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Sandwich structure, molded object, and production processes therefor

A manufacturing method and structure technology, applied in the direction of chemical instruments and methods, lamination, layered products, etc., to achieve the effect of high rigidity, small warpage, and high strength

Active Publication Date: 2018-07-17
TORAY IND INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

[0011] However, the structure of Patent Document 3 has a structure in which the penetration portion of the molding material (A) is smaller than the width of the rib opening, and there is room for improvement in the fillability of the molding material B to the ribs in this structure.
In addition, since the surface layer is formed of discontinuous reinforcing fibers and thermoplastic resin, there is room for improvement in the rigidity and strength of the surface layer

Method used

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  • Sandwich structure, molded object, and production processes therefor
  • Sandwich structure, molded object, and production processes therefor
  • Sandwich structure, molded object, and production processes therefor

Examples

Experimental program
Comparison scheme
Effect test

Embodiment

[0125] Hereinafter, the manufacturing method of the sandwich structure and the molded body will be specifically described using examples, but the following examples do not limit the present invention.

[0126] [Measuring method of fiber mass content of molding materials]

[0127] The fiber mass content of the molding material composed of reinforcing fibers and resin was measured by the following method. A square plate of 100 mm×100 mm (each thickness) was cut out from the molding material, and its weight w0 (g) was measured. Next, the cut-out molding material was heated in air at 500° C. for 1 hour, and the weight w1 (g) of the remaining reinforcing fibers after burning off the resin component was measured. Using the following formula (1), the fiber mass content (mass %) was obtained. All determinations were performed with n=3 and the mean value was used.

[0128] Fiber mass content rate (mass%) = (weight w1 of reinforcing fiber / weight w0 of molding material) x 100...Form...

example 1

[0151] (Material example 1) PAN-based carbon fiber bundle

[0152] A continuous bundle of carbon fibers with a total of 12,000 filaments is obtained by spinning and sintering a polymer mainly composed of polyacrylonitrile. A sizing agent was applied to the carbon fiber continuous bundle by a dipping method, and dried in heated air at a temperature of 120° C. to obtain a PAN-based carbon fiber bundle. The characteristics of this PAN-based carbon fiber bundle are as follows.

[0153] Single fiber diameter: 7μm

[0154] Mass per unit length: 0.83g / m

[0155] Specific gravity: 1.8g / cm 3

[0156] Tensile strength: 4.0GPa

[0157] Tensile modulus of elasticity: 235GPa

[0158] Type of sizing agent: polyoxyethylene oleyl ether

[0159] Sizing agent adhesion amount: 2% by mass

[0160] (Material example 2) Epoxy resin

[0161] Epoxy resin (base resin: dicyandiamide / dichlorophenylmethyl urea curable epoxy resin)

[0162] (Material example 3) Unmodified polypropylene

[0163]...

example 13

[0183] (Material Example 13) Fabric carbon fiber reinforced sheet

[0184] After weaving the PAN-based carbon fiber bundle obtained in Material Example 1 into a sheet, two sheets of epoxy resin films obtained in Material Example 5 were laminated from both sides of the sheet-shaped carbon fiber bundle, and the resin was impregnated with heat and pressure. A woven carbon fiber reinforced sheet made of carbon fibers and epoxy resin with a length of 500 mm, a width of 500 mm, a thickness of 0.3 mm, and a fiber mass content of 55% by mass was prepared as molding material S-3.

[0185] (Material example 14) SMC sheet

[0186] A release sheet (Teflon (registered trademark), 1 mm in thickness) was placed on a metal tool plate, and the epoxy resin film obtained in Material Example 5 was further placed thereon. On this epoxy resin film, the chopped carbon fiber bundles of Insert Material Example 7 were scattered randomly, and it was confirmed visually that the chopped carbon fiber bund...

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Abstract

A sandwich structure which is configured of skin layers each comprising at least one layer selected from among a metal layer, a fiber-reinforced resin layer (X) that comprises continuous fibers and amatrix resin (A), and a fiber-reinforced resin layer (Y) that comprises discontinuous fibers and a heat-curable matrix resin (B) and of a core layer comprising a flowable core layer that comprises discontinuous fibers and a matrix resin (C), wherein the skin layers are constituted of a material which has a flexural modulus higher than that of the core layer, and a through part has been formed in aregion that lies in at least some of the skin layers. In the sandwich structure, an upright part which projects outward from the skin layer(s) and which has high strength and a complicated shape suchas a rib is obtained by an easy method. The sandwich structure is lightweight, has high strength and high rigidity, and warps little. A molded object and processes for producing the sandwich structure and the molded object are also provided.

Description

technical field [0001] The present invention relates to a sandwich structure and molded body, and their manufacturing method. The sandwich structure is light in weight, high in strength and high in rigidity, and is used, for example, as a part or a casing part of a personal computer, OA equipment, a mobile phone, etc., especially Accordingly, even in the case where there are erected portions such as ribs, the erected portion can be easily and reliably molded into a desired shape and strength. Background technique [0002] Currently, with the development of portability of electrical and electronic equipment such as personal computers, OA equipment, AV equipment, mobile phones, landline telephones, facsimile machines, home appliances, and toys, further miniaturization and weight reduction are required. In order to realize this requirement, when a load is applied from the outside to the parts (especially the case) constituting the equipment, it is necessary to prevent the case ...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): B32B5/28B29C43/20B29C70/06B32B5/14B32B7/02B32B37/10B32B38/10B32B7/022
CPCB32B5/14B32B5/28B32B37/10B32B38/10B32B15/085B32B15/092B32B15/18B32B15/20B32B27/12B32B27/20B32B27/22B32B27/281B32B27/285B32B27/288B32B27/302B32B27/304B32B27/308B32B27/322B32B27/34B32B27/36B32B27/365B32B27/42B32B2250/03B32B2250/05B32B2262/0246B32B2262/0261B32B2262/0269B32B2262/0276B32B2270/00B32B2307/202B32B2307/206B32B2307/40B32B2307/546B32B2307/718B32B2457/00B32B2509/00B29C43/021B29C2043/026B29C70/46B32B3/266B32B3/30B32B5/024B32B5/12B32B27/08B32B27/32B32B27/38B32B2250/40B32B2260/023B32B2260/046B32B2262/101B32B2262/106B32B2307/54B29C43/183B29K2105/12B32B7/022B29D99/0014B29C70/14B29C70/081B32B5/26B32B15/14B29C43/206B29K2023/12B29K2063/00B29K2105/0845B29K2105/0881B29K2105/089B29K2307/04B29K2309/08B32B2307/72
Inventor 佐佐木英晃橳岛英树大西孝幸
Owner TORAY IND INC