JPH05508128A - Unidirectionally aligned carbon fiber/phenolic resin prepreg material and its manufacturing method - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

[Detailed description of the invention] Unidirectionally aligned carbon fiber/phenolic resin prepreg material and its manufacturing method (part of the invention) field) The present invention relates to a laminated material and each layer constituting the laminated material, and is particularly applicable to the interior of an aircraft. Regarding the laminated materials used.

In the development of aluminum alloys used for applications such as aircraft interiors, strength, rigidity, and impact resistance are being developed. It is desirable to use high quality materials. Such materials are typically used in aircraft interiors, cargo spaces, etc. It is a substantially flat, multi-layered material in which a synthetic resin is inserted. ideal In addition to providing optimal strength-weight characteristics, it is easy to cut and assemble. It is made of laminated material and is easy to repair. Laminated materials (laminated assembly assemblies) are often A) consists of a single-layer or multi-layer molding material impregnated with synthetic resin. These resin-containing Dipped materials are often known by the term "prepreg." In this specification The term “prepreg” as used in the field refers to means an intermediate product in the manufacturing process.

The invention disclosed herein includes a resin-impregnated material or prepreg, and a resin-impregnated material or prepreg, and The present invention provides a multi-layered laminate material and a method for manufacturing the laminate material. Preferred specific example of multilayer laminate material has superior strength, stiffness and impact resistance compared to currently known materials of the same type. It is characterized by points.

(Background of the invention) Until now, the aim was to maximize strength, stiffness and impact resistance without adding additional loads. To this end, many forms of materials and combinations thereof have been developed. Typically, multilayer Repregs consist of a substantially planar core material with additional structures on one or both sides. Other materials are overlaid to provide structural strength and cohesion between the layers. It takes A cross-section of the material shows an inner core and other layers coated on one or both sides.

In this field: multi-layer prepreg and laminate materials are used as individual layers and certain materials 4-It is known that. For example, glass woven fabric, glass fiber, carbon fiber, etc. are known and their general characteristics are familiar to those skilled in the art.

In most cases, D prepreg laminates contain layers containing some type of glass fiber or carbon fiber. Its characteristic is that it has the following. The properties of laminates and their manufacturing methods vary widely. It can be turned into something. For example, regular glass fiber materials contain very many short fibers. The composition is composed of a sheet in which the resin is arranged in an orderly manner and a resin is added thereto, and the resulting composition is can be molded into the following shapes. Alternatively, each fiber can be woven into cloth form. , this offers certain advantages in strength and is also easy to handle and manufacture. .

Carbon fiber is also known for its use and is currently being woven into prepreg. They are used in a single direction or arranged in a single direction. Unidirectional carbon fiber is not woven so that each fiber runs up and down at right angles to each other. , rather, the fibers all run parallel to each other. In addition, carbon fiber is a spool. It is sold commercially in rolled or cylindrical shapes.

Prepreg is characterized by the use of synthetic resin, which promotes mutual retention of each layer. It also exhibits the ability to provide structural strength and rigidity. In recent years, phenolic resin has been Although it is widely used for legs, prepregs based on this Greasy and brittle coats do not bond well to the materials used as each layer, making them ideal properties. It shows only a slight lack of. Regarding bonding strength and brittleness, epoxy resin It exhibits superior performance over nord resins and also offers manufacturing advantages. because, Epoxy resins can be used without the dilution with solvents required with phenolic resins. This is because it can be used. In addition, epoxy resin prepregs are superior in terms of weight and strength. Because of the benefits it offers, it is widely used and as a result, phenolic resin-based preppers Reg was forced to phase out production. The type of resin used is used Depends on fiber type. For example, when using a solvent-containing resin, Fibers are preferred. Because solvent-containing resin solution systems are This is because it does not exist in terms of use. So for now, the unidirectional array The use of wk fibers is limited to solvent-free epoxy resin applications.

