WO2013099971A1 - 複合材料の接合方法 - Google Patents
複合材料の接合方法 Download PDFInfo
- Publication number
- WO2013099971A1 WO2013099971A1 PCT/JP2012/083703 JP2012083703W WO2013099971A1 WO 2013099971 A1 WO2013099971 A1 WO 2013099971A1 JP 2012083703 W JP2012083703 W JP 2012083703W WO 2013099971 A1 WO2013099971 A1 WO 2013099971A1
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- WO
- WIPO (PCT)
- Prior art keywords
- composite material
- convex portion
- carbon fiber
- joining
- composite materials
- Prior art date
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Images
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- B29C66/8322—Joining or pressing tools reciprocating along one axis
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/91—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux
- B29C66/914—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux
- B29C66/9161—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux
- B29C66/91651—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating
- B29C66/91655—Measuring or controlling the joining process by measuring or controlling the temperature, the heat or the thermal flux by controlling or regulating the temperature, the heat or the thermal flux by controlling or regulating the heat or the thermal flux, i.e. the heat flux by controlling or regulating the heat generated by Joule heating or induction heating by controlling or regulating the current intensity
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/92—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools
- B29C66/929—Measuring or controlling the joining process by measuring or controlling the pressure, the force, the mechanical power or the displacement of the joining tools characterized by specific pressure, force, mechanical power or displacement values or ranges
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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
- B29C66/00—General aspects of processes or apparatus for joining preformed parts
- B29C66/90—Measuring or controlling the joining process
- B29C66/94—Measuring or controlling the joining process by measuring or controlling the time
- B29C66/949—Measuring or controlling the joining process by measuring or controlling the time characterised by specific time values or ranges
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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
- B29K2101/00—Use of unspecified macromolecular compounds as moulding material
- B29K2101/12—Thermoplastic materials
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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
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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
Definitions
- the present invention relates to a method for bonding a composite material containing a carbon fiber with a thermoplastic resin as a matrix. More specifically, the present invention relates to a method for joining a composite material containing a thermoplastic resin and carbon fiber and having a convex portion to another composite material.
- thermoplastic resin As a method for joining composite materials using a thermoplastic resin as a matrix, there are adhesive, welding, fastening with bolts and nuts or rivets, and the like. Bonding with an adhesive cannot be used as a structural member because high bonding strength cannot be obtained.
- welding there is a welding method using a hot plate, vibration, or ultrasonic waves, but since the materials are integrated as they are, there is no increase in weight due to bonding, and high strength is obtained, so it is very advantageous for thermoplastic resins. This can be said to be a joining technique.
- hot plate welding there is a problem that resin adheres to the hot plate due to stringing.
- Patent Document 1 describes a method for manufacturing a fusion bonded body by applying this electric resistance welding technique to a composite of carbon fiber and thermoplastic resin and changing the amount of carbon fiber and fiber direction of the joint. Yes.
- Patent Document 3 a heating element made of carbon fiber is sandwiched between the bonding surfaces of a thermoplastic resin molded product, and a voltage is applied to the heating element while applying pressure with an appropriate force to generate heat to melt the resin on the bonding surface. Then, a method is described in which the application of voltage is stopped, the resin is cooled and cured, and the molded products are welded together.
- Patent Document 2 The method described in Patent Document 2 is concerned that current flows through carbon fibers having good electrical conductivity existing in the thermoplastic resin, and it is difficult to sufficiently melt and bond the thermoplastic resin. Is done.
- An object of the present invention is to provide a method of bonding composite materials containing a thermoplastic resin and carbon fibers with high bonding strength by a simple method.
- a bonded body having good bonding strength can be produced by providing a convex portion on a composite material containing a thermoplastic resin and carbon fiber.
- the present invention is as follows. [1] (i) A composite material comprising a thermoplastic resin and carbon fiber and having a convex portion on one surface, and a composite material B comprising a thermoplastic resin and carbon fiber. (Ii) a process of energizing and joining the joint portion including the convex part to generate heat; A method for joining composite materials comprising: [2] The method for joining composite materials as described above, wherein energization is performed in a current density range of 0.01 A / mm 2 to 100 A / mm 2 . [3] The method for joining composite materials as described above, wherein the composite material is fixed by pressurizing with an electrode.
- the method of joining the composite material containing a thermoplastic resin and carbon fiber with high joining strength by a simple method can be provided.
- it is possible to easily perform welding by providing a projection-shaped convex portion at a joint portion of a composite material containing a thermoplastic resin and carbon fiber, and energizing the joint portion including the convex portion to generate heat.
- the current-carrying portion of the bonded portion includes the convex portion, it is surprisingly possible to obtain a bonded body of a good carbon fiber composite material in which the area to be heat-sealed is stable and the bonding strength is excellent.
- the joining method of the composite material of the present invention is as follows: (I) A composite material A containing a thermoplastic resin and carbon fiber and having a convex portion on one surface, and a composite material B containing a thermoplastic resin and carbon fiber are combined with the convexity of the composite material A. A step of superimposing and fixing the portion with the inside, and (ii) a step of generating heat by energizing the joint portion including the convex portion, including.
- composite materials A and B are overlapped and fixed with the convex portion of composite material A inside” means “composite materials A and B are opposed to the convex portion of composite material A and composite material B”. To touch and fix.
- the “joining portion including the convex portion” is “a region including a portion where the convex portion of the composite material A and the composite material B are in contact with each other”. It becomes. In the present invention, it goes without saying that a step of preparing the composite materials A and B may be included. Embodiments of the present invention will be described below.
- the composite material A used for this invention is a member containing a thermoplastic resin and carbon fiber, and has a convex part on one surface.
- the composite material A is preferably a carbon fiber-containing composite material in which a thermoplastic resin is used as a matrix component and carbon fibers are contained therein.
- thermoplastic resin used for the composite material in the present invention is not particularly limited.
- polyamide for example, nylon 6, nylon 66
- polycarbonate for example, polyoxymethylene
- polyphenylene sulfide for example, polyphenylene ether
- polyester for example, polyethylene terephthalate
- Polybutylene terephthalate polyethylene naphthalate
- polyethylene polypropylene
- polystyrene polymethyl methacrylate
- AS resin and ABS resin. You may use these in mixture of 2 or more types.
- thermoplastic resin used in the composite material in the present invention is preferably polyamide, polyester, polypropylene from the viewpoints of heat resistance, impact resistance, weather resistance, chemical resistance, moldability, strength, cost, and balance thereof. , Polycarbonate, or polyphenylene sulfide.
- Carbon fiber is contained in the composite material.
- a composite material joined body such as a lightweight, high-strength, high-rigidity part can be obtained.
- Such carbon fibers may be subjected to a surface treatment such as a treatment with a coupling agent, a treatment with a sizing agent, or an adhesion treatment of an additive.
- the average fiber diameter of the carbon fibers is preferably 3 to 12 ⁇ m, more preferably 5 to 7 ⁇ m.
- this carbon fiber may be used individually by 1 type, and may use together 2 or more types from which a diameter differs.
- the form of the carbon fiber contained in the composite material is not particularly limited, and may be continuous fiber or discontinuous fiber.
- continuous fibers for example, a form such as a unidirectional substrate or a nonwoven fabric in which carbon fibers are aligned in a uniaxial direction can be mentioned, but this is not restrictive.
- discontinuous fiber it does not specifically limit regarding fiber length.
- those carbon fibers to which a sizing agent is attached are used.
- the adhesion amount of the sizing agent is preferably 0.01 to 10 parts by mass with respect to 100 parts by mass of the reinforcing fiber.
