Fireproof composite material and method for manufacturing the same

The fireproof composite material addresses the issue of combustible gas release in vinyl ester resin by heating the material to specific conditions, achieving both high fireproof performance and strength through reduced styrene gas concentration and enhanced reinforcing effects.

JP7704711B2Active Publication Date: 2025-07-08FUKUBI KAGAKU IND
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Patent Information

Application Number
JP2022071693
Authority / Receiving Office
JP · JP
Patent Type
Patents
Current Assignee / Owner
Filing Date
2022-04-25
Publication Date
2025-07-08
Estimated Expiration
2042-04-25

AI Technical Summary

Technical Problem

Fiber-reinforced composite materials using vinyl ester resin as a base material face challenges in ensuring sufficient fireproof performance due to the release of combustible gases like styrene gas at high temperatures, which can lead to ignition.

Method used

A fireproof composite material is developed with a base material made of vinyl ester resin and reinforcing fibers, where the manufacturing process includes heating the molded body at specific temperatures (290 to 320°C) and times (5 to 20 minutes) to reduce styrene gas concentration to 550 ppm or less, enhancing fireproof properties while maintaining strength.

Benefits of technology

The composite material achieves excellent fireproof performance, with a styrene gas concentration of 550 ppm or less and a flexural strength of 1200 MPa or more, ensuring non-combustibility and high strength even in high-temperature environments.

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Abstract

To provide a fireproof composite material with superior fireproof performance.SOLUTION: A fireproof composite material 1 includes a substrate 2 made from vinyl ester resin, and reinforced fibers 3 contained in the base material 2. In the fireproof composite material 1, the styrene gas level derived from the vinyl ester resin, when measured by gas chromatography at 300°C, is 550 ppm or less. Such a fireproof composite material 1 exhibits a reduced tendency to emit combustible gases, such as styrene, even in high-temperature environments such as a fire, thereby demonstrating superior fireproof performance.SELECTED DRAWING: Figure 1
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Description

Technical Field

[0001] The present invention relates to a fireproof composite material containing reinforcing fibers and a method for manufacturing the same.

Background Art

[0002] Composite materials containing reinforcing fibers and resins are widely used in fields such as railway vehicles, automobiles, civil engineering, and sports goods because they are lightweight and have high strength. For example, Patent Document 1 below discloses a fiber-reinforced composite material in which reinforcing fibers are contained in a thermosetting resin such as vinyl ester resin.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] When the fiber-reinforced composite material described in Patent Document 1 above, particularly a fiber-reinforced composite material using vinyl ester resin as a base material (matrix resin), is placed in a high-temperature environment due to a fire or the like, there is a possibility that combustible gas is released from the vinyl ester resin. For this reason, there has been a problem that it is difficult to ensure sufficient fireproof performance.

[0005] The present invention has been made in view of the above circumstances, and an object thereof is to provide a fireproof composite material having excellent fireproof performance and a method for manufacturing the same.

Means for Solving the Problems

[0006] As a solution to the above problems, a fireproof composite material according to one aspect of the present invention is a composite material having fireproof properties, and includes a base material made of vinyl ester resin and reinforcing fibers contained in the base material. When measured by gas chromatograph analysis at 300 ° C, the concentration of styrene gas generated from the vinyl ester resin in the composite material is Above 287 ppm 550 ppm or less, which is characterized (Claim 1).

[0007] In this specification, fireproof refers to a broad concept representing the property of being difficult to burn, and includes concepts such as non-combustible, flame-retardant, and fire-resistant.

[0008] The fireproof composite material of the present invention has the property that when subjected to gas chromatograph analysis, the concentration of styrene gas generated from the vinyl ester resin constituting the base material is within 550 ppm. This means that even in a high-temperature environment due to a fire or the like, combustible gases mainly composed of styrene gas are difficult to be released from the fireproof composite material. Therefore, even if the fireproof composite material approaches fire, it will not ignite, and the fireproof property of the fireproof composite material can be ensured well.

[0009] Specifically, the fireproof composite material can be evaluated as non-combustible by Test Method I for non-metallic materials for railway vehicles in accordance with Article 83 of Section 5, Chapter 8, "Measures against Vehicle Fires, etc." of Ordinance of the Ministry of Land, Infrastructure, Transport and Tourism No. 151 (Claim 2).

[0010] Furthermore, the fireproof composite material can have a flexural strength of 1200 MPa or more according to JIS K7074 (Claim 3).