Unfortunately, prepregs used in aircraft interiors are sometimes or often On the other hand, it comes into contact with flames and high temperatures. In such cases, the epoxy resin It is known that there is a risk of ignition and combustion, and that toxic gases are generated under high temperature conditions. This epoxy When the dangers of plastic resins were discovered, the US Federal Aviation Administration recommended their regulation; , epoxy resins are being phased out despite their well-known benefits. I was absorbed in it. Phenolic resins, on the other hand, have inherent disadvantages associated with solvent-based manufacturing methods. Despite this, it has once again come into wide use. At this point, the braided fibers fibers has become a more industrially standard method than unidirectionally aligned fibers. because , because knitted fibers are easier to handle when using solvent-containing resin solutions. Ru. For this reason, in the methods currently used, almost all woven fabrics made by knitting fibers are used as fabrics. Prepreg is produced by impregnating it with phenolic resin/solvent/solution and drying it. This is the current situation.

(Summary of the invention) According to the present invention, unidirectionally aligned carbon fibers are used with a phenolic resin solvent/solution. can be used. According to the manufacturing method disclosed herein, phenolic resin-impregnated ・Manufacturing sheets of unidirectionally aligned carbon fibers, which are ultimately formed by molding. It is used as a laminated material (laminated assembly). to test data According to the authors, laminates incorporating such prepregs have superior strength, stiffness and It has been proven that it has good properties in terms of smoke generation and combustion. It is.

As mentioned above, at the current state of the art, prepreg for aircraft interiors is almost entirely made of gas. It is made of a woven fabric made of lath fibers or carbon fibers, and this woven fabric is coated with a resin solution and then painted. - Par honeycomb is laminated on both sides of the core. as a function of permissible load and desired strength. In order to manufacture specific prepregs designed with Glass fiber or carbon fiber can be used. In addition, various qualities and types resins and various resin application methods can be used.

The amount of carbon fiber present in each type of prepreg can be expressed by rthin 1iJ. , this areal weight can be obtained by measuring the carbon weight (g) per meter of final prepreg. I can do it. Commercially available Amoco EXAS-33-500 epoxy resin base prepre The prepreg has a surface weight of 150 g/m''7, and the laminated material equipped with this prepreg has high impact resistance. It has a value of about 60 inches-bond.

Compared to this commercially available product, the embodiment of the present invention has an areal weight of 150 g/m' and 14 Shows impact resistance up to 0 inch-void. According to the embodiment of the present invention, the same as commercially available products. A surface weight as low as 120 g/m' is sufficient to obtain similar impact values.

Regarding the Brib I Nog total weight, Model L-525, 1583 Style Prep The leg (manufactured by J.D. Lincoln Innocopoli 4911) is Approximately 16 times the weight per unit area of preg, approximately 85 inches - impact force of bond can withstand

Manufactured by Fiberlite Incorporated or Matsukugniel-Daugra The prepreg used in SMD-80 has an impact resistance value of 90 inches-bond. However, it has more than twice the weight of the material of the present invention.

It is thus an object of the present invention to provide an improved prepreg material.

It is also an object of the invention to provide an improved multilayer laminate.

Furthermore, it is an object of the present invention to provide high strength and low The objective is to provide a multilayer material with a high weight.

It is a further object of the present invention to provide improved prepreg materials and improved multilayer laminate materials. The aim is to provide a new manufacturing method.

(Detailed explanation of the invention) The invention will now be described in more detail with reference to the accompanying drawings.

FIG. 1 is a perspective view of an embodiment of the invention, showing the layers of the final laminate separated from each other. L2 clarifies the relationship between each layer composed of the target prepreg.

Figure 2 shows the equipment used in the sorting production process of resin-impregnated unidirectionally aligned carbon fibers. FIG.

Figure 3 is a partial cross-sectional view showing each layer of the final laminate, with one possible orientation of each layer. shows.

The technical aspects of the invention are explained by describing each layer and the method of making each layer and the final product. Explain the idea and its specific examples.

FIG. 1 shows the inner core material, which is comprised of several low cost, light weight materials.

In an embodiment of the invention, aramid paper is conventionally preformed into a honeycomb shape and phenolized. A core l immersed in resin is used.

Another layer is adhesive film layer 2, which is often used in other commercially available prepregs. Trademark name: “Hondo Eight (product number L-310)” Khan Incoholatiad, Kalimoto Runi 7, E19MeV, product developed by the inventor used in the specific examples of the present invention]. Adhesive film M2 is phenol It contains a resin (composition unknown) to promote bonding of the inner core 1 to the outer layer.