- such carbon fibers are preferably arranged so as to be isotropically randomly dispersed and overlapped in the composite material. That is, it is preferable that the carbon fibers are arranged in a non-oriented manner in the in-plane direction of one surface of the sheet-like composite material A. By dispersing in this manner, it is possible to obtain a bonded body of a good carbon fiber composite material in which the area to be heat-sealed is particularly stable and the strength of the bonded portion is stable.
- the fiber length of the carbon fiber in this case is preferably an average fiber length of 1 mm or more and 100 mm or less, more preferably 5 mm or more and 100 mm or less, and further preferably more than 5 mm and less than 100 mm.
- the upper limit of the average fiber length is preferably 50 mm.
- the carbon fiber used in the present invention preferably has an average fiber length in the above range, but the discontinuous fiber having a length of less than 1 mm or the discontinuous fiber having a length of more than 100 mm is a ratio of 20% by mass or less of the entire carbon fiber. May be included. However, from the viewpoint of bonding strength, it is preferable that a discontinuous fiber having a length of less than 1 mm or a discontinuous fiber exceeding 100 mm is not substantially contained.
- the single yarn fineness of the carbon fiber is preferably 100 to 5,000 dtex, more preferably 1,000 to 2,000 dtex. Further, in the case of carbon fiber, a continuous fiber composed of substantially untwisted yarns (strands) in which the number of filaments is 3,000 to 6,000 is used, or a short fiber bundle obtained by cutting this is used. .
- the content ratio of the thermoplastic resin and the carbon fiber is preferably 50 to 1,000 parts by mass of the thermoplastic resin with respect to 100 parts by mass of the carbon fiber. More preferably, the thermoplastic resin is 50 to 400 parts by mass with respect to 100 parts by mass of the carbon fiber, and still more preferably 50 to 100 parts by mass with respect to 100 parts by mass of the carbon fiber. By setting the ratio, the moldability is good, and the finally obtained joined body has high mechanical strength.
- the composite material may contain various additives within a range that does not impair the object of the present invention (for example, a range of 20% by mass or less).
- the additive include a flame retardant, a heat stabilizer, an ultraviolet absorber, a nucleating agent, and a plasticizer.
- the composite material A As a manufacturing method of the composite material A, it can manufacture by methods, such as press molding, injection molding, and extrusion molding.
- a composite material containing the discontinuous carbon fibers in a fiber bundle state is preferable. More preferably, it is a composite material that controls the degree of carbon fiber opening and includes a specific number of carbon fiber bundles having a specific number or more and other opened carbon fibers.
- the following formula (1) Critical number of single yarns 600 / D (1) (Where D is the average fiber diameter ( ⁇ m) of the carbon fiber) With respect to the carbon fiber bundle (A) constituted by the number of critical single yarns defined in (1) above, it is preferable for the purpose of obtaining more excellent mechanical properties that the volume ratio is 20 Vol% or more and 99 Vol% or less.
- a carbon fiber other than the carbon fiber bundle (A) a fiber bundle constituted by a single yarn state or less than the critical single yarn number may exist.
- the ratio of the carbon fiber bundle (A) in the case of obtaining a molded body having further excellent mechanical properties is more preferably 30 Vol% or more and less than 90 Vol%, and further preferably 30 Vol% or more and less than 80 Vol%.
- the average number of fibers (N) in the carbon fiber bundle (A) composed of the number of critical single yarns or more is represented by the following formula (2).
- 0.7 ⁇ 10 4 / D 2 ⁇ N ⁇ 1 ⁇ 10 5 / D 2 (2) (Where D is the average fiber diameter ( ⁇ m) of the carbon fiber) It is preferable to satisfy.
- the above formula (2) is expressed by the following formula (2 ′) 0.7 ⁇ 10 4 / D 2 ⁇ N ⁇ 6.0 ⁇ 10 4 / D 2 (2 ′) It is more preferable to satisfy.
- the composite material A has a convex portion on at least one surface.
- One surface having such a convex portion may be a flat surface or a curved surface.
- the composite material A has at least one plane portion and has a convex portion on the plane portion. It is preferable that the composite material B also has a flat portion for joining to the convex portion of the composite material A.
- the composite materials A and B are preferably both sheet-like materials.
- the flat portion may be slightly curved as long as it can be joined.
- the thickness of the sheet-like composite material is preferably within a range of 0.1 mm to 10 mm.
- the shape of such a composite material is not limited to the above shape.
- the composite material in the present invention will be described by taking a sheet-like material as a representative example. Furthermore, when the composite material is arranged so that the carbon fibers are randomly dispersed in the in-plane direction, the composite material has substantially no in-plane anisotropy in physical properties, for example, strength and elastic modulus. It becomes. If the joint surface is parallel to the in-plane direction using such a composite material, the finally obtained joined body has excellent strength in one direction, which is advantageous depending on the application.
- At least one surface of the composite material A in the present invention is provided with a projection-shaped convex portion for melting and bonding to one surface of the composite material B.
- the convex portion is preferably made of the same material as the composite material A.
- the protrusion shape for example, a shape like the convex portion 2 in the composite material 1 shown in FIG.
- the convex part in this invention is a magnitude
- spherical shapes such as a cylinder, a prism, a truncated cone, a truncated pyramid, a hemisphere, and the shape approximated to these are mentioned. Further, it may be formed of a combination of the above shapes, such as a circular cylinder, a prism, a cone, or a tip of a pyramidal protrusion that is rounded (dome type).
- a sharp pointed tip such as a cone or a pyramid is not preferable because carbon fibers are unlikely to exist at the tip of the convex portion.
- the shape contacting as a joint is represented by a circle, an ellipse, a polygon, or a fan shape.
- the shape may be a combination of straight lines and curves. If the tip shape of the portion that contacts the counterpart of the convex portion (here, the composite material B) is the same surface shape as the joint portion of the composite material B, the joint area is widened, so that good joint strength is easily obtained. For example, if the joint part in the composite material B is a flat surface, it is preferable that the tip of the convex portion is also a flat surface.
- the tip of the convex portion has a similar curved shape.
- the area of the bottom of the convex portion is preferably in the range of 0.25 mm 2 to 2500 mm 2 . If the area is 0.25 mm 2 or more, the carbon fiber can easily enter the convex portion. Therefore, it is preferable because joining by energization becomes easy.
- the area of the tip of the convex portion of the composite material A joined to the composite material B is preferably 0.1 mm 2 or more.
- the area of the front end surface of the convex portion is 0.1 mm 2 or more, carbon fiber can easily enter the front end of the convex portion, and the convex end tip is difficult to be made of only a thermoplastic resin. Is preferable.
- a plurality of small protrusions may be provided for each joint location. In this case, it is preferable that the total tip end area per joint portion is 0.1 mm 2 or more.
- the current value at the time / the area to be joined) is preferably 0.01 A / mm 2 to 100 A / mm 2 . More preferably, it is in the range of 0.01 A / mm 2 to 10 A / mm 2 .
- limiting about the height of a convex part It is preferable that it is the range of 0.01 mm to 20 mm from the ease of implementation to join.
- the rising angle of the convex portion is preferably in the range of 0.1 ° to 89.9 ° from the viewpoint of moldability.
- Columnar protrusions can be mentioned.
- Particularly preferred examples of the convex portion include a prismatic protrusion having a side of 9 mm and a height of 1 mm, and a cylindrical protrusion having a diameter of 10 mm and a height of 1 mm. Note that the number of convex portions on the surface of the composite material may be one, but of course two or more.
- the composite material B in the present invention is a member containing a thermoplastic resin and carbon fibers.
- the thermoplastic resin of composite material B, carbon fiber, those ratios, a manufacturing method, etc. the same thing as the said composite material A can be mentioned.