[0011] That is, by manufacturing the fireproof composite material by the manufacturing method described later, while suppressing the concentration of the styrene gas to 550 ppm or less and imparting a fireproof property corresponding to non-combustibility, a flexural strength of 1200 MPa or more can be ensured. Thereby, a fireproof composite material having high fireproof properties and strength can be realized.

[0012] The manufacturing method of the fireproof composite material according to another aspect of the present invention includes a step of molding a prepreg material in which a reinforcing fiber is impregnated with a vinyl ester resin, a step of introducing the molded prepreg material into a mold and performing a drawing molding, and a step of heating the molded body obtained by the drawing molding in a heating furnace at 290°C or higher and 320°C or lower for 5 minutes or longer and 20 minutes or shorter (Claim 4).

[0013] According to the manufacturing method of the present invention, by heating the molded body after the drawing molding under the conditions of a specific temperature (290 to 320°C) and time (5 to 20 minutes), the concentration of styrene gas generated from the vinyl ester resin can be reduced to 550 ppm or less in the measurement by gas chromatograph analysis at 300°C. Thereby, the fireproof property of the molded body after the heat treatment, that is, the fireproof composite material, can be enhanced. Moreover, according to the conditions of the heat treatment described above, the degree of decrease in the strength of the vinyl ester resin that may occur due to the heat treatment can be minimized. If the decrease in strength due to the heat treatment is small, the amount of increase in strength due to the reinforcing effect of the reinforcing fiber exceeds the amount of decrease in strength, so that the strength of the fireproof composite material can be enhanced as a whole.

Effects of the Invention

[0014] As described above, according to the present invention, a fireproof composite material having excellent fireproof properties can be provided.

Brief Description of the Drawings

[0015]

Figure 1

Figure 2

Figure 3

Figure 4

Embodiments for Carrying Out the Invention

[0016] [Structure of Fireproof Composite Material] Figure 1 is a perspective view showing a fireproof composite material 1 according to an embodiment of the present invention. As shown in this figure, the fireproof composite material 1 includes a base material 2 and reinforcing fibers 3 contained in the base material 2. In this embodiment, the fireproof composite material 1 is a plate-shaped member having a certain thickness t and width W.

[0017] The base material 2 is a resin member shaped into a plate shape through the drawing process described later. The base material 2 is composed of a vinyl ester resin, that is, a thermosetting resin obtained by adding an acrylic group or a methacrylic group to an epoxy resin.

[0018] The reinforcing fibers 3 are a number of filamentous bodies contained to reinforce the base material 2, and are arranged inside the base material 2 in a state of being oriented in a certain direction along the longitudinal direction X of the fireproof composite material 1. As the reinforcing fibers 3, carbon fibers, glass fibers, aramid fibers, ceramic fibers, etc. can be used. Among them, carbon fibers are advantageous in improving the strength and corrosion resistance of the molded product. As the carbon fibers, it is preferable to use PAN (polyacrylonitrile)-based carbon fibers with particularly high strength.

[0019] Regarding the content rate of the reinforcing fibers 3 in the fireproof composite material 1, it is preferable that the fiber weight content rate (Wf) is set to 65% or more and 85% or less, and the fiber volume content rate (Vf) is set to 50% or more and 80% or less.

[0020] [Manufacturing Method of Fireproof Composite Material] Figure 2 is a diagram showing a schematic configuration of a drawing device 20 for manufacturing the above-described fireproof composite material 1. As shown in this figure, the drawing device 20 includes a fiber feeder 21, a resin impregnation tank 22, a forming die 23, a heating furnace 24, a take-up machine 25, and a cutting machine 26. The fiber feeder 21, the resin impregnation tank 22, the forming die 23, the heating furnace 24, the take-up machine 25, and the cutting machine 26 are arranged in this order from the upstream side (the left side in Figure 2) in the drawing direction.

[0021] The fiber feeder 21 is a device that feeds the reinforcing fiber 3 downstream toward the resin impregnation tank 22. The fiber feeder 21 includes a plurality of feed rollers 31 around which the reinforcing fiber 3 is wound, and a plurality of guide rollers 32 that guide the reinforcing fiber 3 fed out from the feed rollers 31 downstream. The reinforcing fiber 3 is wound around the feed rollers 31 in a bundled sheet-like state and is fed downstream in accordance with the rotation of the feed rollers 31. In other words, what is fed out from the feed rollers 61 is a sheet-like body in which continuous reinforcing fibers 3 extending along the feeding direction are bundled in a sheet shape. Hereinafter, this will be referred to as the fiber sheet 3A. As the fiber sheet 3A, a sheet-like non-opened fiber bundle may be used as it is, or a fiber bundle obtained by opening and spreading the fiber bundle may be used. Alternatively, a combination of non-opened fiber bundles by means such as stitching may be used as the fiber sheet 3A. Each fiber sheet 3A fed out from the plurality of feed rollers 31 is guided by the guide rollers 32 and is led out toward the downstream resin impregnation tank 22.

