Papermaking tank for producing carbon fiber reinforced plastic sheets

Abstract

The purpose of this project is to reduce production costs and carbon dioxide emissions by effectively utilizing recycled carbon fiber and using metal substitutes, and to provide a papermaking tank for manufacturing carbon fiber reinforced plastic sheets that minimizes variation in material strength. [Solution] In a papermaking tank 1 for manufacturing carbon fiber reinforced plastic plates made by a papermaking method using carbon fiber, phenolic resin (a thermosetting resin component), and a fixing agent, the shape of the papermaking tank is formed so that its planar dimensions are greater than its height dimensions, and it is formed with partition frames that divide the inside of the tank into multiple sections.

Description

[Technical field]

[0001] The present invention relates to a papermaking tank for producing rust-resistant carbon fiber reinforced plastic (hereinafter referred to as "CFRP") sheets, which can be expected to have bending strength equivalent to that of iron or stainless steel, yet are one-fifth the weight of iron. [Background technology] [Background technology]

[0002] Conventionally, it has become possible to provide lightweight and rust-resistant structural steel materials, and it is beneficial in that it can meet social needs by using recycled carbon fiber. In actual measurements, when comparing recycled carbon fiber with phenolic resin, a thermosetting resin, and SUS304, the bending strength was 646 MPa for this invention, while the transverse strength, which is considered to be equivalent to the bending strength of metal, was 520 MPa, and the tensile load strength was 520 MPa compared to 304 MPa. Although the tensile strength is slightly inferior, it was confirmed to be equal to or greater than the 70 to 130 MPa of aluminum.

[0003] The papermaking method in the papermaking process of the papermaking tank for manufacturing carbon fiber reinforced plastic plates is a generally known method. The purpose of the papermaking process is to efficiently fix the resin to the fibers. The details of the papermaking method are as shown in Patent No. 7546986 (Patent Document 1). In this papermaking method, a dispersion water in which heat-resistant fibers are dispersed is stored in a papermaking tank with a large number of openable drainage holes formed on the bottom surface, and the drainage holes of the papermaking tank are simultaneously opened to release the dispersion water, and the water is drained from the papermaking tank, and the heat-resistant fibers are removed with a papermaking net placed in the papermaking tank. Since the insertion size of the drying furnace in the subsequent drying process is limited, the paper product is formed into a 50 cm square, and the height of the papermaking tank is increased to about 1 m to increase productivity. The dispersion water at this time is 250 TIFF0003250400000002.tif7154, which caused the resin to not disperse properly after draining the water, resulting in variations in strength after molding.

[0004] On the other hand, one domestic aircraft manufacturer produces 70 tons of carbon fiber waste per year, and developing ways to utilize this waste has become an urgent task. However, the above problems have not yet been solved.

[0005] Solutions to the problem of reducing weight by using carbon fiber to convert the above metals into resins include the invention in Utility Model Registration No. 3225768 (Patent Document 2) and one using glass fiber and thermosetting resin in Patent No. 2907679 (Patent Document 3).However, these did not eliminate the variation in product strength that arises from the shape of the papermaking tank.

[0006] [Prior art documents] [Patent documents]

[0007] [Patent Document 1] Patent Number 7546986 [Patent Document 2] Utility Model Registration No. 3225768 [Patent Document 3] Patent Number 2907679 Summary of the Invention [Problem to be solved by the invention]

[0008] The present invention was developed in consideration of the above, and is a papermaking tank for manufacturing carbon fiber reinforced plastic sheets that makes it possible to extremely reduce the variation in strength of the product at the final stage.

[0009] This is a papermaking tank for producing carbon fiber reinforced plastic plates made of carbon fiber reinforced plastic, with the component ratio of the molded product being 40 to 60 w% carbon fiber and 60 to 40 w% phenolic resin, which is a thermosetting resin, and the concentration of aramid fiber in the overall product being 5 to 8 w%. [Means for solving the problem]

[0010] This invention achieves weight reduction by using carbon fiber reinforced plastic, which is rust-resistant, lightweight, and has bending strength and compressive strength comparable to that of steel, and improves strength through a papermaking process, while minimizing variation in product strength and improving productivity.

[0011] This papermaking tank for producing carbon fiber reinforced plastic plates is made by using a papermaking method to make carbon fiber, phenolic resin, which is a thermosetting resin component, and a fixing agent.The shape of the papermaking tank is formed so that its planar dimensions are greater than its height dimensions, and it is formed with partition frames that separate the layers into multiple sections. Although not shown in the figure, it goes without saying that drainage channels, which will be described later, are provided.