- the composite material B may have a convex portion on one surface in the same manner as the composite material A.
- the convex portion may be on either the side in contact with the composite material A or the opposite side, and such convex portion can be used as a bonding site in the bonding with the composite material A.
- the overall shape of the composite materials A and B used in the present invention is not particularly limited.
- the shape of the composite materials A and B may be a sheet shape as described above, and is not limited to a sheet shape, and may be a plate shape.
- the shapes of the composite materials A and B may have a curved surface portion.
- the shapes of the composite materials A and B may be T-shaped, L-shaped, U-shaped, hat-shaped, and three-dimensional shapes including these, and composite materials having these various shapes.
- the composite material bonding method shown in the present invention can be applied.
- FIG. 2 shows a schematic view according to an embodiment for explaining the joining method of the present invention by resistance welding.
- a joint portion where the composite materials A and B are overlapped with the composite material B with the convex portion of the composite material A inside is shown.
- 1 is a carbon fiber composite material A
- 1 ′ is a carbon fiber composite material B
- 4 is a convex portion on one surface of the composite material A
- 3 is an electrode.
- a pair of molded bodies of two composite materials A and B to be overlapped and welded is prepared.
- a protrusion shape (convex portion) serving as a joint portion is provided on one side surface of the composite material A which is one of the molded bodies.
- the composite materials A and B are overlapped with the convex portion of the composite material A inside. At this time, the composite material B is in contact with the convex portion of the composite material A.
- fixing is performed in a state where the convex portion of the composite material A and the composite material B are in contact with each other.
- the term “fixing” used herein can maintain a state where the convex portion of the composite material A and the composite material B are in contact with each other. It only has to be. Moreover, you may fix using a well-known fixing means. It is preferable to press the joint portion including the contact portion between the convex portion of the composite material A and the composite material B so as to sandwich the composite material A.
- the joint portion is energized.
- a method in which the composite material A and the composite material B are sandwiched between a pair of electrodes and a current flows between the electrodes is preferable.
- the fixing, pressurization, and energization may be performed using different means or apparatuses, but it is preferable to fix and pressurize the composite material sandwiched between electrodes in order to simplify the process.
- a current flows from the composite material A through the convex portion of the composite material A to the composite material B, or a current flows from the composite material B through the convex portion of the composite material A to the composite material A.
- the joint part including the convex part is heated by heat generated by energization.
- the temperature of the thermoplastic resin in the composite materials A and B at the joining site that has been warmed rises and eventually melts.
- thermoplastic resin solidified, the convex portion becomes substantially flat, and a molded body (joined body) in which the composite materials A and B are joined is obtained. It is done.
- the bonding method it is only necessary to pressurize and energize the bonded portion with the composite materials A and B interposed therebetween.
- the plurality of convex portions are joined to the bonding portion.
- the power source used for joining may be an AC power source or a DC power source, but a DC power source is preferable when it is desired to generate heat efficiently.
- the material and electrode diameter of the electrode used, but it is preferable to use copper or a copper alloy as the material, and the electrode diameter is preferably about ⁇ 3 (diameter 3 mm) to ⁇ 30 (diameter 30 mm).
- the shape of the electrode is not particularly limited, and examples thereof include a rod-shaped or block-shaped electrode.
- the bonding method of the composite material of the present invention is a method of welding by melting the matrix resin with Joule heat, it is preferable to control the energization amount in accordance with the melting point of the matrix resin.
- the range of the current value that flows during the joining is preferably in the range of 1A to 500A, and more preferably in the range of 1A to 200A. More preferably, it is 10A to 200A.
- the energization time is preferably within 60 seconds, and the substantial lower limit is 0.1 seconds. Although there is no restriction
- the applied pressure is preferably 0.01 MPa or more, and the substantial condition is 1000 MPa or less.
- the applied pressure may be constant or may be increased or decreased depending on the process.
- the thermoplastic resin that generates heat by energization and forms the convex portion of the composite material A is warmed, and in some cases, melted, and a joined body integrally joined with the composite material B can be obtained. .
- the convex portion is crushed and almost disappeared by this, and the convex portion basically does not remain in the joint portion of the obtained joined body, but it is sufficient that sufficient bonding strength is obtained even if it remains.
- the peripheral part of the convex part is also warmed depending on the case and contributes to joining.
- the method for obtaining the ratio of the carbon fiber bundle (A) contained in the composite material is as follows. The composite material is cut into 100 mm ⁇ 100 mm, heated in a furnace at 500 ° C.
- N ⁇ Ni / I
- VR ⁇ (Wi / ⁇ ) ⁇ 100 / ((Wk + ⁇ Wi) / ⁇ )
- the obtained composite material had a thickness of 1.6 mm.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- the number of critical single yarns in this composite material was 86, and the proportion of the carbon fiber bundle (A) composed of the number of critical single yarns or more was 35%.
- the average number of fibers was 240.
- this composite material was manufactured using a mold having a convex portion having a specific size, and provided with a cylindrical convex portion as shown in FIG.
- the shape of the convex portion was a cylindrical shape (joint surface was round) having a height of 1 mm and ⁇ 10 (diameter 10 mm).
- the position of the convex portion is 15 mm from one end in the longitudinal direction and the center in the width direction.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- the number of critical single yarns in this composite material was 86, and the proportion of the carbon fiber bundle (A) composed of the number of critical single yarns or more was 34%.
- the average number of fibers was 266.
- Reference Example 3 Creation of a composite material having a convex portion with a rectangular joint surface
- a composite material was prepared in the same manner as in Reference Example 2 except that a prismatic protrusion having a rectangular 9 mm side joining surface was provided instead of the cylindrical protrusion in Reference Example 2.
- the height of the convex part was 1 mm.
- the number of critical single yarns in this composite material was 86, and the proportion of the carbon fiber bundle (A) composed of the number of critical single yarns or more was 34%.
- the average number of fibers was 266.
- Example 1 (Joining) One composite material prepared based on Reference Example 1 and one composite material prepared based on Reference Example 2 were prepared, and these were aligned in the width direction, and a region of 25 mm from one end in the longitudinal direction was overlapped. .
- the convex portion is arranged on the joint surface side, and the joint portion including the convex portion is added to the copper electrode of ⁇ 14 by adding 3 kN. I pinched it with pressure. Next, a current of 50 A was applied between the electrodes for 3 seconds, and then the pressure was maintained until it was cooled to near room temperature to obtain a joined body. The convex portion disappeared and was flattened.
- Example 2 (Joining) One composite material prepared based on Reference Example 1 and one composite material prepared based on Reference Example 3 were prepared, and these were aligned in the width direction, and a region of 25 mm from one end in the longitudinal direction was overlapped. .
- the convex portion is arranged on the joint surface side, and the joint portion including the convex portion is added to the copper electrode of ⁇ 14 by adding 3 kN. I pinched it with pressure. Next, a current of 50 A was applied between the electrodes for 3 seconds, and then the pressure was maintained until it was cooled to near room temperature to obtain a joined body. The convex portion disappeared and was flattened.
- Example 3 (Joining) The same as Example 1 except that one composite material prepared based on Reference Example 1 and one composite material prepared based on Reference Example 2 were prepared, these were superposed, and the electrode diameter was ⁇ 16 (diameter 16 mm). A joined body was obtained. (Evaluation) When the tensile shear strength of the obtained joined body was measured, the fracture load was an average of 3.9 kN and the standard deviation was 0.234 kN.
