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JP3672684B2 - Continuous rod-shaped molded product intermediate, method for producing the same, molded product and molded method thereof - Google Patents

Continuous rod-shaped molded product intermediate, method for producing the same, molded product and molded method thereof Download PDF

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JP3672684B2
JP3672684B2 JP29805196A JP29805196A JP3672684B2 JP 3672684 B2 JP3672684 B2 JP 3672684B2 JP 29805196 A JP29805196 A JP 29805196A JP 29805196 A JP29805196 A JP 29805196A JP 3672684 B2 JP3672684 B2 JP 3672684B2
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continuous rod
molded product
matrix resin
reinforcing
reinforcing fiber
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JPH10119139A (en
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康久 永田
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Teijin Ltd
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Toho Tenax Co Ltd
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Description

【0001】
【産業上の利用分野】
本発明のロッド状成形物中間体は、土木建築材料,輸送用機器,航空宇宙用材料,一般産業用途などに有用な優れた機械的強度と取扱性を持った繊維強化複合材料中間体及びその成形方法に関するものである。
【0002】
特に、本発明の中間体を用いると、中間体自身の自重により垂れ下がらない程度の硬さを持ち、且つ、外力により曲げることができる柔軟性があるため、コンクリ−トやプラスチックのようなマトリックス中に埋め込んだ後に硬化させることも可能で、比較的取り扱いが容易で補強用材料として有用である。また、中間体の状態でスプリングやコイル状といった複雑形状を与えた後に硬化させ、成形体とすることもでき、機械的強度に優れた複雑な形状の成形体及びその成形方法を与えるものである。
【0003】
【従来の技術】
近年、炭素繊維,芳香族ポリアミド繊維,ガラス繊維等を強化繊維として用いた複合材料は、その高い比強度,比剛性を利用して、ゴルフシャフト等のスポ−ツ・レジャ−用品,航空機等の構造材,自動車の部材,コンクリ−トの補強用等に幅広く用いられてきた。
【0004】
これらの複合材料は、強化繊維にマトリックス樹脂を含浸させた中間製品であるシ−ト状のプリプレグを所定の形状に切断し、特定形状の成形用の型にセットした後、オ−トクレ−ブ成形やホットプレス成形といった、加圧下で加熱する成形加工工程を経て高強度の成形体として用いられる場合が多い。シ−ト状のプリプレグに用いられるマトリックス樹脂としては、熱硬化性樹脂としてエポキシ樹脂,ビスマレイミド樹脂,不飽和ポリエステル樹脂,ポリイミド樹脂等が用いられ、また、最近ではポリエ−テルエ−テルケトンといった熱可塑性樹脂も用いられるようになってきており、何れの樹脂を用いた場合も、複合材料は、その優れた耐熱性、機械的特性、寸法安定性、耐薬品性、耐候性が特徴とされていた。
【0005】
【発明が解決しようとする課題】
プリプレグは、一般に繊維目付10〜1000g/m2 で繊維を一方向に均一に引き揃えるか、予め織物に加工したシ−トに熱硬化性樹脂を含浸させて作られたもので、シ−トの幅は50〜100cm程度で長手方向に連続したものが多い。あるいは強化繊維の単繊維を3000〜12000本集めて一本のストランドとしたものに、前記熱硬化性樹脂を含浸させて作ったストランドプリプレグと呼ばれるものもプリプレグの形態の一種として挙げられる。
【0006】
一般にプリプレグは、成形用中間体としてシ−ト状あるいはストランド状のものが殆どで、単繊維100000本以上で構成された、あるいは直径3mm以上の連続ロッド状のプリプレグも理論的には作製可能であるが、ロッドの直径が太くなると繊維に樹脂を複合させる際に均一に樹脂を含浸させることが難しくなる。また、溶媒に樹脂を溶かして繊維に含浸させた後の乾燥が不充分になる等の問題が多くあるため、直径の大きいロッド状のプリプレグは作られていなかった。
【0007】
一方で、連続ロッド状プリプレグは、一般産業用途で望まれていた。例えば、近年の大型構造物のコンクリ−ト等の補強用としての鉄筋は、比重が大きく軽量化が難しい他、サビやすい等の問題があるため、代替として繊維強化樹脂複合材料筋の出現が望まれ、比強度では鉄筋を凌駕する他、耐環境性に関しても高い性能を示すものであった。
【0008】
特開平6−264563号公報にはコンクリ−トの型枠内に炭素繊維糸条のプリプレグを張りめぐらし、通電加熱させて熱硬化性樹脂を硬化せしめた後、コンクリ−トを流して構造物を作る方法が明示されている。しかしながら、このような方法に用いる炭素繊維糸条のプリプレグは、直径が細く柔らかく自己支持性がなく、自重により垂れ下がるため、枠内の係止具に引っかけて緊張状態で配筋することが記載されている。
【0009】
このような方法では、単位体積当たりに仕込まれる炭素繊維糸条の本数や配置方法や位置が規制され設計が固定化されてしまう他、作業性も複雑で現場作業において簡便にできるものではなかった。
【0010】
特開平7−178728号公報には、コンクリート補強筋として強化繊維プリプレグを用いること、また、プリプレグの一例として、ストランドの外周に強化繊維を螺旋状に被覆し形成するプリプレグが明示されている。しかし、このプリプレグは、マトリックス樹脂に湿気硬化樹脂を用いているため、水分の浸透が困難なプリプレグ中心部で硬化しにくいという問題があった。
【0011】
その他の用途として、炭素繊維強化複合材料で作製されたスプリング状のような複雑形状の成形体の作製や家庭用の補修材として、簡便に扱える中間体の要望も多いが、従来の繊維強化複合材料の成形概念では、方法が複雑になり、コストアップになる傾向であった。
【0012】
【課題を解決するための手段】
即ち本発明は、連続ロッド状成形物中間体において、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維とからなり、かつ第2の強化繊維で第1の強化繊維束が結束さた連続ロッド状成形物中間体であって、連続ロッド状成形物中間体が20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないような充分な硬さを有し、且つマトリックス樹脂の硬化開始温度以下の温度で中間体の直径の少なくとも10倍の径のパイプに巻き付けることができる柔軟性も兼ね備えたことを特徴とする連続ロッド状成形物中間体である。
【0013】
また、その連続ロッド状成形物中間体の製造法は、未硬化の熱硬化性マトリックス樹脂を含浸した第1の強化繊維束の外周に第2の強化繊維を、巻き圧力1kg/mm2以上の巻き圧でスパイラル状に巻き付け、第1の強化繊維束を第2の強化繊維で結束することを特徴とする。
【0014】
連続ロッド状成形体の成形方法は、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維とからなり、かつ第2の強化繊維で第1の強化繊維束が結束さた連続ロッド状成形物中間体であって、連続ロッド状成形物中間体が20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないような充分な硬さを有し、且つマトリックス樹脂の硬化開始温度以下の温度で中間体の直径の少なくとも10倍の径のパイプに巻き付けることができる柔軟性も兼ね備えた連続ロッド状成形物中間体に通電し、炭素繊維の電気抵抗を利用して発熱させ、熱硬化性マトリックス樹脂成分を硬化させることを特徴とする。
【0015】
本発明の連続ロッド状成形物中間体は、自己支持性があり中間体自身の自重により垂れ下がらないような充分な硬さを持ち、且つ外力により曲げることができる可撓性も兼ね備えているため、コンクリ−トの補強用途あるいはスプリング状のような複雑形状の成形体の作製に効果的である。本発明の連続ロッド状成形物中間体は、自動車、航空機を含む輸送体に使用されるスプリング類などの成形体、家屋などの建築物の補強、端などの構造物の補強等の用途に好適である
【0016】
本発明の連続ロッド状成形中間体を図面によって説明する。図1は連続ロッド状成形中間体斜視図を示したものである。本発明の連続ロッド状成形物中間体は、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束1と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維2とからなり、かつ第2の強化繊維2で第1の強化繊維束1が結束されている。