[0022] The resin impregnation tank 22 is a tank for impregnating the fiber sheet 3A with resin. Inside the resin impregnation tank 22, a liquid impregnating resin 12 is stored. The impregnating resin 12 is the resin that constitutes the base material 2 (FIG. 1) after molding. That is, the impregnating resin 12 is a liquid vinyl ester resin. Note that additives such as a flame retardant can be included in the impregnating resin 12.

[0023] Each fiber sheet 3A fed out from the fiber feeder 21 is individually introduced into the impregnating resin 12, whereby each fiber sheet 3A is impregnated with the impregnating resin 12. The fiber sheet 3A impregnated with the impregnating resin 12 is led out of the resin impregnation tank 22 through the guide roller 33 or the like.

[0024] The fiber sheet 3A derived from the resin impregnation tank 22 is a sheet-like body composed of the reinforcing fibers 3 impregnated with the impregnating resin 12, which is hereinafter referred to as the prepreg sheet 3B. The prepreg sheet 3B includes the reinforcing fibers 3 continuous in the drawing direction and the impregnating resin 12 (vinyl ester resin) impregnated in the reinforcing fibers 3, corresponding to the "prepreg material" in the present invention. A plurality of prepreg sheets 3B derived from the resin impregnation tank 22 are guided downstream while being laminated and shaped in the thickness direction by a plurality of guides 34, and sent out to the molding die 23.

[0025] The molding die 23 is a mold that receives and heats the laminated prepreg sheet 3B supplied from the resin impregnation tank 22 through the guide 34. The molding die 23 has a cavity penetrating in the drawing direction inside. That is, the molding die 23 receives the laminated prepreg sheet 3B into the cavity, and by heating the received prepreg sheet 3B, shapes the prepreg sheet 3B into a cross-sectional shape corresponding to the cavity. In the present embodiment, the molding die 23 has a cavity with a rectangular cross section corresponding to the fireproof composite material 1 (FIG. 1). The prepreg sheet 3B is shaped in such a cavity and discharged downstream as a molded body 11 with a rectangular cross section.

[0026] The molding die 23 incorporates a heating device (not shown). This heating device heats the prepreg sheet 3B until the temperature of the impregnating resin 12 exceeds the curing temperature of the material (vinyl ester resin) at least in the downstream portion of the molding die 23. That is, the molded body 11 discharged from the molding die 23 is a molded body with a rectangular cross section containing the cured impregnating resin 12 (vinyl ester resin) and the reinforcing fibers 3.

[0027] The heating furnace 24 is a furnace that heats the formed body 11. The heating furnace 24 includes a heating chamber through which the formed body 11 discharged from the forming die 23 passes, and a heat source that maintains the inside of the heating chamber at a high temperature within a predetermined range (both are not shown). In the present embodiment, the temperature of the heating chamber, that is, the internal temperature of the heating furnace 24, is set to be 290°C or higher and 320°C or lower. Further, the length of the heating furnace 24 is set such that the time required for the formed body 11 to pass through the heating furnace 24 is 5 minutes or more and 20 minutes or less. That is, in the present embodiment, the formed body 11 is heat-treated at a heating temperature of 290 to 320°C for 5 to 20 minutes. By this heat treatment, combustible gas is released from the vinyl ester resin contained in the formed body 11.

[0028] From the heating furnace 24, the formed body 11 that has undergone the above heat treatment is discharged as the fireproof composite material 1. That is, the fireproof composite material 1 includes a base material 2 made of a vinyl ester resin from which combustible gas has been released by heating, and reinforcing fibers 3 arranged inside the base material 2 in a state of being aligned in the same direction (drawing direction) (see FIG. 1).

[0029] The take-up machine 25 is a device that takes up the fireproof composite material 1 discharged from the forming die 23 and sends it further downstream. In the present embodiment, the take-up machine 25 includes a plurality of pairs of rollers 35 and a pair of endless belts 36 that are arranged corresponding to the vertical direction and wound around the rollers 35. However, the take-up machine is not limited to the one using such endless belts 36, and an appropriate type of take-up machine suitable for the shape of the formed body 11, such as a clamp type, can be used.