- Example 4 (Creation of composite material without protrusions) A matrix resin in which carbon fibers (Tenax (registered trademark) STS40 24K manufactured by Toho Tenax, average fiber diameter 7 ⁇ m) cut to an average fiber length of 20 mm are randomly dispersed by hand so as to have an average basis weight of 980 g / m 2. Used is a blend of 96% by mass of Prime Polymer Prime Polypro J108M and 4% by mass of maleic anhydride-modified polypropylene Toyotack PMAH1000P manufactured by Toyobo Co., Ltd. It was set in a flat mold having a size of 200 mm ⁇ 200 mm so as to be 52% on the basis and 35% on the volume basis.
- the thickness of the obtained composite material was 1.6 mm.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- Carbon fibers cut to an average fiber length of 20 mm (Tenax (registered trademark) STS40 24K, manufactured by Toho Tenax Co., Ltd., average fiber diameter: 7 ⁇ m) are randomly dispersed so as to have an average basis weight of 980 g / m 2, and the matrix resin is primed.
- %, 35% on a volume basis was set in a flat mold having a size of 200 mm ⁇ 200 mm. These were held at a temperature of 190 ° C. for 10 minutes under a pressure of 10 MPa, and a composite material was obtained after cooling the mold. At this time, the thickness of the obtained composite material was 1.6 mm. A plate having a length of 100 mm, a width of 25 mm, and a thickness of 1.6 mm was cut out from the composite material. Further, this composite material was manufactured using a mold having a protrusion having a specific size, and provided with a protrusion as shown in FIG.
- the shape of the convex portion was a cylindrical shape (joint surface was round) having a height of 1 mm and ⁇ 10 (diameter 10 mm).
- the position of the convex portion is 15 mm from one end in the longitudinal direction and the center in the width direction.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- the convex portion was arranged on the joining surface side, and the joining portion including the convex portion was sandwiched between the ⁇ 14 copper electrodes with a pressure of 3 kN.
- a current of 25 A was applied between the electrodes for 3 seconds, and then held under pressure until cooled to near room temperature to obtain a joined body.
- the convex portion disappeared and was flattened.
- the current density at this time was 0.32 A / mm 2 .
- Example 5 Carbon fibers cut to an average fiber length of 20 mm (Tenax (registered trademark) STS40 24K manufactured by Toho Tenax Co., Ltd., average fiber diameter: 7 ⁇ m) are randomly dispersed so as to have an average basis weight of 980 g / m 2.
- the thickness of the obtained composite material was 1.6 mm.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- Carbon fibers cut to an average fiber length of 20 mm (Tenax (registered trademark) STS40 24K manufactured by Toho Tenax Co., Ltd., average fiber diameter: 7 ⁇ m) are randomly dispersed so as to have an average basis weight of 980 g / m 2.
- a powder made of VALOX resin manufactured by Subic was used, and set in a flat mold having a size of 200 mm ⁇ 200 mm so that the carbon fiber content was 52% by mass and 35% by volume. These were held at a temperature of 250 ° C. for 10 minutes under a pressure of 10 MPa, and a composite material was obtained after cooling the mold.
- the thickness of the obtained composite material was 1.6 mm.
- a plate having a length of 100 mm, a width of 25 mm, and a thickness of 1.6 mm was cut out from the composite material.
- this composite material was manufactured using a mold having a protrusion having a specific size, and provided with a protrusion as shown in FIG.
- the shape of the convex portion was a cylindrical shape (joint surface was round) having a height of 1 mm and ⁇ 10 (diameter 10 mm).
- the position of the convex portion is 15 mm from one end in the longitudinal direction and the center in the width direction.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- (Joining) A composite material provided with the composite material and a round-shaped convex portion was prepared, and these were aligned in the width direction, and an area of 25 mm from one end in the longitudinal direction was overlapped. At this time, about the composite material provided with the convex portion, the convex portion was arranged on the joining surface side, and the joining portion including the convex portion was sandwiched between the ⁇ 14 copper electrodes with a pressure of 3 kN. Next, a current of 25 A was applied between the electrodes for 3 seconds, and then held under pressure until cooled to near room temperature to obtain a joined body.
- Example 7 (Joining) One composite material prepared based on Reference Example 1 and one composite material prepared based on Reference Example 3 were prepared, and these were aligned in the width direction, and a region of 25 mm from one end in the longitudinal direction was overlapped. .
- the convex portion is arranged on the joint surface side, and the joint portion including the convex portion is added to the copper electrode of ⁇ 14 by adding 3 kN. I pinched it with pressure.
- a current of 25 A was applied between the electrodes for 3 seconds, and then held under pressure until cooled to near room temperature to obtain a joined body.
- the current density at this time was 0.31 A / mm 2 .
- Example 8 Two composite materials prepared on the basis of Reference Example 2 were prepared and overlapped so that the convex portions were in contact with each other. More specifically, two composite materials were aligned in the width direction, and a region 30 mm from the end of one end in the longitudinal direction was overlapped so that the circles that are the joint surfaces of both convex portions matched each other. The joint portion including the convex portion was sandwiched by a copper electrode of ⁇ 14 with a pressure of 3 kN. Next, a current of 25 A was applied between the electrodes for 3 seconds, and then held under pressure until cooled to near room temperature to obtain a joined body. The convex portion disappeared and was flattened. The current density at this time was 0.32 A / mm 2 . (Evaluation) When the tensile shear strength of the obtained joined body was measured, the breaking load was an average of 4.6 kN and the standard deviation was 0.238 kN.
- Example 9 (Making composite material with truncated cone-shaped projections) A matrix resin in which carbon fibers (Tenax (registered trademark) STS40 24K manufactured by Toho Tenax, average fiber diameter 7 ⁇ m) cut to an average fiber length of 20 mm are randomly dispersed by hand so as to have an average basis weight of 980 g / m 2.
- a unitized product of Unitika Nylon 6 manufactured by Unitika Co., Ltd. was used, and set in a flat mold having a size of 200 mm ⁇ 200 mm so that the mass ratio of carbon fiber was 52% and the volume was 35%. These were held at a temperature of 250 ° C.
- this composite material was manufactured using a mold having a convex portion having a specific size, and provided with a truncated cone-shaped convex portion.
- the shape of the convex portion was 1 mm in height, the shape of the bottom of the truncated cone was ⁇ 12 (diameter 12 mm), and the angle rising from the bottom and the bottom of the truncated cone section was 45 degrees.
- the position of the convex portion is 15 mm from one end in the longitudinal direction and the center in the width direction.
- the carbon fibers are dispersed non-oriented in the in-plane direction, and is substantially isotropic in this direction.
- (Joining) Prepare one composite material prepared on the basis of Reference Example 1 and one composite material provided with the above-mentioned frustoconical projections, align them in the width direction, and overlap an area of 25 mm from one end in the longitudinal direction. Combined. At this time, about the composite material provided with the convex portion, the convex portion was arranged on the joining surface side, and the joining portion including the convex portion was sandwiched between the ⁇ 14 copper electrodes with a pressure of 3 kN.
- the joined body obtained by the joining method according to the present invention is firmly joined using the convex portion as a joining portion. Furthermore, the joint location and strength to be heat-sealed were stable, and the standard deviation of the fracture load was small in the tensile shear strength. This is presumably because the part to be energized is limited or because the carbon fibers are in-plane oriented, but the details are unknown.
- the method of joining the composite material containing a thermoplastic resin and carbon fiber with high joining strength by a simple method can be provided.
- it is possible to easily perform welding by providing a projection-shaped convex portion at a joint portion of a composite material containing a thermoplastic resin and carbon fiber, and energizing the joint portion including the convex portion to generate heat. it can.