【0017】
本発明の連続ロッド状中間体において、第1および第2の強化繊維の種類は、炭素繊維である。炭素繊維としては、アクリル系炭素繊維、ピッチ系炭素繊維等特に制限はなく、引張り強さ350Kgf/mm2,引張弾性率24ton/mm2のものが汎用として用いられている。引張弾性率24ton/mm2以上の高弾性率繊維も使用できる。複合材料の機械的特性を向上させた、引張り強さ400Kgf/mm2以上、弾性率30T/mm2レベルの、いわゆる中弾性高強度炭素繊維も用いることもできる。
【0018】
第1の強化繊維の形態は、単繊維を3000〜12000本集めて一本のストランドとしたものを、更に集めて、組紐,織物,撚糸,合糸あるいはこれらを組合わせた形態で使用することもできる。あるいは単繊維が12000本以上収束されたトウ状の連続糸を用いることもできる。または、強化繊維に熱硬化性樹脂を含浸させた連続状の一方向シート、織物、短繊維マット状のププレグ等を丸めてロッド状にしたもの、あるいはストランド状プリプレグを束ねたもの、あるいはこれらを組み合わせたものを用いることができる。外周に配された第2の強化繊維の種類は、第1の強化繊維と同一の繊維種の物を使用する
【0019】
第2の強化繊維の形態は、ストランド、シ−ト、織物、組紐、撚糸、合糸、あるいはこれらを組み合わせたものを用いることができる。熱硬化性樹脂を含浸させたテ−プ状のプリプレグを用いることもできる。第2の強化繊維としてストランドを用いたときは、ストランドに1〜10/mの撚りを付与してあると、中間体を一定方向に巻き付けるときに、単繊維相互のずれがなく中間体の形態を崩すことなく巻き付けることができる。よりがない繊維では機械巻きするときにこすれて繊維表面が損傷しやすくなるため好ましくない。第2の強化繊維は、第1の強化繊維の上から任意のピッチでもってスパイラル状に巻つけ、第1の強化繊維を結束している構成となる。
【0020】
巻き付け時の圧力は1Kg/cm2以上であることが必要である。1Kg/cm2を下回ると加熱による熱硬化性樹脂の硬化後の成形体に空孔部や微小ボイド等の欠陥が多く残り、成形体の機械的強度を低下させるので好ましくない。
【0021】
第1および第2の強化繊維に含浸させる熱硬化性マトリックス樹脂としての、熱硬化性樹脂組成物は、エポキシ樹脂,ビスマレイミド樹脂、不飽和ポリエステル樹脂、ポリイミド樹脂等特に制限されない。第1および第2の強化繊維層には、熱硬化性マトリックス樹脂成分を含有している
【0022】
連続ロッド状成形物中間体における樹脂組成物の含有率は30〜50体積%が適当である。樹脂が30%以下の場合は成形後、温度ムラが大きくなり、樹脂が50%以上の場合は通電加熱での温度ムラが大きくなるため好ましくない。
【0023】
また、熱硬化性樹脂に熱可塑性樹脂等を混合して用いても構わない。この場合、熱可塑性樹脂の量が多くなると中間体の柔軟性が失われる場合があるため、熱可塑性樹脂は全体の30体積%を越えないことが好ましい。
【0024】
本発明の連続ロッド状成形物中間体は、その芯部の第1の強化繊維と熱硬化性樹脂とを主成として構成された内層、該内層の外周に配された第2の強化繊維と熱硬化性樹脂とを主成分として構成され、第2の強化繊維によって結束されているため、中間体自身の自重により容易に垂れ下がることない、自己支持性を有する。しかも外力により曲げることができる、可撓性を有する。ここで、自己支持性とは、20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないことをいう。また、可撓性とは、マトリックス樹脂の硬化開始温度以下の温度で本発明の中間体の直径の少なくとも10倍の径のパイプに巻き付けることのできる特性を言う。この特性は、本発明の中間体をコンクリートの補強筋として使用するときの、ベンダー行程、配筋作業に重要な特性である。
【0025】
このような特性を中間体に付与するために、第1の強化繊維を第2の強化繊維で結束している。連続ロッド状成形物中間体の作製においてロッドの直径が3mm以上になると、通常のプリプレグ作製方法では樹脂の含浸や乾燥不足の問題があるため、本発明の方法で連続ロッド状成形物中間体を作製することが好ましい。
【0026】
本発明の連続ロッド状成形物中間体の製造方法について一例を示すと次の通りである。図2のように、第1の強化繊維束1を一定の速度で送りながら、第2の強化繊維束2を連続的に第一の強化繊維束の回りを回転させながら巻き付けていく。
【0027】
本発明の連続ロッド状成形物中間体を用いて成型物を得る方法について一例を示すと次の通りである。図3のように、芯金4にロッド状成形物中間体3を巻きつけて、加熱して、樹脂を硬化させた後、芯金を抜いて、成形物(スプリング)とする。
【0028】
連続ロッド状成形物中間体を加熱する手段として、炭素繊維の電気抵抗を利用して電流を流すことによって発熱させ、熱硬化性樹脂成分を硬化させて成形体を得る場合、通電させる上で中間体の全体に対する炭素繊維の含有率が30体積%以上、好ましくは50体積%以上であることが望まれる。硬化後のロッド状成形体の繊維体積含有率は、機械的性質を適正化する上で50〜70体積%の範囲内にあることが好ましい。
【0029】
これらの連続ロッド状成形物中間体は、外力により曲げることができる柔軟性があるためにボビンやクリ−ル等にコンパクトに巻き取れ、持ち運びが容易で現場に持ち込むこともできる。連続ロッド状成形物中間体は、所定の形状あるいは型に充填したり巻きつけた後、加熱して熱硬化性樹脂成分を硬化せしめることによって成形物とすることができる。
【0030】
連続ロッド状成形物中間体を円筒状の型にコイル状に巻つけ加熱することによって、スプリング等の特殊形状の成形体を作製することができる。加熱の温度は用いる熱硬化性樹脂成分の種類によって変わるが、一般には70〜300℃の範囲内である。
【0031】
本発明の連続ロッド状成形物中間体は、内層及び該内層を被覆する外側から構成され、巻きの圧力は1Kg/mm2以上であるため、プレス機やオ−トクレ−ブあるいはゴム型のような成形時に圧力が掛かるように工夫された治具等を使用しないでも、欠陥の少ない成形体を得ることができる。
【0032】
得られた成形体の中には、炭素繊維などの強化繊維を一方向に50体積%以上の高い割合で充填させることが可能で、長さ方向の引張り及び圧縮強度に優れた成形体とすることができる。
【0033】
強化繊維に電気伝導性のある繊維を用いた場合、通電加熱によって中間体自身を発熱させ熱硬化性樹脂成分を硬化せしめることができ、簡便な方法で硬化の作業が完了できる。構造物の上から巻つけた後に通電加熱によって硬化させることも可能で、簡便な方法で構造物の補強ができ有効である。電気伝導性の強化繊維としては、強度的な要因だけでなく、繊維自身が発熱させるのに適した抵抗値を持つ炭素繊維が良い。コンクリ−ト補強用として本発明の連続ロッド状成形物中間体を用いる場合、熱硬化性樹脂成分を硬化させない中間体の状態でコンクリ−トを流し込み、コンクリ−トが固まった後に通電加熱によって樹脂を硬化させ成形体にすることができる。
【0034】
この場合、クリ−ル等に巻かれた中間体を連続的に取り出しながら作業できるので、作業性には問題ない。この方法では、熱硬化性樹脂を硬化させる前にコンクリ−トに充填した後、通電加熱によって樹脂を硬化させるため、コンクリ−トとロッド状成形物との接着性に優れたコンクリ−ト/繊維強化複合材料を作製することができた。
【0035】
予想外の効果として、中間体表面の炭素繊維等の繊維切れによるケバや突起が硬化後にアンカ−効果となり補強効果を高めるものとなった。また、成形体中の繊維密度が高くボイド等の欠陥が少ないため、コンクリ−ト等のマトリックス中に、高い充填密度で連続ロッド状成形体を配置させることが可能となる。炭素繊維などの電気伝導性のある強化繊維を主成分とする連続ロッド状成形物中間体において、通電する方法は、一般にロッドの両端部に金属製の端子を取り付け、この端子より電気を流すことによって中間体が発熱し、熱硬化性樹脂成分を硬化させる。
【0036】
電源からの印加電圧は、硬化した熱硬化性樹脂が分解しない範囲の電圧を用いることが望まれる。電源は直流でも交流でも構わない。本発明の連続ロッド状成形物中間体及びその成形体は、コイル状などの複雑形状の強化繊維プラスチックを形成させる上で有効である他、コンクリ−ト等の構造物の強化や補強に有効である。
【0037】
特に、炭素繊維などの強化繊維をロッドの長さ方向に一方向に高い割合で引き揃え充填させることが可能となるため、長さ方向の引張り及び圧縮強度に優れた成形体とすることができ、有効である。
【0038】
[実施例]
以下、本発明を実施例1〜3によって更に詳細に説明するが、本発明はこれらの実施例によって制限されるものではない。
[実施例1]
連続した東邦レ−ヨン社製ベスファイト HTA−12K(繊維重さ:0.8g/m,引張り強さ:350Kg/mm2,引張り弾性率:24トン/mm2 )一本にエポキシ樹脂組成物を38重量%(炭素繊維含有率62重量%)含浸させてストランド状のプリプレグを作製した。エポキシ樹脂組成物は、フェノ−ルノボラック型エポキシ樹脂とビスフェノ−ルA型エポキシ樹脂を主成分とし、硬化剤にジシアンジアミドを主剤とするものである。このストランド状のプリプレグを30本一方向に引き揃えて並べて内層とした。次に、この内層の上からベスファイトHTA−12Kのストランド1本で2mmの巻きピッチで内層の上から巻き圧力2kg/cm2 で強く巻きつけ、直径が約5mmの連続ロッド状成形物中間体を作製した。
【0039】