[0030] The cutting machine 26 is a device that includes a saw blade 37 for cutting the fireproof composite material 1 sent out from the take-up machine 25 into a predetermined length. After the fireproof composite material 1 is cut into a predetermined length by the saw blade 37, it is carried out downstream by a conveying unit (not shown).

[0031] [Function and Effect] As described above, in the present embodiment, the prepreg sheet 3B in which the reinforcing fiber 3 is impregnated with a vinyl ester resin (impregnating resin 12) is introduced into the molding die 23 and drawn to form a molded body 11, and the molded body 11 obtained thereby is heated in a heating furnace 24 at 290 to 320 °C for 5 to 20 minutes, whereby the fireproof composite material 1 is manufactured. As is clear from the evaluations of the respective examples described later, the fireproof composite material 1 manufactured by such a method has excellent properties in terms of both fire resistance and strength.

[0032] That is, in the present embodiment, since the molded body 11 is heated by the heating furnace 24 at a specific temperature (290 to 320 °C) and time (5 to 20 minutes), a significant amount of combustible gas can be released from the vinyl ester resin by the heat treatment. This means that the components that can volatilize as combustible gas have decreased from the vinyl ester resin. Therefore, the fireproof composite material 1 obtained through the above heat treatment has the property that even if it is placed in a high-temperature environment due to a fire or the like, less combustible gas can volatilize from its base material 2 (vinyl ester resin). In other words, since the fireproof composite material 1 hardly releases combustible gas even in a high-temperature environment, it does not catch fire even when approaching fire and has excellent fire resistance. Moreover, the conditions of the heat treatment described above are necessary and sufficient conditions for ensuring fire resistance and do not heat the vinyl ester resin at excessive temperature and time. For this reason, the degree of strength reduction of the vinyl ester resin that may occur due to the heat treatment can be minimized. If the strength reduction due to the heat treatment is small, the amount of strength increase due to the reinforcing effect of the reinforcing fiber 3 exceeds the amount of strength reduction, so that the strength of the fireproof composite material 1 can be increased as a whole.

[0033] [Examples] The results obtained by actually manufacturing the fireproof composite material 1 by the method of the embodiment described above are shown in FIG. 3 as Examples 1 to 9. That is, while varying the temperature and time of the heat treatment by the heating furnace 24 within the range falling within the conditions (290 to 320 ° C. / 5 to 20 minutes) of the above embodiment, a flat fireproof composite material 1 is manufactured according to the manufacturing method shown in FIG. 2, and the obtained results are taken as Examples 1 to 9 respectively. The fiber weight content (Wf) of Examples 1 to 9, that is, the weight ratio of the reinforcing fiber 3 in the fireproof composite material 1 was all set to 66%.

[0034] The manufacturing conditions other than the heat treatment in Examples 1 to 9 are as follows. (Manufacturing conditions) · Dimensions: thickness (t) × width (W) = 2 mm × 30 mm · Matrix resin: Lipoxy (manufactured by Showa Denko) · Reinforcing fiber: Carbon fiber T-700 (manufactured by Toray) · Mold temperature: 160 ° C · Linear speed: 0.2 m / min

[0035] Note that, under the above manufacturing conditions, the matrix resin refers to the resin (vinyl ester resin) constituting the base material 2, the mold temperature refers to the heating temperature at the molding die 23, and the linear speed refers to the speed at which the fireproof composite material 1 is taken up by the take-up machine 25, in other words, the drawing speed through the molding die 23.

[0036] In FIG. 3, Comparative Examples 1 to 3 are also shown. In Comparative Examples 1 to 3, the conditions of the heat treatment in the heating furnace 24 are different from those of the above embodiment. Specifically, those subjected to heat treatment at a temperature different from the temperature condition (290 to 320 ° C) of the above embodiment are taken as Comparative Examples 1 and 2, and those in which the heat treatment itself is omitted are taken as Comparative Example 3. Other manufacturing conditions are the same as those in Examples 1 to 9.

[0037] The fireproof properties and strength of the above examples and comparative examples were evaluated by the following method.

[0038] (i) Gas chromatograph analysis For the above Examples and Comparative Examples, gas chromatographic analysis at 300 °C was performed using a thermal desorption-gas chromatograph mass spectrometer (TG-GC / MS apparatus). Gas chromatographic analysis is an analytical method in which a sample is heated to a specific temperature (here, 300 °C), and the components volatilized from the sample due to the heating are measured. The analysis conditions (measurement conditions) are as shown in FIGS. 4(a) and (b). The combustible gas recognized as a volatile component in this gas chromatographic analysis at 300 °C was mainly styrene gas. Therefore, for the Examples and Comparative Examples, an analysis was performed to measure the concentration (ppm) of styrene gas. The results are shown in FIG. 3 as the styrene gas concentration. Note that the styrene gas concentration in FIG. 3 refers to the initial detection concentration of styrene gas.