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Abstract
Description
接着剤による接合は高い接合強度を得られないため、構造部材には不向きである。
溶着は、熱板や振動、超音波を利用した溶着手法があるが、素材をそのまま一体化させるため、接合による重量増加もなく、高い強度が得られるため、熱可塑性樹脂においては非常に有利な接合手法といえる。しかしながら、熱板溶着では糸ひきのため熱板に樹脂が付着する問題がある。振動溶着では被溶着物毎に専用の治具が必要であることと、接合面を振動させることが必要なため、複雑な形状には対応できない問題がある。また、超音波溶着はホーンのサイズに制限があり、大型の被溶着物に対応しにくいことと、高周波音が発生するなどの問題がある。
このように、熱可塑性樹脂をマトリックスとした複合材料の接合方法として、被溶着物の大きさや形状に左右されず、しかも短時間に高強度を得られる接合方法は知られていない。
特許文献3には、熱可塑性樹脂成形品の接合面に、炭素繊維から成る発熱体を挟み込み、適宜な力で加圧しながら前記発熱体へ電圧を印加して発熱させて接合面の樹脂を溶融し、その後、電圧の印加を止めて樹脂を冷却し、硬化させることにより、成形品同士を溶着させる方法が記載されている。
本発明の目的は、熱可塑性樹脂と炭素繊維を含有する複合材料同士を、簡便な方法により、高い接合強度で接合させる方法を提供することにある。
[1] (i)熱可塑性樹脂と炭素繊維を含有してなり、一つの面に凸部を有する複合材料Aと、熱可塑性樹脂と炭素繊維を含有してなる複合材料Bとを、複合材料Aの凸部を内側にして重ね合わせ固定する工程、および
(ii)当該凸部を含む接合部位に通電して発熱させる工程、
を含む複合材料の接合方法。
[2]通電を、電流密度0.01A/mm2から100A/mm2の範囲で行なうことを特徴とする上記記載の複合材料の接合方法。
[3]複合材料の固定を、電極により加圧して行なう上記記載の複合材料の接合方法。
[4]複合材料Bが一つの面に凸部を有する上記記載の複合材料の接合方法。
[5]複合材料AおよびBにおける炭素繊維体積含有率(Vf=100×炭素繊維の体積/(炭素繊維の体積+熱可塑性樹脂の体積))が5%から80%である上記記載の複合材料の接合方法。
[6]複合材料AおよびBにおける炭素繊維の平均繊維長が1mmから100mmである上記記載の複合材料の接合方法。
[7]複合材料Aの凸部を有する面の面内方向において、炭素繊維が無配向に分散して配置している上記記載の複合材料の接合方法。
[8]凸部の形状が円柱、角柱、円錐台、角錐台および半球からなる群から選ばれる少なくとも1種の形状である、上記記載の複合材料の接合方法。
本発明では、熱可塑性樹脂と炭素繊維を含有する複合材料の接合部に突起形状の凸部を設け、この凸部を含む接合部に通電して発熱させることにより、簡便に溶着を行うことができるとともに、当該溶着箇所が安定した接合体を得ることができる。
こうして接合部の通電部分が凸部を含むことにより、驚くべきことに、加熱融着させる面積が安定し、接合強度に優れた良好な炭素繊維複合材料の接合体を得ることができる。
(i)熱可塑性樹脂と炭素繊維を含有してなり、一つの面に凸部を有する複合材料Aと、熱可塑性樹脂と炭素繊維を含有してなる複合材料Bとを、複合材料Aの凸部を内側にして重ね合わせ固定する工程、および
(ii)当該凸部を含む接合部位に通電して発熱させる工程、
を含む。
ここで、「複合材料AとBを、複合材料Aの凸部を内側にして重ね合わせ固定する」とは、「複合材料AとBを、複合材料Aの凸部と複合材料Bを対向させて接触させて固定する」ことである。
また、「凸部を含む接合部位」とは、「複合材料Aの凸部と複合材料Bとが接触している部分を含む領域」であり、この領域が通電による発熱で溶着して接合部位となる。
なお、本発明において、複合材料A及びBを準備する工程を有してもよいことは言うまでもない。
以下本発明の実施形態について説明する。
[複合材料A]
本発明に用いられる複合材料Aは、熱可塑性樹脂と炭素繊維を含有してなる部材であり、一つの面に凸部を有する。複合材料Aは、好ましくは熱可塑性樹脂をマトリックス成分とし、これに炭素繊維を含有させてなる炭素繊維含有複合材料である。
本発明における複合材料に使用する熱可塑性樹脂としては、特に限定はなく、例えば、ポリアミド(例えば、ナイロン6、ナイロン66)、ポリカーボネート、ポリオキシメチレン、ポリフェニレンスルフィド、ポリフェニレンエーテル、ポリエステル(例えば、ポリエチレンテレフタレート、ポリブチレンテレフタレート、ポリエチレンナフタレート)、ポリエチレン、ポリプロピレン、ポリスチレン、ポリメチルメタクリレート、AS樹脂およびABS樹脂などが挙げられる。これらは2種類以上混合して用いてもよい。
本発明における複合材料に使用する熱可塑性樹脂としては、耐熱性、耐衝撃性、耐候性、耐薬品性、成形性、強度、コスト、及びこれらのバランスの観点から、好ましくはポリアミド、ポリエステル、ポリプロピレン、ポリカーボネート、又はポリフェニレンスルフィドである。
本発明では、複合材料中に炭素繊維を含有する。その結果、軽量かつ高強度、高剛性の部品などの複合材料接合体が得られる。かかる炭素繊維には、カップリング剤による処理、サイジング剤による処理、添加剤の付着処理などの表面処理が施されていてもよい。
炭素繊維の平均繊維径としては、好ましくは3~12μmであり、より好ましくは5~7μmである。また、かかる炭素繊維は、1種類を単独で用いてもよいし、径が異なる2種類以上を併用してもよい。
本発明で用いる複合材料における、熱可塑性樹脂と炭素繊維の含有割合としては、炭素繊維100質量部に対し熱可塑性樹脂が50~1,000質量部含まれているものであることが好ましい。より好ましくは、炭素繊維100質量部に対し、熱可塑性樹脂50~400質量部、更に好ましくは、炭素繊維100質量部に対し、熱可塑性樹脂50~100質量部である。前記割合とすることにより、成形性が良好で、最終的に得られる接合体の機械的強度も高い。
複合材料中における上記炭素繊維の体積含有率(Vf=100×炭素繊維の体積/(炭素繊維の体積+熱可塑性樹脂の体積))は、特に制限はないが、強度面で5~80%であることが望ましい。
臨界単糸数=600/D (1)
(ここでDは炭素繊維の平均繊維径(μm)である)
で定義する臨界単糸数以上で構成される炭素繊維束(A)について、炭素繊維全量に対する割合が体積比率で20Vol%以上99Vol%以下であることが、より優れた機械物性を得る目的において好ましい。なお、かかる複合材料には、炭素繊維束(A)以外の炭素繊維として、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してもよい。よりいっそう機械物性に優れた成形体を得ようとする場合の、炭素繊維束(A)の割合はより好ましくは30Vol%以上90Vol%未満であり、さらに好ましくは30Vol%以上80Vol%未満である。
0.7×104/D2<N<1×105/D2 (2)
(ここでDは炭素繊維の平均繊維径(μm)である)
を満たすことが好ましい。上記式(2)は、下記式(2’)
0.7×104/D2<N<6.0×104/D2 (2’)
を満たすことがより好ましい。
本発明において、複合材料Aは少なくとも一つの面に凸部を有する。かかる凸部を有する一つの面は平面であっても曲面であってもよい。複合材料Aは、少なくとも一つの平面部を有し、該平面部上に凸部を有することが好ましい。複合材料Bも複合材料Aの凸部と接合するための平面部を有することが好ましい。上記複合材料A及びBは両方ともシート状の材料であることが好ましい。なお、前記平面部は接合できる範囲であれば多少湾曲していてもよい。シート状の複合材料の厚みとしては0.1mm~10mmの範囲内のものであることが好ましい。しかしながら、このような複合材料の形状は上記形状に限定されない。
さらに上記複合材料は、面内方向において、炭素繊維を無作為に分散するように配置させると、物性、例えば、強度・弾性率等が面内方向の異方性を実質的に有しない複合材料となる。そのような複合材料を用いて接合面が当該面内方向に対し平行であれば、最終的に得られる接合体は、一方向の強度に優れたものとなり、用途によっては好都合である。
本発明における複合材料Aの少なくとも一方の面には、複合材料Bの一面と溶融接着するための突起形状の凸部が設けられている。かかる凸部は、複合材料Aと同じ素材からなるものがよい。
突起形状の例としては、例えば図1に示した複合材料1における凸部2のような形状が挙げられる。
本発明における凸部は、接合後に製品形状、製品寸法に影響を与えない大きさのものであって、特に制限はないが、例えば以下のようなものが挙げられる。
柱状や錐台のように相手材(複合材料B)との接触部分に面が存在する場合、接合部として接触する形状は、丸、楕円、多角形、または、扇型に代表されるような直線と曲線を組合せた形状でもよい。凸部の相手方(ここでは複合材料B)と接触する部分の先端形状は、複合材料Bの接合部と同じ面形状であると接合面積が広くなるので良好な接合強度が得られやすい。例えば、複合材料Bにおける接合部位が平面であれば凸部の先端も平面であることが好ましい。複合材料Bにおける接合部位が緩やかな曲面形状であれば凸部の先端も同様の曲面形状であることが好ましい。