A notebook of non-unidirectionally aligned carbon fiber 3.3' is manufactured by the novel method of the present invention, According to this new method, the fibers are arranged in a sort of uniform layer thickness and then immersed in a resin bath. do. The novel manufacturing method for such a resin outer layer fiber is disclosed in this specification for the first time by the present inventor. It is to be disclosed. However, dipping the fibers in synthetic resin is a known method; This can be done in various ways. Layers 3 and 3° are resin impregnated unidirectionally aligned carbon fibers The two layers are made by substantially the same process and each contain a respective carbon fiber. The fibers are arranged substantially perpendicular to each other so that they are oriented at 0 degrees or 90 degrees on the sheet. has been done. The 0 degree and 90 degree directions are preferred embodiments. However, other directions are also Depending on the strength, impact resistance, and weight restrictions required for each application, it can be made suitable. Wear. Layer 4 is a scrim glass cloth, which is attached to a layer of carbon fiber 3.3". Attach. Finally, for final prepreg/laminate applications, this laminated material is cured in a lamination press to fuse the layers together.

As mentioned above, the present invention relates to a continuous sheet of resin-impregnated unidirectionally aligned carbon fibers. Discloses a new manufacturing method. Figure 2 shows one preferred method, which For example, strands or “ribbons” of tray T-700 carbon fiber 12 may be It is drawn from Rule 11. The number and orientation of each spool 11 is for illustrative purposes only. Therefore, the actual number of spools 11 can be very large, or In addition, the arrangement can be made into a number of suitable arrangements. The number of spool +1 is spool I The width and thickness of the carbon fiber strand wound around I, and the suitable charcoal in the prepreg. It can be changed depending on the elementary weight. After taking it out from the spool 11 , the carbon edge #120 strand is passed through a guide or series of guides 13. Kaka The kite 13 arranges and collects the strands so that the strands have a desired width and width. They are arranged in such a direction as to form a seven-layered layer 14 with a wide and thick layer. Collect as above To increase the number of sheets of fiber @7, increase the number of carbon fiber spools. It's enough. The uniformity of the layer thickness is ensured by inserting the carbon fiber strands into a series of cylindrical bars (15). Pass the bar above and below the strand so that it slightly deflects the strand passage. It can be achieved with The two cylindrical bars 15 shown in FIG. One or more representative examples of the equipment required to produce continuous sheets of elementary fibers. It means something. At this stage, the carbon fiber strands are formed into a substantially uniform layer thickness. The sheet is formed in such a way that there are no depressions or holes on the sheet, which prevents immersion into the resin. The carbon fiber notes should be continuous and uniform after soaking.

In the present invention, pre-manufactured! The finger film layer can be used with any type/form of fibers Rather than passing it over a layer that is There is. Returning again to FIG. The viscosity of the resin is reduced by impregnating the fibers with the resin. In addition, the degree of impregnation of the resin into the fibers can be increased. Furthermore, the present invention The method can increase the bonding of the resin to the fibrous substrate. I mentioned fiber above. After arranging the carbon fibers, the resulting continuous sheet is then passed through a resin bath 16 to form carbon fibers. Coat with phenolic resin. The phenolic resin bath liquid 17 is a liquid resin dissolved in a solvent. including. In a preferred embodiment, the resin is the commercially available phenolic resin Chemubond 6010. be. The commercially available phenolic resin solution has a solid content of 60% phenolic resin. Included in the file. To blend resin bath liquid 17, add ethanol to resin bath liquid 1. The specific gravity of 7 is approximately 0.94 g/ml.

Continuing with Figure 2, the carbon fiber sort exits the bath and the resulting single strand A resin-impregnated continuous notebook of oriented carbon fibers is drawn to the underside of edge 18. In addition, Edge 18 removes excess resin from the notebook. Therefore, unidirectionally aligned carbon fiber 19 Place the continuous sort on a roll of silicone coated paper 20 and place it in the oven 21 for 6 minutes. Pass at indoor atmospheric temperature of 210±10°F. The resulting resin-impregnated unidirectionally aligned carbon fibers The sheet 22 of phenolic resin is incorporated into the final product. Contains about 36-44% hard cedar.