中間体全体に対する炭素繊維含有量は67重量%であった。この中間体を直径10cmの絶縁された50cm長さの円筒の型に巻きピッチ2cmでスパイラル状に10回巻きつけ、型と共にオ−トクレ−ブ内に吊してセットした。オ−トクレ−ブにて成形圧力3Kg/cm2 ,成形温度130℃,成形時間1時間の条件で中間体のエポキシ樹脂組成物を硬化させ、得られた成形体を円筒より取りはずし端部を切断しスプリング状の成形体とした。このスプリングは、1トンの引張り荷重に耐えるものであった。
【0040】
[実施例2]
連続した東邦レ−ヨン社製ベスファイト HTA−12K(繊維重さ:0.8g/m,引張り強さ:350Kg/mm2 ,引張り弾性率:24トン/mm2 )を30本一方向に引き揃え、エポキシ樹脂組成物を含浸させて繊維目付300g/m2 で樹脂含有率38重量%のシ−ト状の一方向プリプレグを作製した。エポキシ樹脂組成物は、フェノ−ルノボラック型エポキシ樹脂とビスフェノ−ルA型エポキシ樹脂を主成分とし、硬化剤にジシアンジアミドを主剤とするものである。このプリプレグを繊維の方向が一方向になるように束ね合わせて内層とした。次に、この内層の上から1m当たり40回の撚りをかけたベスファイトHTA−12Kのストランド1本で2mmの巻きピッチで内層の上から巻き圧力2kg/cm2 で強く巻きつけ、直径が約5mmの連続ロッド状成形物中間体を作製した。実施例1と同様に、10cmの絶縁された50cm長さの円筒の型に巻きピッチ2cmでスパイラル状に10回巻きつけた。
【0041】
中間体全体対する炭素繊維含有量は67重量%であった。ロッド状成形物中間体の両端に金属製金具を電極端子として取り付け固定した。電極端子より中間体に20Vの電流を流したところ、中間体が発熱し130℃に達し、中間体のエポキシ樹脂組成物が硬化反応を開始した。通電した状態を60分間続け、硬化反応を完了させた後、得られた成形体を円筒より取りはずし端部を切断しスプリング状の成形体とした。このスプリングは、実施例1と同様に1トンの引張り荷重に耐えるものであった。
【0042】
[実施例3]
実施例1と同様に連続ロッド状成形物中間体を作製した。この中間体を長さ300mmに切断し、両端に金属製金具を電極端子として取り付けた後、両端に張力をかけて固定した。電極端子より中間体に20Vの電流を流したところ、中間体が発熱し130℃に達し、中間体のエポキシ樹脂組成物が硬化反応を開始した。通電した状態を60分間続け、硬化反応を完了させた後、得られた成形体は直径5mmの丸棒状の成形体であった。この丸棒の引張り試験を行ったところ、荷重3.5トンで破壊した。
【0043】
[比較例1]
実施例1と同様にエポキシ樹脂組成物を38重量%含浸させたストランド状のプリプレグを作製した。このストランド状のプリプレグ30本を撚り合わせて引き揃え、見かけの直径8mmのロ−プ状の成形物中間体を作製した。中間体全体に対する炭素繊維含有量は62重量%であった。実施例3と同様に、中間体を長さ300mmに切断し、両端に金属製金具を電極端子として取り付け通電して樹脂を硬化させた。得られた成形体はロ−プ状ではあるが、部分的にストランド間が剥離して一体化していなかった。この成形体の引張り試験を行ったところ、荷重1.5トンより破壊が始まった。
【0044】
[実施例4]
実施例1と同様に連続ロッド状成形物中間体を作製した。この中間体を300mmの長さで4本準備し、断面が25mm角の型枠中に中間体同志の間隔が5mmになるように両端に張力をかけて固定し、両端に金属製金具を電極端子として取り付けた。この型枠中に無補強の圧縮強度が350kgf/cm2 となるコンクリ−トを流し込み、室温で養生させながらコンクリ−トを硬化させた。硬化後、中間体に張力をかけたまま、電極端子より中間体に20Vの電流を流し中間体を発熱させ、中間体のエポキシ樹脂組成物を硬化させ、コンクリ−ト中に炭素繊維のロッド状成形物を作製させた。室温まで冷却の後、この補強コンクリ−ト角棒より長さ100mmの試験片を切り出し圧縮試験を行ったところ、最大荷重8.0トンで破壊した。
【0045】
【発明の効果】
以上述べたように、本発明は、自重により垂れ下がらない、硬さを有し、しかも、外力により曲げることができる柔軟性をも兼ね備えた連続ロッド状成形物中間体であり、直径の太い当該ロッド状成形物中間体を提供することができた。このため、コンクリートやプラスチックに埋め込んだ後に硬化させることができ、取扱い性に優れていた。
【0046】
また、スプリングやコイル状のような複雑形状の成形にも適し、機械的強度の優れた成形体を提供できるものであった。。
【図面の簡単な説明】
【図1】 本発明の連続ロッド状中間体の概略図である。
【図2】 本発明の連続ロッド状中間体製造装置の概略図である。
【図3】 本発明の連続ロッド状中間体を芯金に巻きつけた様子を示した図である。
【符号の説明】
1 第1の強化繊維束
2 第2の強化繊維束
3 ロッド状成形物中間体
4 芯金
[0001]
[Industrial application fields]
The rod-shaped molded product intermediate of the present invention is a fiber-reinforced composite material intermediate having excellent mechanical strength and handleability useful for civil engineering and building materials, transportation equipment, aerospace materials, general industrial applications, and the like. The present invention relates to a molding method.
[0002]
In particular, when the intermediate of the present invention is used, it has a hardness that does not sag due to its own weight and can be bent by an external force. It can be cured after being embedded therein, and is relatively easy to handle and useful as a reinforcing material. In addition, a complex shape such as a spring or a coil shape is given in an intermediate state and then cured to obtain a molded body, which provides a molded body having a complicated shape with excellent mechanical strength and a molding method thereof. .
[0003]
[Prior art]
In recent years, composite materials using carbon fibers, aromatic polyamide fibers, glass fibers, and the like as reinforcing fibers have been used for sports and leisure products such as golf shafts, aircraft, etc., using their high specific strength and specific rigidity. It has been widely used for structural materials, automotive parts, concrete reinforcement and the like.
[0004]
These composite materials are obtained by cutting a sheet-shaped prepreg, which is an intermediate product obtained by impregnating a reinforcing fiber with a matrix resin, into a predetermined shape, setting it into a molding die having a specific shape, and then autoclave. It is often used as a high-strength molded body through a molding process such as molding or hot press molding that is heated under pressure. As the matrix resin used in the sheet-like prepreg, epoxy resin, bismaleimide resin, unsaturated polyester resin, polyimide resin, etc. are used as thermosetting resins, and recently, thermoplastics such as polyether ether ketone are used. Resins are also being used, and in any case, composite materials were characterized by their excellent heat resistance, mechanical properties, dimensional stability, chemical resistance, and weather resistance. .