[0012] TIFF0003250400000003.tif7152, which shortens the distance the dispersed water falls in the vertical direction. Since the insertion width of the drying oven is 50 cm on each side, the oven is divided into four parts by partition frames so that the paper products can be dried in the subsequent process.

[0013] The 10mm thick plate material produced by the papermaking method of this invention is made by kneading 45w% carbon fiber, 50w% thermosetting phenolic resin, and 5w% fixing material and forming it by the papermaking method, and the thickness of the base material is 100mm. It is then dried and formed by hot pressing at 140℃ into a 5mm thick plate material. The shape can be determined by the shape of the mold.

[0014] In the above embodiment, as an example, when the fiber length was set to 10 mm, the average bending strength was 545 MPa when the number of fibers was 40. This was found to be a favorable result, and corresponds to 520 MPa for SUS304.

[0015] In the above embodiment, a molding having a thickness of 5 mm is exemplified, but if a thickness of 10 mm to 20 mm is desired depending on the size of the molded product and the purpose of use, the base material is molded to about 100 mm to 200 mm, and after press molding in the same manner as above, it is molded to a thickness of 10 mm to 20 mm. Effect of the Invention

[0016] In actual measurements, the carbon fiber reinforced plastic plate of this invention made of recycled carbon and phenolic resin has a bending strength equivalent of 650MPa for S55C iron and 520MPa for SUS304, which is almost the same, but this figure is the minimum strength, and in order to stabilize the product, it is necessary to reduce the difference between the maximum and minimum values. With this invention, we have been able to make the variation extremely small. [Brief description of the drawings]

[0017] [Figure 1] 1 is a perspective view of a papermaking tank for producing carbon fiber reinforced plastic plates according to the present invention. [Diagram 2] 3 is a perspective view of a partition frame that divides the papermaking tank after papermaking. FIG. [Diagram 3] This is an oblique view of the present invention with a partition frame fitted into a papermaking tank. [Figure 4] A flow diagram showing a general papermaking method. 1 Papermaking tank 2 Bottom of papermaking tank 3 Partition frame DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0018] To explain an embodiment of this invention, carbon fiber cut to a length of 10 mm is mixed with phenolic resin in a ratio of 4:6 and fixing agent in a large amount of water, and then dehydrated to form a base body. After that, it is inserted into a drying oven to dry at 80℃ for 3 hours, and then pressurized and heated for molding. The moisture content is about 10% in the above drying, the heating temperature is 140℃, and the molded product is pressed and molded for 5 minutes in a 150 ton press to obtain a 5 mm thick molded product.

[0019] In the above embodiment, one example is shown, but the pressing pressure and time are adjusted depending on the size. This papermaking tank for producing carbon fiber reinforced plastic plates is made by using a papermaking method to produce carbon fiber, phenolic resin, which is a thermosetting resin component, and a fixing agent.The shape of the papermaking tank is formed so that its planar dimensions are greater than its height dimensions, and the tank is formed with partition frames that separate the layer into multiple sections.

[0020] To explain with reference to the drawings, Figure 1 shows a papermaking tank 1 used in the papermaking method. Although not shown, a mesh net or the like is installed at the bottom 2 of the papermaking tank 1 to drain the dispersed water and to allow the base material made of carbon fiber and thermosetting resin to deposit in layers. A partition frame 3 for dividing the above-mentioned raw material is removably fitted into the papermaking tank 1.

[0021] This invention can be used as a substitute for metal materials such as iron and stainless steel, and since its production does not require the melting process at temperatures of several thousand degrees Celsius that is required for metal products, it can make a significant contribution to reducing carbon dioxide emissions. [Industrial Applicability]

[0022] This invention can make a great contribution to the metal materials industry as a new material to replace metal in construction work, the machinery industry and safety work, as a measure that emphasizes the workplace environment by reducing weight, and is extremely useful in eliminating variations in product strength.

Claims

[Claim 1] A papermaking tank for producing carbon fiber reinforced plastic plates is made by using a papermaking method to process carbon fiber, phenolic resin, which is a thermosetting resin component, and a fixing agent.The shape of the papermaking tank is formed so that its planar dimensions are greater than its height dimensions, and the tank is formed with partition frames that divide the tank into multiple sections.

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