After the production of each layer is completed, prepreg, which is an intermediate product, is assembled. single The first layer of oriented carbon fibers consists of a series of resin-impregnated carbon fiber sheets with a textured backing paper. can be manufactured into desired shapes and dimensions. Additional resin-impregnated carbon fiber Apply the layer to the first layer. Note that using a treated backing paper allows you to apply an additional layer. This allows the carbon fibers in each layer to oppose and contact each other, and also allows the carbon fibers in each layer to The treated backing paper applied during manufacturing is removed to apply layers or different components to the final laminate. You can also

In a preferred embodiment, the second layer of unidirectionally aligned carbon fibers is substantially perpendicular to the first layer. is placed on the first layer at an angle of . These two layers are combined across the layer plane A metal roller is applied to pine surge, which forms a layer of smooth surface. to promote bonding between layers. Hereinafter, this structure will be described as It is called "plain fiber prepreg". Peel off the treated backing paper from one side of the structure. backing paper Obtained by applying No. 108 scrim glass cloth to the side from which the This covers the entire surface of the prepreg, which forms the outer surface of the final product. This layer is It facilitates the handling of the obtained product, prevents wear and tear of the product, and protects the product from wear. When cut to suit the purpose of use, it is possible to prevent wear of other underlay layers. can.

In one preferred embodiment, two fibrous layers 22 and one scrim glass cloth 4 ( (The dimensions and manufacturing method are the same as above) are separately manufactured. Next, the adhesive The film layer 2 is attached to both sides of the honeycomb core material I of the desired shape. Finally, the rest Peel off the backing paper from the carbon fiber layer and scrim glass cloth layer, and The carbon fiber layer is placed in direct contact with the adhesive film layer by placing the layer closest to the core material. let Therefore, in this embodiment of the invention the outer layer between the final laminates is glass. It is made up of crosses.

After all the layers are combined, place the final laminate into the lamination press and press for about 10 minutes to about 2 minutes. time, temperature of about 260 to 350°F and pressure of 25 to 200, preferably about 50 Cure at psi.

Typically, the resulting laminate will be approximately 10 to 12 mm thick, subject to allowable weight and space requirements. Its thickness can be varied depending on the desired strength.

Another preferred embodiment includes a unidirectionally aligned carbon fiber layer, an adhesive film layer and a screen. Mugras cloth layers are bonded without internal cores. 0/90 degree unidirectional charcoal A plain fiber Bripreg is produced as described above. Then apply a layer of scrim glass cloth. On one side, an adhesive film layer is attached on the other side. The obtained laminated material is laminated. Place it in a plastic container and hold it at about 125 to +75°F at about 5 psi for about IO minutes to 2 hours. Ru. This process may be carried out under vacuum, but the quality of the desired prepreg depends on the vacuum It appears to be unaffected by conditions. Therefore, in this specific example, the prepreg layer is In order to bond without using an internal core material, it is an essential constituent material of such prepregs. Use a commercially available product that is not bound to a specific core material.

As will be apparent to those skilled in the art, the invention disclosed herein and its embodiments may be modified in various ways. Variations and improvements can be made. Accordingly, the present invention relates to the specific embodiments disclosed. It should not be limited to examples only.

abstract The present invention discloses a laminate material often used as a decorative material for aircraft interiors, or In addition, the phenol that ultimately constitutes all the layers of the laminated material and is formed into prepreg. Discloses the use of unidirectionally aligned carbon fibers (14) on the resin upper half. Furthermore, the present invention discloses a novel method for making such prepregs and products from the method. formation The final laminate product exhibits excellent strength and impact resistance, as well as smoke and It exhibits favorable characteristics regarding fuel consumption and combustion.

international search report

Claims (19)