[0005]
[Problems to be solved by the invention]
A prepreg is generally made by drawing fibers uniformly in one direction at a fiber basis weight of 10 to 1000 g / m 2 or by impregnating a sheet that has been processed into a woven fabric with a thermosetting resin. The width of is often about 50 to 100 cm and is continuous in the longitudinal direction. Alternatively, what is called a strand prepreg made by impregnating 3000 to 12000 reinforcing fiber single fibers into one strand and impregnating the thermosetting resin can also be mentioned as one type of prepreg.
[0006]
In general, prepregs are mostly sheet-like or strand-like intermediates for molding, and it is theoretically possible to produce prepregs composed of 100,000 or more single fibers, or a continuous rod-like prepreg with a diameter of 3 mm or more. However, when the diameter of the rod is increased, it is difficult to uniformly impregnate the resin when the resin is combined with the fiber. Moreover, since there are many problems such as insufficient drying after the resin is dissolved in the solvent and impregnated into the fiber, a rod-shaped prepreg having a large diameter has not been made.
[0007]
On the other hand, a continuous rod-shaped prepreg has been desired for general industrial use. For example, reinforcing bars such as concrete for large-scale structures in recent years have problems such as high specific gravity, difficulty in weight reduction, and rusting. Rarely, the specific strength surpassed that of reinforcing steel, and also showed high performance in terms of environmental resistance.
[0008]
In JP-A-6-264563, a prepreg of carbon fiber yarns is stretched in a concrete form of a concrete, and the thermosetting resin is cured by energization and heating, and then the concrete is poured into the structure. The method of making is specified. However, the carbon fiber yarn prepreg used in such a method is thin and soft, has no self-supporting property, and hangs down due to its own weight. ing.
[0009]
In such a method, the number of carbon fiber yarns to be charged per unit volume, the arrangement method and the position are regulated and the design is fixed, and the workability is also complicated and cannot be easily performed in the field work. .
[0010]
Japanese Patent Application Laid-Open No. 7-178728 discloses the use of a reinforcing fiber prepreg as a concrete reinforcing bar and, as an example of the prepreg, a prepreg in which reinforcing fibers are spirally coated on the outer periphery of a strand. However, since this prepreg uses a moisture-curing resin as the matrix resin, there is a problem that it is difficult to cure at the central portion of the prepreg where moisture penetration is difficult.
[0011]
As other applications, there are many demands for intermediates that can be handled easily as preparations of complex shaped bodies such as springs made of carbon fiber reinforced composite materials and repair materials for home use, but conventional fiber reinforced composites The material molding concept tends to be complicated and costly.
[0012]
[Means for Solving the Problems]
That is, the present invention, in the continuous rod-shaped molded product intermediate, the first reinforcing fiber bundle consisting of long fiber bundles containing carbon fibers impregnated with an uncured thermosetting matrix resin component, and the outer periphery of the bundle is arranged , It consists of a second reinforcing fibers consisting of long fiber bundles comprising carbon fibers impregnated with thermosetting matrix resin component of the uncured, and the second first continuous rod reinforcing fiber bundle is bundled in the reinforcing fibers When the continuous rod-shaped intermediate body is upright at a length of 100 times the diameter of the intermediate body under the condition of 20 ° C., it is bent to an angle of 90 ° or more by itself. it has no such sufficient hardness, continuous, characterized in that also has flexibility and can be wound on the pipe at least 10 times the diameter of the diameter of the intermediate at a temperature of curing initiation temperature below the matrix resin In rod-shaped molding It is a body.