凸部底部の面積は、0.25mm2から2500mm2の範囲であることが好ましい。面積が0.25mm2以上あれば、凸部の中へ炭素繊維が入りやすい。そのため、通電による接合が容易となるので好ましい。円錐台、角錐台の断面においては、複合材料Bと接合する複合材料Aの凸部の先端の面積は、0.1mm2以上であることが好ましい。凸部先端面の面積が0.1mm2以上であれば、凸部先端にも炭素繊維が入りやすく、凸部先端が熱可塑性樹脂のみになりにくいため、電気抵抗が高くならず、通電による接合が容易となるので好ましい。また、接合箇所毎に小さい突起を複数設けても良く、この場合は接合1箇所あたりの突起先端総面積を0.1mm2以上とすることが好ましい。
凸部の高さについては制限はないが、接合する実施の容易さから0.01mmから20mmの範囲であることが好ましい。
凸部の立ち上り角度は、成形性の点から0.1°から89.9°の範囲であることが好ましい。
凸部の好ましい例として、1辺0.1~30mmで高さ0.5~20mmの角柱状突起、Φ0.1~30(直径0.1~30mm)で高さ0.5~20mmの円柱状突起などが挙げられる。
凸部の特に好ましい例として、1辺9mmで高さ1mmの角柱状突起、Φ10(直径10mm)で高さ1mmの円柱状突起などが挙げられる。
なお、複合材料の表面の凸部は1つでもよいが、むろん2つ以上であってもよい。
本発明における複合材料Bは、熱可塑性樹脂と炭素繊維を含有してなる部材である。複合材料Bの熱可塑性樹脂、炭素繊維、それらの割合、製法等については、前記複合材料Aと同じものを挙げることができる。特に、複合材料Bに含まれる熱可塑性樹脂及び炭素繊維は、複合材料Aと同じものを用いることが生産性の面で都合がよい。
また、複合材料Bは複合材料Aと同様に凸部を一方の面に有していても良い。その場合凸部は複合材料Aと接する側、反対側のどちらにあってもよく、かかる凸部を複合材料Aとの接合における接合部位とすることができる。
なお、本発明で用いる複合材料A,Bの全体の形状としては特に限定されない。複合材料A,Bの形状は、上記のようにシート状でもよいし、シート状に限らず、板状でもよい。複合材料A,Bの形状は、曲面部を有していてもよい。また、複合材料A,Bの形状は、断面がT字型、L字型、コの字型、ハット型およびこれらを含む三次元形状のものであってもよく、これら種々の形状の複合材料に対して、本発明に示す複合材料の接合方法を適用できる。
本発明の好ましい接合方法について、以下に説明するが、本発明はこれらに限定されるものではない。
図2に、抵抗溶接による本発明の接合方法を説明するための実施形態に係る概略図を示す。この概略図では、複合材料AとBを、複合材料Aの凸部を内側にして複合材料Bと重ね合わせた接合部位を示している。1は炭素繊維複合材料A、1’は炭素繊維複合材料B、4は複合材料Aの一方の面にある凸部、3は電極である。
重ね合せて溶着させるA,B2つの複合材料の成形体を一対準備する。その一方の成形体である複合材料Aの片側表面には、接合部分となる突起形状(凸部)が設けられている。
本発明の接合方法では、複合材料AとBを、複合材料Aの凸部を内側にして重ね合わせる。このとき、複合材料Bは、複合材料Aの凸部と接触している。本発明においては、複合材料Aの凸部と複合材料Bとが接触した状態で固定するが、ここでいう固定とは、複合材料Aの凸部と複合材料Bとが接触した状態を維持できていればよい。また、公知の固定手段を用いて固定してもよい。
複合材料Aの凸部と複合材料Bとの接触箇所を含む接合部分を、挟むようにして加圧することが好ましく、複合材料Aに対しては複合材料Bに向かう方向に、複合材料Bに対しては複合材料Aに向かう方向に、加圧することがより好ましい。複合材料A及びBがシートであれば、該シートの平面方向に対して垂直方向、すなわち厚み方向に加圧するのが好ましい。
(通電工程)
続いて、本発明では、上記接合部位に通電させる。通電の手段としては、複合材料Aと複合材料Bを一対の電極で挟み、電極間に電流を流す方法が好ましい。このとき、上記の固定、加圧と、通電はそれぞれ異なる手段や装置を用いて行なってもよいが、プロセスの簡単化のため、複合材料を電極で挟んで固定、加圧することが好ましい。このように複合材料の固定は、電極により加圧して行なうことが好ましい。通電工程では、複合材料Aから複合材料Aの凸部を通って複合材料Bに電流が流れる、又は複合材料Bから複合材料Aの凸部を通って複合材料Aに電流が流れることが好ましい。当該凸部を含む接合部位は通電により発生する熱で加熱される。暖められた接合部位の複合材料A,B中の熱可塑性樹脂は温度が上昇しやがて溶融し、溶着する。その後通電を止め、十分に冷却するまで加圧保持し、当該熱可塑性樹脂は固化して凸部は実質的に平らになり、複合材料AとBが接合された成形体(接合体)が得られる。
接合に用いる電源としては交流電源でも直流電源でもよいが、効率的に発熱させたい場合には、直流電源の方が好ましい。
使用する電極の材質、電極径に限定はないが、材質としては銅や銅合金を使用することが好ましく、電極径としてはφ3(直径3mm)からφ30(直径30mm)程度であることが好ましい。電極の形状は、特に限定されることはないが、例えば棒状またはブロック状の電極などがある。
接合の際に流す電流値の範囲としては、1Aから500Aの範囲が好ましく、さらに好ましくは1Aから200Aの範囲である。さらに好ましくは10Aから200Aであることが好ましい。通電時間は60秒以内であることが好ましく、実質下限は0.1秒である。このときの通電量の制御に関して制限はないが、例えば、一定電流を所定時間通電させる方法、通電させた電力量が一定になるようにする方法などが挙げられる。また、加圧力は0.01MPa以上であることが好ましく、実質条件は1000MPa以下である。加圧力は一定であっても、プロセスに応じて加減してもよい。
[接合体]
本発明によれば、通電により発熱し複合材料Aの凸部を構成する熱可塑性樹脂が暖められ、場合によっては溶融し、複合材料Bと一体となって接合された接合体を得ることができる。該凸部はこれによってつぶれてほとんど消滅し、得られる接合体の接合部には凸部は基本的に残らないが、残っていても十分な接合強度が得られていればよい。凸部の周辺部分も場合によっては暖められ、接合に寄与する。
(引張試験)
接合体を10個作成し、インストロン社製万能試験機5578 300kN容量床置型試験機を用い、JISK6850(1999年)に基づいて引張せん断試験を実施した。引張速度は1mm/minとした。得られた10個のデータから破壊荷重の平均値、標準偏差を算出した。また、ナイロン6をマトリックス樹脂とした複合材料の場合(実施例1~3、6~9)については、良否の判断を以下のように行った。
○:(引張せん断試験での破壊荷重の平均値)-3×(引張せん断試験での破壊荷重の標準偏差)が3kN以上
×:(引張せん断試験での破壊荷重の平均値)-3×(引張せん断試験での破壊荷重の標準偏差)が3kN未満
(炭素繊維束)
複合材料に含まれる炭素繊維束(A)の割合の求め方は、以下の通りである。
複合材料を100mm×100mmに切り出し、500℃の炉内で1時間程度加熱し、樹脂を完全に除去した後、繊維束をピンセットで全て取り出し、繊維束の長さ(Li)と質量(Wi)、繊維束数(I)を測定した。ピンセットにて取り出すこと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した(Wk)。質量の測定には、1/100mgまで測定可能な天秤を用いる。
測定後、以下の計算を行った。使用している炭素繊維の繊度(F)より、個々の繊維束の繊維本数(Ni)は、次式により求めた。
繊維本数(Ni)=Wi/(Li×F)
炭素繊維束(A)中の平均繊維数(N)は、以下の式により求めた。
N=ΣNi/I
また、炭素繊維束(A)の繊維全体に対する割合(VR)は、炭素繊維の密度(ρ)を用いて次式により求めた。
VR=Σ(Wi/ρ)x100/((Wk+ΣWi)/ρ)
炭素繊維束(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均繊維長20mmになるようにカットした。これを平均目付け980g/m2、となるよう手でランダムに分散させて配置し、マトリックス樹脂にはユニチカ株式会社製ユニチカナイロン6を粉体状にしたものを用いた。ついで、炭素繊維の含有割合が質量基準で45%、体積基準で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で250℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料は厚みが1.6mmであった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。
得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
この複合材料における臨界単糸数は86であり、臨界単糸数以上で構成される炭素繊維束(A)が占める割合は35%であった。また、平均繊維数は240であった。
炭素繊維束(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均繊維長20mmになるようにカットした。ついでこれを平均目付け980g/m2、となるよう手でランダムに分散させて配置し、マトリックスにはユニチカ株式会社製ユニチカナイロン6を粉体状にしたものを用い、炭素繊維の含有割合が質量基準で45%、体積基準で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で250℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料の厚みは1.6mmであった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。また、この複合材料は特定の大きさの凸部を有する金型を用いて製造し、図1のような円柱形状の凸部を設けた。凸部の形状は、高さ1mm、φ10(直径10mm)の円柱形状(接合面は丸型)とした。凸部の位置は、長手方向の片端に端から15mm、幅方向中央である。
