請求項14または15記載の製造方法。
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WO2014021315A1 (ja) * | 2012-08-01 | 2014-02-06 | 帝人株式会社 | ランダムマットおよび繊維強化複合材料成形体 |
WO2014208626A1 (ja) * | 2013-06-26 | 2014-12-31 | 帝人株式会社 | ランダムマット、繊維強化複合材料成形体、および炭素繊維マット |
EP3029089A4 (en) * | 2013-08-01 | 2016-08-17 | Teijin Ltd | FIBER REINFORCED COMPOSITE MATERIAL AND METHOD FOR PRODUCING THE SAME |
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WO2018143283A1 (ja) | 2017-02-03 | 2018-08-09 | 帝人株式会社 | 炭素繊維と熱可塑性樹脂を含む複合材料、並びにこれを用いた成形体の製造方法及び成形体 |
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JPWO2020067058A1 (ja) * | 2018-09-28 | 2021-08-30 | 東レ株式会社 | 繊維強化樹脂成形材料および成形品 |
US11746200B2 (en) | 2018-09-28 | 2023-09-05 | Toray Industries, Inc. | Fiber-reinforced resin molding material and molded article |
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Also Published As
Publication number | Publication date |
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EP2796604A1 (en) | 2014-10-29 |
CN104011276A (zh) | 2014-08-27 |
EP2796604A4 (en) | 2015-09-23 |
US20150031257A1 (en) | 2015-01-29 |
KR20140107282A (ko) | 2014-09-04 |
JPWO2013094706A1 (ja) | 2015-04-27 |
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