[0013]
Moreover, the manufacturing method of the intermediate | middle rod-shaped molded object intermediate | middle is as follows. The 2nd reinforcement fiber is wound on the outer periphery of the 1st reinforcement fiber bundle impregnated with the uncured thermosetting matrix resin, and the winding pressure is 1 kg / mm 2 or more. It is characterized by being wound in a spiral shape with a winding pressure and binding the first reinforcing fiber bundle with the second reinforcing fiber.
[0014]
The method of forming a continuous rod-shaped molded body includes a first reinforcing fiber bundle composed of a long fiber bundle containing carbon fibers impregnated with an uncured thermosetting matrix resin component , and an uncured heat disposed on the outer periphery thereof. curable matrix consists of a second reinforcing fibers consisting of long fiber bundles comprising carbon fibers impregnated with a resin component, and the second reinforcing fibers with the first reinforcing fiber bundle is bunched continuous rod-like molding intermediate A continuous rod-shaped molded product intermediate that does not bend to an angle of 90 ° or more by itself when the intermediate product is upright at a temperature of 20 ° C. with a length 100 times the diameter of the intermediate product. A continuous rod-shaped molded product having a high hardness and having a flexibility capable of being wound around a pipe having a diameter of at least 10 times the diameter of the intermediate at a temperature lower than the curing start temperature of the matrix resin. , Carbon fiber electrical resistance Heat is generated by utilizing, characterized in that curing the thermosetting matrix resin component.
[0015]
The continuous rod-shaped molded product intermediate of the present invention is self-supporting, has sufficient hardness so that it does not hang down due to its own weight, and also has flexibility that can be bent by external force. It is effective for the reinforcement of concrete or the production of a molded body having a complicated shape such as a spring shape. The continuous rod-shaped molded product intermediate of the present invention is suitable for applications such as molded products such as springs used in automobiles, transportation vehicles including aircraft, reinforcement of buildings such as houses, and reinforcement of structures such as edges. [0016]
The continuous rod-shaped forming intermediate of the present invention will be described with reference to the drawings. FIG. 1 is a perspective view of a continuous rod-shaped forming intermediate. The intermediate product of the continuous rod-shaped product of the present invention comprises a first reinforcing fiber bundle 1 composed of a long fiber bundle including carbon fibers impregnated with an uncured thermosetting matrix resin component , The second reinforcing fibers 2 are made of long fiber bundles containing carbon fibers impregnated with a cured thermosetting matrix resin component , and the first reinforcing fiber bundles 1 are bound by the second reinforcing fibers 2. .
[0017]
In a continuous rod-like intermediate body of the present invention, the first and second types of reinforcing fibers are carbon fibers. The carbon fibers are not particularly limited, such as acrylic carbon fibers and pitch-based carbon fibers, and those having a tensile strength of 350 kgf / mm 2 and a tensile elastic modulus of 24 ton / mm 2 are used for general purposes. High elastic modulus fibers having a tensile elastic modulus of 24 ton / mm 2 or more can also be used. A so-called medium-elastic high-strength carbon fiber having a tensile strength of 400 Kgf / mm 2 or more and an elastic modulus of 30 T / mm 2 that improves the mechanical properties of the composite material can also be used.
[0018]
As for the form of the first reinforcing fiber, 3000 to 12000 single fibers are collected to form one strand, and further collected and used in a form of braid, woven fabric, twisted yarn, combined yarn or a combination thereof. You can also. Alternatively, a tow-shaped continuous yarn in which 12,000 or more single fibers are converged can also be used. Or, unidirectional sheets impregnated with a thermosetting resin to the reinforcing fiber continuous shape, fabrics, those were the rod-shaped rolled staple fibers matted Prin prepreg or the like, or those bundled strand-like prepreg, or A combination of these can be used. The second type of reinforcing fibers arranged in an outer peripheral uses those of the first reinforcing fibers and the same fiber types.
[0019]
As the form of the second reinforcing fiber, a strand, a sheet, a woven fabric, a braid, a twisted yarn, a combined yarn, or a combination thereof can be used. A tape-shaped prepreg impregnated with a thermosetting resin can also be used. When a strand is used as the second reinforcing fiber, when the strand is given a twist of 1 to 10 / m, there is no deviation between the single fibers when the intermediate is wound in a certain direction. It can be wound without breaking. Lesser fibers are not preferred because they are rubbed when mechanically wound and the fiber surface tends to be damaged. The second reinforcing fiber has a configuration in which the first reinforcing fiber is bound in a spiral shape with an arbitrary pitch from above the first reinforcing fiber, and the first reinforcing fiber is bound.
[0020]
The pressure at the time of winding needs to be 1 kg / cm 2 or more. If it is less than 1 kg / cm 2 , many defects such as voids and microvoids remain in the molded product after curing of the thermosetting resin by heating, and the mechanical strength of the molded product is lowered, which is not preferable.
[0021]
The thermosetting resin composition as the thermosetting matrix resin to be impregnated into the first and second reinforcing fibers is not particularly limited, such as an epoxy resin, a bismaleimide resin, an unsaturated polyester resin, and a polyimide resin. The first and second reinforcing fiber layer, containing a thermosetting matrix resin component.
[0022]
The content of the resin composition in the continuous rod-shaped molded product intermediate is suitably 30 to 50% by volume. When the resin is 30% or less, the temperature unevenness is increased after molding, and when the resin is 50% or more, the temperature unevenness due to current heating increases, which is not preferable.
[0023]
Moreover, you may mix and use a thermoplastic resin etc. in a thermosetting resin. In this case, since the flexibility of the intermediate may be lost when the amount of the thermoplastic resin increases, it is preferable that the thermoplastic resin does not exceed 30% by volume.
[0024]
Continuous rod-like preform intermediates of the present invention, the second reinforcing fibers arranged a first reinforcing fibers and a thermosetting resin of the core portion inside layer configured as a principal component, the outer periphery of the inner layer And thermosetting resin as the main components, and is bound by the second reinforcing fiber, it has a self-supporting property that does not easily sag due to its own weight. In addition, it has flexibility that can be bent by an external force. Here, the self-supporting property means that when it stands upright at a length of 100 times the diameter of the intermediate body under the condition of 20 ° C., it does not bend to an angle of 90 degrees or more by itself. Further, the flexibility means a characteristic that can be wound around a pipe having a diameter at least 10 times the diameter of the intermediate of the present invention at a temperature not higher than the curing start temperature of the matrix resin. This characteristic is an important characteristic for bender process and bar arrangement work when the intermediate of the present invention is used as a reinforcing bar for concrete.