なお得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
この複合材料における臨界単糸数は86であり、臨界単糸数以上で構成される炭素繊維束(A)が占める割合は34%であった。また、平均繊維数は266であった。
上記参考例2における円柱形状の凸部の代わりに、1辺9mmの接合面が矩形の角柱形状の凸部を設ける以外は上記参考例2と同様にして複合材料を作成した。凸部の高さは1mmとした。
この複合材料における臨界単糸数は86であり、臨界単糸数以上で構成される炭素繊維束(A)が占める割合は34%であった。また、平均繊維数は266であった。
(接合)
参考例1に基づいて作成した同一の複合材料を2つ準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せ、重ね合わせた部分のほぼ中央付近をφ14(直径14mm)の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に50Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。このときの電流密度は0.33A/mm2であった。
(評価)
結果を表1に示す。得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均3.9kN、標準偏差が1.43kNであった。接合体の接合箇所をはがして観察したところ、電極を当てた部分を中心として、おおよそ直径25mmの範囲内に、マトリックス樹脂が溶着して接合していたと思われる小さな部分(面積にして5~50mm2)の円形または楕円形)が3~5箇所、点在して見られた。比較例1で得られた複合材料は、加熱融着した接合部位が安定せずに接合したものと思われる。
(接合)
参考例1に基づいて作成した複合材料1つと参考例2に基づいて作成した複合材料1つを準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、参考例2に基づいて凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に50Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度(通電時の電流値/凸部の接合面の面積)は0.63A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均4.4kN、標準偏差が0.186kNであった。結果を表1に示す。
(接合)
参考例1に基づいて作成した複合材料1つと参考例3に基づいて作成した複合材料1つを準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、参考例3に基づいて凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に50Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.62A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均4.1kN、標準偏差が0.206kNであった。結果を表1に示す。
(接合)
参考例1に基づいて作成した複合材料1つと参考例2に基づいて作成した複合材料1つを準備し、これらを重ね合せ、電極径をΦ16(直径16mm)とした以外は実施例1と同様に接合体を得た。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均3.9kN、標準偏差が0.234kNであった。
(凸部を有さない複合材料の作成)
平均繊維長20mmにカットした炭素繊維(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均目付け980g/m2となるように、手でランダムに分散させて配置し、マトリックス樹脂にはプライムポリマー製プライムポリプロJ108Mを96質量%と東洋紡社製無水マレイン酸変性ポリプロピレン トーヨータックPMAH1000Pを4質量%とをブレンドしたものを粉体状にしたものを用い、炭素繊維の含有割合が質量基準で52%、体積基準で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で190℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料の板厚は1.6mmだった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。
得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
(接合面が丸型の凸部を設けた複合材料の作成)
平均繊維長20mmにカットした炭素繊維(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均目付け980g/m2となるように、ランダムに分散させて配置し、マトリックス樹脂をプライムポリマー製プライムポリプロJ108Mを96質量%と東洋紡社製無水マレイン酸変性ポリプロピレン トーヨータックPMAH1000Pを4質量%とをブレンドしたものを粉体状にしたものを用い、炭素繊維の含有割合が質量基準で52%、体積基準で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で190℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料の厚みは1.6mmだった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。また、この複合材料は特定の大きさの凸部を有する金型を用いて製造し、図1のような凸部を設けた。凸部の形状は、高さ1mm、φ10(直径10mm)の円柱形状(接合面は丸型)とした。凸部の位置は、長手方向の片端に端から15mm、幅方向中央である。
なお得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
(接合)
上記複合材料と丸型の凸部を設けた複合材料を準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に25Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.32A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均2.0kN、標準偏差が0.113kNであった。
(凸部を有さない複合材料の作成)
平均繊維長20mmにカットした炭素繊維(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均目付け980g/m2となるように、ランダムに分散させて配置し、マトリックス樹脂にはサビック社製VALOX樹脂(ポリブチレンテレフタレートを含む樹脂)を粉体状にしたものを用い、炭素繊維の含有割合が質量基準で52%、体積基準で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で250℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料の板厚は1.6mmだった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。
得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
(接合面が丸型の凸部を設けた複合材料の作成)
平均繊維長20mmにカットした炭素繊維(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均目付け980g/m2となるように、ランダムに分散させて配置し、マトリックス樹脂にはサビック社製VALOX樹脂を粉体状にしたものを用い、炭素繊維の含有割合が質量基準で52%、体積基準で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で250℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料の厚みは1.6mmだった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。また、この複合材料は特定の大きさの凸部を有する金型を用いて製造し、図1のような凸部を設けた。凸部の形状は、高さ1mm、φ10(直径10mm)の円柱形状(接合面は丸型)とした。凸部の位置は、長手方向の片端に端から15mm、幅方向中央である。
なお得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
(接合)