[Claims] 1. A material consisting of unidirectionally aligned carbon fibers impregnated with a melt-based synthetic resin. 2. The material according to claim 1, wherein the synthetic resin is a phenolic resin. 3. Synthetic resin-impregnated, unidirectionally aligned carbon arranged in a substantially 0/90 degree angle configuration A material consisting of multiple layers of fibers. 4. 4. The material according to claim 3, wherein the synthetic resin is a phenolic resin. 5. Double-sided flat core material with adhesive film layer, substantially 0/90 degree angle shape Synthetic resin-impregnated, unidirectionally aligned carbon fiber and scrim glass black A multilayer material consisting of 6. The core material is a core material preformed into a honeycomb structure and impregnated with phenolic resin. The material according to claim 5, which is mid paper. 7. 6. A material according to claim 5, wherein the adhesive film layer is in contact with the heartwood. 8. the material comprises a core that is flat on both sides and an adhesive film layer on one side of the core; The carbon fibers form a layer fixed to one side of the core by the adhesive film layer, or A scrim glass cloth is placed on each carbon fiber layer as the outer layer of the material. The material according to claim 5, which is rim grass cloth. 9. Claim 5, wherein the unidirectionally aligned carbon fibers are impregnated with a phenolic resin. material. 10. The adhesive film layer is made of soluble nylon copolymer and phenolic resin. The material according to claim 5. 11. Internal honeycomb aramid paper core, adhesive filaments bonded to both sides of the internal core. film layer, attached to said adhesive film layer, in substantially 0/90 degree angular configuration. A layer of unidirectionally aligned carbon fiber impregnated with a phenolic resin and a strip forming the outer surface. A multilayer material characterized by consisting of a crimgrass cloth layer. 12. Unidirectionally aligned carbon fibers are passed through a synthetic resin bath dissolved in an alcohol solvent. and impregnated with the synthetic resin. A manufacturing method for materials characterized by: 13. 13. The method according to claim 12, wherein the synthetic resin is a phenolic resin. 14. The resulting sheet of resin-impregnated carbon fiber is passed through an open tube and cured. The manufacturing method according to item 12. 15. The unidirectionally aligned carbon fibers are passed through a bath of synthetic resin dissolved in an alcohol solvent. Impregnated with the synthetic resin, the resulting sheet is passed through an open tube and cured to substantially multiple synthetic resin-impregnated, unidirectionally aligned carbon fiber sheets arranged perpendicularly to each other. By compressing, a multilayer sheet of unidirectionally aligned carbon fibers with a 0/90 degree angle configuration is created. form a A sheet of glass cloth is attached to one side of unidirectionally aligned carbon fibers in a 0/90 degree angle configuration. Attachment, Adhesive film layers are attached to both sides of the inner core material, carbon fiber layer and glass cloth the glass cloth layer, each attached to the inner core and one side of the adhesive film layer. as the outermost layer, and the resulting multilayer material is pressed in a press at a temperature of about 260°F for about 2 It is characterized by laminating and curing for about 10 minutes at a temperature of about 350°F. The manufacturing method of the material. 16. 16. The method according to claim 15, wherein the synthetic resin is a phenolic resin. 17. The unidirectionally aligned carbon fibers are passed through a synthetic resin bath dissolved in an alcohol solvent. impregnated with synthetic resin and then placed the resulting sheet in an oven at a temperature of about 210±1 Strain to dry at 0°F, A system of multiple synthetic resin-impregnated, unidirectionally aligned carbon fibers arranged substantially perpendicular to each other. By mutually compressing the sheets, unidirectionally aligned carbon fibers with a 0/90 degree angle configuration are produced. forming a multilayer sheet of fibers, A sheet of glass cloth is attached to one side of unidirectionally aligned carbon fibers in a 0/90 degree angle configuration. Attachment, The adhesive film layer is placed at a 0/90 degree angle with no scrim glass cloth covered. The unidirectionally aligned carbon fibers are attached to the surface of the unidirectionally aligned carbon fibers, and the combined layers are deposited in a lamination press for approximately 5 Compress at about 125-175°F at psi for about 10 minutes to about 2 hours. A manufacturing method for materials characterized by: 18. 18. The method according to claim 17, wherein the synthetic resin is a phenolic resin. 19. Claim No. 1, in which the combined layers are compressed together under vacuum conditions in a lamination press. The manufacturing method described in item 17.