[0025]
In order to impart such characteristics to the intermediate, the first reinforcing fibers are bundled with the second reinforcing fibers. If the diameter of the rod is 3 mm or more in the production of the continuous rod-shaped molded product intermediate, there is a problem of resin impregnation and insufficient drying in the ordinary prepreg production method. It is preferable to produce it.
[0026]
An example of the method for producing the continuous rod-shaped molded product intermediate of the present invention is as follows. As shown in FIG. 2, the second reinforcing fiber bundle 2 is continuously wound around the first reinforcing fiber bundle while the first reinforcing fiber bundle 1 is fed at a constant speed.
[0027]
An example of a method for obtaining a molded product using the continuous rod-shaped molded product intermediate of the present invention is as follows. As shown in FIG. 3, the rod-shaped molded product intermediate 3 is wound around the metal core 4 and heated to cure the resin, and then the metal core is pulled out to form a molded product (spring).
[0028]
As a means to heat the continuous rod-shaped molded product, heat is generated by passing an electric current using the electric resistance of carbon fiber, and when a molded product is obtained by curing the thermosetting resin component, it is necessary to intermediate It is desired that the carbon fiber content relative to the whole body is 30% by volume or more, preferably 50% by volume or more. The fiber volume content of the rod-shaped molded body after curing is preferably in the range of 50 to 70% by volume in order to optimize the mechanical properties.
[0029]
Since these continuous rod-shaped intermediate products are flexible enough to be bent by an external force, they can be compactly wound around a bobbin, a creel or the like, and are easy to carry and can be brought into the field. The continuous rod-shaped molded product intermediate can be formed into a molded product by filling a predetermined shape or mold or winding it, and then heating to cure the thermosetting resin component.
[0030]
By winding the continuous rod-shaped molded product intermediate body around a cylindrical mold in a coil shape and heating it, a molded product having a special shape such as a spring can be produced. The heating temperature varies depending on the type of the thermosetting resin component used, but is generally in the range of 70 to 300 ° C.
[0031]
The intermediate product of the continuous rod-shaped product of the present invention is composed of an inner layer and an outer side covering the inner layer, and the winding pressure is 1 Kg / mm 2 or more, so that it is like a press machine, an autoclave or a rubber mold. Even without using a jig or the like devised so that pressure is applied during proper molding, a molded product with few defects can be obtained.
[0032]
The obtained molded body can be filled with reinforcing fibers such as carbon fibers at a high rate of 50% by volume or more in one direction, and is a molded body having excellent tensile and compressive strength in the length direction. be able to.
[0033]
When a fiber having electrical conductivity is used as the reinforcing fiber, the intermediate itself can be heated by electric heating to cure the thermosetting resin component, and the curing operation can be completed by a simple method. It is also possible to harden by energization heating after being wound from above the structure, and the structure can be reinforced by a simple method, which is effective. As the electrically conductive reinforcing fiber, not only a strength factor but also a carbon fiber having a resistance value suitable for heating the fiber itself is preferable. When using the continuous rod-shaped molded product intermediate of the present invention for reinforcing a concrete, the concrete is poured in the state of an intermediate that does not cure the thermosetting resin component, and after the concrete has hardened, the resin is heated by electric heating. Can be cured into a molded body.
[0034]
In this case, there is no problem in workability since the work can be performed while continuously taking out the intermediate body wound around a creel or the like. In this method, the concrete / fiber is excellent in adhesiveness between the concrete and the rod-shaped molded article because the resin is cured by energization heating after filling the concrete before curing the thermosetting resin. A reinforced composite material could be made.
[0035]
As unexpected effect, fluff and projections by Re fiber switching such as carbon fiber of intermediate surface anchor after curing - it was intended to enhance the effect with becomes reinforcing effect. Further, since the fiber density in the molded body is high and there are few defects such as voids, it is possible to arrange the continuous rod-shaped molded body with a high packing density in a matrix such as concrete. In a continuous rod-shaped molded product intermediate composed mainly of reinforcing fibers with electrical conductivity such as carbon fiber, the method of energizing is generally that metal terminals are attached to both ends of the rod, and electricity flows from these terminals. Causes the intermediate to generate heat and cures the thermosetting resin component.
[0036]
The applied voltage from the power source is desirably a voltage within a range where the cured thermosetting resin is not decomposed. The power source may be direct current or alternating current. The continuous rod-shaped molded product intermediate and the molded product of the present invention are effective for forming a reinforced fiber plastic having a complicated shape such as a coil shape, and also effective for reinforcing and reinforcing a structure such as a concrete. is there.
[0037]
In particular, reinforcing fibers such as carbon fibers can be aligned and filled at a high rate in one direction in the length direction of the rod, so that a molded body having excellent tensile and compressive strength in the length direction can be obtained. ,It is valid.
[0038]
[Example]
EXAMPLES Hereinafter, although this invention is demonstrated further in detail by Examples 1-3, this invention is not restrict | limited by these Examples.
[Example 1]
Epoxy resin composition in one continuous Besfight HTA-12K (fiber weight: 0.8 g / m, tensile strength: 350 Kg / mm 2 , tensile elastic modulus: 24 ton / mm 2 ) manufactured by Toho Rayon Co., Ltd. Was impregnated with 38% by weight (carbon fiber content: 62% by weight) to prepare a strand-shaped prepreg. The epoxy resin composition is mainly composed of a phenol novolac type epoxy resin and a bisphenol A type epoxy resin, and dicyandiamide as a curing agent. Thirty strand-shaped prepregs were aligned in one direction to form an inner layer. Next, a continuous rod-shaped molded product intermediate having a diameter of about 5 mm is wound from above the inner layer with one strand of Besfite HTA-12K at a winding pitch of 2 mm with a winding pressure of 2 kg / cm 2. Was made.
[0039]
The carbon fiber content relative to the entire intermediate was 67% by weight. This intermediate was wound around an insulated 50 cm long cylindrical mold having a diameter of 10 cm and spirally wound 10 times at a pitch of 2 cm, and was suspended in an autoclave together with the mold. The intermediate epoxy resin composition is cured with an autoclave under conditions of a molding pressure of 3 kg / cm 2 , a molding temperature of 130 ° C., and a molding time of 1 hour. The resulting molded body is removed from the cylinder and the end is cut off. A spring-shaped molded body was obtained. This spring was able to withstand a tensile load of 1 ton.
[0040]
[Example 2]
Thirty continuous Besfight HTA-12K (fiber weight: 0.8 g / m, tensile strength: 350 Kg / mm 2 , tensile elastic modulus: 24 ton / mm 2 ) manufactured by Toho Rayon Co., Ltd. are drawn in one direction. The sheet was then impregnated with an epoxy resin composition to prepare a sheet-like unidirectional prepreg having a fiber basis weight of 300 g / m @ 2 and a resin content of 38% by weight. The epoxy resin composition is mainly composed of a phenol novolac type epoxy resin and a bisphenol A type epoxy resin, and dicyandiamide as a curing agent. This prepreg was bundled so that the direction of the fibers was one direction to form an inner layer. Next, one strand of Besphite HTA-12K, twisted 40 times per meter from the top of this inner layer, was strongly wound at a winding pressure of 2 kg / cm 2 from above the inner layer at a winding pitch of 2 mm. A 5 mm continuous rod-shaped molded product intermediate was produced. As in Example 1, it was wound 10 times in a spiral shape at a winding pitch of 2 cm around a 10 cm insulated cylindrical cylinder of 50 cm length.