上記複合材料と丸型の凸部を設けた複合材料を準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に25Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.32A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均3.1kN、標準偏差が0.140kNであった。
(接合)
参考例1に基づいて作成した複合材料1つと参考例2に基づいて作成した複合材料1つを準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、参考例2に基づいて凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に25Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.32A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均4.2kN、標準偏差が0.169kNであった。
(接合)
参考例1に基づいて作成した複合材料1つと参考例3に基づいて作成した複合材料1つを準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、参考例3に基づいて凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に25Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.31A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均4.0kN、標準偏差が0.199kNであった。
(接合)
参考例2に基づいて作成した複合材料2つを準備し、互いの凸部同士が接触するように重ね合せた。より詳細には、2つの複合材料を幅方向に揃え、かつ双方の凸部の接合面である円同士が合致するようにして、長手方向の片端の端から30mmの領域を重ね合わせた。この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に25Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.32A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均4.6kN、標準偏差が0.238kNであった。
(円錐台型の凸部を設けた複合材料の作成)
平均繊維長20mmにカットした炭素繊維(東邦テナックス製テナックス(登録商標)STS40 24K、平均繊維径7μm)を平均目付け980g/m2となるように、手でランダムに分散させて配置し、マトリックス樹脂としてユニチカ株式会社製ユニチカナイロン6を粉体状にしたものを用い、炭素繊維の質量割合で52%、体積で35%になるよう、200mmx200mmサイズの平らな金型にセットした。これらを10MPaの圧力下で250℃の温度で10分間保持し、金型を冷却後に複合材料を得た。このとき、得られた複合材料の厚みは1.6mmだった。この複合材料から長さ100mm×幅25mm×厚み1.6mmの板を切り出した。また、この複合材料は特定の大きさの凸部を有する金型を用いて製造し、円錐台型の凸部を設けた。凸部の形状は、高さ1mm、円錐台底部の形状がφ12(直径12mm)、円錐台断面の底部と底部から垂直方向に立上る角度を45度とした。凸部の位置は、長手方向の片端に端から15mm、幅方向中央である。
なお得られた複合材料は、炭素繊維が面内方向において無配向に分散しており、かかる方向において実質的に等方性である。
(接合)
参考例1に基づいて作成した複合材料1つと上記円錐台型の凸部を設けた複合材料1つを準備し、これらを幅方向に揃えて、長手方向の片端の端から25mmの領域を重ね合せた。このとき、凸部を設けた複合材料については、凸部を接合面側に配置し、この凸部を含んだ接合部位を、φ14の銅製の電極にて、3kNの加圧力で挟んだ。ついで、電極間に25Aの電流を3秒間通電させた後、室温近くまで冷却するまで加圧保持し、接合体を得た。凸部は消滅し平坦化されていた。このときの電流密度は0.31A/mm2とした。
(評価)
得られた接合体の引張せん断強度を測定したところ、破壊荷重は平均4.2kN、標準偏差が0.255kNであった。
本発明では、熱可塑性樹脂と炭素繊維を含有する複合材料の接合部に突起形状の凸部を設け、この凸部を含む接合部に通電して発熱させることにより、簡便に溶着を行うことができる。
本出願は、2011年12月27日出願の日本特許出願(特願2011-285610)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。
1’:複合材料B
2、4:凸部
3:電極
Claims (8)
- (i)熱可塑性樹脂と炭素繊維を含有してなり、一つの面に凸部を有する複合材料Aと、熱可塑性樹脂と炭素繊維を含有してなる複合材料Bとを、複合材料Aの凸部を内側にして重ね合わせ固定する工程、および
(ii)当該凸部を含む接合部位に通電して発熱させる工程、
を含む複合材料の接合方法。 - 通電を、電流密度0.01A/mm2から100A/mm2の範囲で行なうことを特徴とする請求項1に記載の複合材料の接合方法。
- 複合材料の固定を、電極により加圧して行なう請求項1または2に記載の複合材料の接合方法。
- 複合材料Bが一つの面に凸部を有することを特徴とする請求項1~3のいずれか1項に記載の複合材料の接合方法。
- 複合材料AおよびBにおける炭素繊維体積含有率(Vf=100×炭素繊維の体積/(炭素繊維の体積+熱可塑性樹脂の体積))が5%から80%であることを特徴とする請求項1~4のいずれか1項に記載の複合材料の接合方法。
- 複合材料AおよびBにおける炭素繊維の平均繊維長が1mmから100mmであることを特徴とする請求項1~5のいずれかに記載の複合材料の接合方法。
- 複合材料Aの凸部を有する面の面内方向において、炭素繊維が無配向に分散して配置していることを特徴とする請求項1~6のいずれか1項に記載の複合材料の接合方法。
- 凸部の形状が円柱、角柱、円錐台、角錐台および半球からなる群から選ばれる少なくとも1種の形状である、請求項1~7のいずれか1項に記載の複合材料の接合方法。
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US14/369,212 US20150013898A1 (en) | 2011-12-27 | 2012-12-26 | Method for Joining Composite Materials |
CN201280064479.4A CN104023946A (zh) | 2011-12-27 | 2012-12-26 | 复合材料的接合方法 |
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JP2020510559A (ja) * | 2017-03-13 | 2020-04-09 | アルケマ フランス | 熱可塑性ポリマー複合材部品を製造するための方法、及び前記方法により得られる物体 |
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JP6280839B2 (ja) * | 2014-08-22 | 2018-02-14 | 本田技研工業株式会社 | 繊維強化樹脂接合体の製造方法 |
KR101807039B1 (ko) * | 2016-04-28 | 2017-12-08 | 현대자동차 주식회사 | 접합용 스틸이 인서트 성형된 복합소재 |
WO2018159882A1 (ko) * | 2017-03-03 | 2018-09-07 | 유신정밀공업 주식회사 | 발열 구조물 |
DE102017217294A1 (de) * | 2017-09-28 | 2019-03-28 | Airbus Operations Gmbh | Verfahren zum Widerstandsschweißen von Faserverbundbauteilen zu einer Faserverbundstruktur, Faserverbundstruktur und Faserverbundbauteil |
KR102394629B1 (ko) | 2017-12-07 | 2022-05-06 | 현대자동차주식회사 | 핫스탬핑 강판의 접합방법 |
KR102011062B1 (ko) * | 2018-01-10 | 2019-08-14 | 한화큐셀앤드첨단소재 주식회사 | 버링홀을 포함하는 복합재 부품 |
CN110306167B (zh) * | 2019-06-06 | 2021-06-04 | 沈阳航空航天大学 | 一种原位生长cnt层增强轻质合金胶接界面强度的方法 |
KR102233567B1 (ko) * | 2019-11-15 | 2021-03-29 | 재단법인 한국탄소융합기술원 | 고밀도 탄소섬유 복합재 제조방법 |
US20220410497A1 (en) * | 2021-06-23 | 2022-12-29 | Arris Composites Inc. | Modular thermoplastic composite structures |
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