[0041]
The carbon fiber content relative to the whole intermediate was 67% by weight. Metal fittings were attached and fixed as electrode terminals to both ends of the rod-shaped molded product intermediate. When a current of 20 V was passed from the electrode terminal to the intermediate body, the intermediate body generated heat and reached 130 ° C., and the epoxy resin composition of the intermediate body started a curing reaction. The energized state was continued for 60 minutes to complete the curing reaction, and then the obtained molded body was removed from the cylinder and the end was cut to obtain a spring-shaped molded body. This spring was able to withstand a tensile load of 1 ton as in Example 1.
[0042]
[Example 3]
In the same manner as in Example 1, a continuous rod-shaped molded product intermediate was produced. This intermediate was cut to a length of 300 mm, and metal fittings were attached to both ends as electrode terminals, and then fixed by applying tension to both ends. When a current of 20 V was passed from the electrode terminal to the intermediate body, the intermediate body generated heat and reached 130 ° C., and the epoxy resin composition of the intermediate body started a curing reaction. After the energized state was continued for 60 minutes to complete the curing reaction, the obtained molded body was a round bar-shaped molded body having a diameter of 5 mm. When this round bar was subjected to a tensile test, it was broken at a load of 3.5 tons.
[0043]
[Comparative Example 1]
In the same manner as in Example 1, a strand-shaped prepreg impregnated with 38 wt% of the epoxy resin composition was produced. Thirty strand-shaped prepregs were twisted and aligned to produce a rope-shaped molded product intermediate having an apparent diameter of 8 mm. The carbon fiber content relative to the entire intermediate was 62% by weight. Similarly to Example 3, the intermediate body was cut to a length of 300 mm, and metal fittings were attached to both ends as electrode terminals, and the resin was cured by energization. Although the obtained molded body was in a loop shape, the strands were partially separated and were not integrated. When this molded body was subjected to a tensile test, fracture started from a load of 1.5 tons.
[0044]
[Example 4]
In the same manner as in Example 1, a continuous rod-shaped molded product intermediate was produced. Four of these intermediate bodies are prepared with a length of 300 mm, and are fixed by applying tension to both ends in a 25 mm square mold so that the distance between the intermediate bodies is 5 mm. Installed as a terminal. A concrete having an unreinforced compressive strength of 350 kgf / cm 2 was poured into the mold, and the concrete was cured while being cured at room temperature. After curing, with the tension applied to the intermediate body, a current of 20 V is passed from the electrode terminal to the intermediate body to heat the intermediate body, the intermediate epoxy resin composition is cured, and the carbon fiber rod-shaped in the concrete A molded product was produced. After cooling to room temperature, a test piece having a length of 100 mm was cut out from the reinforced concrete square bar and subjected to a compression test. The specimen was broken at a maximum load of 8.0 tons.
[0045]
【The invention's effect】
As described above, the present invention is a continuous rod-shaped molded product intermediate that does not hang down due to its own weight, has hardness, and also has flexibility that can be bent by an external force, and has a large diameter. A rod-shaped molded product intermediate could be provided. For this reason, it was hardened after embedding in concrete or plastic, and it was excellent in handleability.
[0046]
Further, it is suitable for molding a complicated shape such as a spring or a coil, and can provide a molded body having excellent mechanical strength. .
[Brief description of the drawings]
FIG. 1 is a schematic view of a continuous rod-like intermediate according to the present invention.
FIG. 2 is a schematic view of the continuous rod-shaped intermediate production apparatus of the present invention.
FIG. 3 is a view showing a state in which the continuous rod-shaped intermediate body of the present invention is wound around a cored bar.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 1st reinforcing fiber bundle 2 2nd reinforcing fiber bundle 3 Rod-shaped molded product intermediate body 4 Core metal

Claims (12)

連続ロッド状成形物中間体において、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維とからなり、かつ第2の強化繊維を、巻き圧力1kg/mm 2 以上の巻き圧でスパイラル状に巻き付けることにより第1の強化繊維束が結束さた連続ロッド状成形物中間体であって、連続ロッド状成形物中間体が20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないような充分な硬さを有し、且つマトリックス樹脂の硬化開始温度以下の温度で中間体の直径の少なくとも10倍の径のパイプに巻き付けることができる柔軟性も兼ね備えたことを特徴とする連続ロッド状成形物中間体。In a continuous rod-shaped molded product intermediate, a first reinforcing fiber bundle comprising a long fiber bundle containing carbon fibers impregnated with an uncured thermosetting matrix resin component , and an uncured thermosetting disposed on the outer periphery thereof A second reinforcing fiber composed of a long fiber bundle containing carbon fibers impregnated with a conductive matrix resin component , and the second reinforcing fiber is wound in a spiral shape with a winding pressure of 1 kg / mm 2 or more. A continuous rod-shaped molded product intermediate body in which the first reinforcing fiber bundles are bundled, and the continuous rod-shaped molded product intermediate body is erected at a length of 100 times the diameter of the intermediate body at 20 ° C. Sometimes it winds around a pipe with a diameter that is at least 10 times the diameter of the intermediate at a temperature that is sufficient to prevent it from bending to an angle of 90 degrees or more by itself and at a temperature not higher than the curing start temperature of the matrix resin. In Continuous rod-like preform intermediates, characterized in that flexibility combines that. 成形物中間体全体における熱硬化性マトリックス樹脂成分と強化繊維の合計に対する全強化繊維の含有率が、50体積%以上である請求項1記載の連続ロッド状成形物中間体。  The continuous rod-shaped molded product intermediate according to claim 1, wherein the content of all reinforcing fibers relative to the total of the thermosetting matrix resin component and the reinforcing fibers in the entire molded product intermediate is 50% by volume or more. 第1の強化繊維束が、その外周に配された第2の強化繊維でスパイラル状に巻きつけられて結束されていることを特徴とする請求項1乃至記載の連続ロッド状成形物中間体。The continuous rod-shaped molded product intermediate according to claim 1 or 2, wherein the first reinforcing fiber bundle is wound and bundled in a spiral shape with a second reinforcing fiber disposed on an outer periphery thereof. . 外周に配された第2の強化繊維が、組紐、織物、撚糸、合糸あるいはこれらを組合せたもので形成されていることを特徴とする請求項1乃至記載の連続ロッド状成形物中間体。The continuous rod-shaped molded product intermediate according to any one of claims 1 to 3 , wherein the second reinforcing fibers arranged on the outer periphery are formed of braid, woven fabric, twisted yarn, synthetic yarn, or a combination thereof. . 第2の強化繊維が、1〜10個/mの撚りを有する長繊維である請求項1乃至記載の連続ロッド状成形物中間体。Second reinforcing fibers, continuous rod-like preform intermediate of claims 1 to 4, wherein the long fiber having a twist of 1-10 / m. 第1の強化繊維が、炭素繊維を50体積%以上含む繊維束である請求項1乃至記載の連続ロッド状成形物中間体。First reinforcing fibers, continuous rod-like preform intermediate of claims 1 to 5, wherein a fiber bundle comprising carbon fibers 50% by volume or more. 端末部に通電用の電極を有する請求項1乃至記載の連続ロッド状成形物中間体。Continuous rod-like preform intermediate of claims 1 to 6, wherein having an electrode for energizing the terminal portion. ロッド径が3mm以上である請求項1乃至記載の連続ロッド状成形物中間体。Continuous rod-like preform intermediate of claims 1 to 7, wherein the rod diameter is 3mm or more. 未硬化の熱硬化性マトリックス樹脂を含浸した第1の強化繊維束の外周に第2の強化繊維を、巻き圧力1kg/mm2以上の巻き圧でスパイラル状に巻き付け、第1の強化繊維束を第2の強化繊維で結束することを特徴とする請求項1記載の連続ロッド状成形物中間体の製造法。A second reinforcing fiber is wound around the outer periphery of the first reinforcing fiber bundle impregnated with an uncured thermosetting matrix resin in a spiral shape with a winding pressure of 1 kg / mm 2 or more, and the first reinforcing fiber bundle is wound. The method for producing a continuous rod-shaped molded product intermediate according to claim 1, wherein the second reinforcing fibers are bound together. 未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維とからなり、かつ第2の強化繊維を、巻き圧力1kg/mm 2 以上の巻き圧でスパイラル状に巻き付けることにより第1の強化繊維束が結束さた連続ロッド状成形物中間体であって、連続ロッド状成形物中間体が20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないような充分な硬さを有し、且つマトリックス樹脂の硬化開始温度以下の温度で中間体の直径の少なくとも10倍の径のパイプに巻き付けることができる柔軟性も兼ね備えた連続ロッド状成形物中間体に通電し、炭素繊維の電気抵抗を利用して発熱させ、熱硬化性マトリックス樹脂成分を硬化させることを特徴とする連続ロッド状成形体の成形方法。A first reinforcing fiber bundles having a length fiber bundles comprising carbon fibers impregnated with thermosetting matrix resin component of the uncured, disposed on the outer periphery, the carbon fibers impregnated with thermosetting matrix resin component of the uncured long fiber bundle consists of a second reinforcing fiber made of, and of the second reinforcing fibers, first the reinforcing fiber bundle by wrapping the spirally wound pressure 1 kg / mm 2 or more wound pressure bundling including When the continuous rod-shaped molded product intermediate is made upright at a length of 100 times the diameter of the intermediate product under the condition of 20 ° C. , the continuous rod-shaped molded product intermediate is more than 90 degrees by itself. A continuous rod that has sufficient hardness so that it does not bend to an angle and also has the flexibility to be wound around a pipe having a diameter at least 10 times the diameter of the intermediate at a temperature not higher than the curing start temperature of the matrix resin. Condition Energized to form compound intermediate, to generate heat by utilizing the electrical resistance of the carbon fibers, the molding method of a continuous rod-shaped article, characterized in that curing the thermosetting matrix resin component. 未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維とからなり、かつ第2の強化繊維を、巻き圧力1kg/mm 2 以上の巻き圧でスパイラル状に巻き付ける ことにより第1の強化繊維束が結束さた連続ロッド状成形物中間体であって、連続ロッド状成形物中間体が20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないような充分な硬さを有し、且つマトリックス樹脂の硬化開始温度以下の温度で中間体の直径の少なくとも10倍の径のパイプに巻き付けることができる柔軟性も兼ね備えた連続ロッド状成形物中間体を、所望の形状に整形し、次いで熱硬化性マトリックス樹脂成分を硬化させることを特徴とする連続ロッド状成形体の成形方法。A first reinforcing fiber bundles having a length fiber bundles comprising carbon fibers impregnated with thermosetting matrix resin component of the uncured, disposed on the outer periphery, the carbon fibers impregnated with thermosetting matrix resin component of the uncured long fiber bundle consists of a second reinforcing fiber made of, and of the second reinforcing fibers, first the reinforcing fiber bundle by wrapping the spirally wound pressure 1 kg / mm 2 or more wound pressure bundling including When the continuous rod-shaped molded product intermediate is made upright at a length of 100 times the diameter of the intermediate product under the condition of 20 ° C. , the continuous rod-shaped molded product intermediate is more than 90 degrees by itself. A continuous rod that has sufficient hardness so that it does not bend to an angle and also has the flexibility to be wound around a pipe having a diameter at least 10 times the diameter of the intermediate at a temperature not higher than the curing start temperature of the matrix resin. Condition The form was intermediate, shaped into a desired shape, and then forming method of continuous rod-shaped article, characterized in that curing the thermosetting matrix resin component. 未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第1の強化繊維束と、その外周に配された、未硬化の熱硬化性マトリックス樹脂成分を含浸した炭素繊維を含む長繊維束からなる第2の強化繊維とからなり、かつ第2の強化繊維を、巻き圧力1kg/mm 2 以上の巻き圧でスパイラル状に巻き付けることにより第1の強化繊維束が結束さた連続ロッド状成形物中間体であって、連続ロッド状成形物中間体が20℃の条件化で中間体の直径の100倍の長さで直立させたときに、自体によって90度以上の角度に撓まないような充分な硬さを有し、且つマトリックス樹脂の硬化開始温度以下の温度で中間体の直径の少なくとも10倍の径のパイプに巻き付けることができる柔軟性も兼ね備えた連続ロッド状成形物中間体を所望の形状に整形し、次いで熱硬化性マトリックス樹脂成分を硬化させてなる連続ロッド状成形体。A first reinforcing fiber bundles having a length fiber bundles comprising carbon fibers impregnated with thermosetting matrix resin component of the uncured, disposed on the outer periphery, the carbon fibers impregnated with thermosetting matrix resin component of the uncured long fiber bundle consists of a second reinforcing fiber made of, and of the second reinforcing fibers, first the reinforcing fiber bundle by wrapping the spirally wound pressure 1 kg / mm 2 or more wound pressure bundling including When the continuous rod-shaped molded product intermediate is made upright at a length of 100 times the diameter of the intermediate product under the condition of 20 ° C. , the continuous rod-shaped molded product intermediate is more than 90 degrees by itself. A continuous rod that has sufficient hardness so that it does not bend to an angle and also has the flexibility to be wound around a pipe having a diameter at least 10 times the diameter of the intermediate at a temperature not higher than the curing start temperature of the matrix resin. Condition Form was intermediate was shaped into a desired shape, then a continuous rod-shaped molded body formed by curing the thermosetting matrix resin component.
JP29805196A 1996-10-22 1996-10-22 Continuous rod-shaped molded product intermediate, method for producing the same, molded product and molded method thereof Expired - Fee Related JP3672684B2 (en)

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