[0039] (ii) Flexural strength measurement For the above Examples and Comparative Examples, the flexural strength, that is, the flexural test, was performed. The test conditions conformed to JIS K7074. The test piece subjected to this flexural test was assumed to have a size of thickness × width × length of 2 mm × 15 mm × 100 mm. For the test piece of this size, a flexural test was performed by Method A (three-point bending) of JIS K7074, and the stress (MPa) at which the test piece reached fracture was measured. The results are shown in FIG. 3 as the flexural strength. Also, the strength ratio (%) when the flexural strength in the case where the heat treatment was omitted (Comparative Example 3) was set to 100 is also shown in FIG. 3.

[0040] (iii) Fire resistance evaluation For the above-described Examples and Comparative Examples, a fire resistance evaluation was conducted according to Test Method I for non-metallic materials for railway vehicles, which complies with Article 83 of Section 5, Chapter 8, "Measures against Vehicle Fires, etc." of Ordinance No. 151 of the Ministry of Land, Infrastructure, Transport and Tourism in 2001. Note that Test Method I for non-metallic materials for railway vehicles that complies with this law is the test method stipulated in the interpretation criteria established for the above ordinance, that is, the "Interpretation Criteria for Ordinances Establishing Technical Standards for Railways", and is generally carried out by the following method. That is, an alcohol container is placed under the center of a test piece (182 mm × 257 mm) held in a posture inclined at 45 degrees, and it is burned until 0.5 cc of pure ethyl alcohol contained in the alcohol container burns out. Then, the ignition, flame ignition, smoke generation state, and flame state of the test piece during alcohol combustion are investigated, and the afterflame, residue, carbonization, and deformation state of the test piece after alcohol combustion are investigated. Based on these investigation results, it is determined which of "non-combustible", "extremely difficult to burn", and "difficult to burn" (or whether it does not fall into any of them) it corresponds to. The results of evaluating the fire resistance of the Examples and Comparative Examples by such a test method are shown in FIG. 3. In FIG. 3, the fact that the non-combustibility is "〇" indicates that the evaluation result by the above test method was "non-combustible", which is the most excellent in fire resistance, and the fact that the non-combustibility is "×" indicates that the evaluation result was not "non-combustible", that is, the fire resistance is relatively inferior.

[0041] As understood from FIG. 3, the heat treatment conditions when producing Examples 1 to 9 are all included in the temperature range of 290 to 320°C and the time range of 5 to 20 minutes. The styrene gas concentration of Examples 1 to 9 obtained under such conditions, that is, the concentration of styrene gas generated from the vinyl ester resin in the composite material in the measurement by gas chromatograph analysis at 300°C, was 287 ppm at the lowest (Example 9) and 550 ppm at the highest (Example 1). That is, for Examples 1 to 9, it was confirmed that the concentration of styrene gas generated from the vinyl ester resin in the composite material was within 550 ppm. And because the concentration of styrene gas was 550 ppm or less, the fire resistance evaluations of Examples 1 to 9 were all "non-combustible".

[0042] In contrast, in Comparative Example 1 where the heat treatment temperature was set at 280°C, which is lower than that in Examples 1 to 9, the concentration of styrene gas was as high as 600 ppm, resulting in a fire resistance evaluation lower than "non-combustible". Also, in Comparative Example 3 where no heat treatment was performed, the concentration of styrene gas increased to 1300 ppm, naturally resulting in an evaluation result lower than "non-combustible". On the other hand, for Comparative Example 2 where the heat treatment temperature was set at 330°C, which is higher than that in Examples 1 to 9, although the concentration of styrene gas decreased to 248 ppm, it was found that the resin deteriorated due to excessive heating and cracks occurred, making it unusable as a product (molding defect).

[0043] Regarding the flexural strength, the flexural strength of Comparative Example 3 without heat treatment was the highest at 1479 MPa. In Examples 1 to 9 with heat treatment, the flexural strength decreased compared to Comparative Example 3, but even in the lowest case (Example 9), the flexural strength only decreased to 1218 MPa, and it was found that a strength ratio of 82% was ensured compared to Comparative Example 3. In Example 1 with the highest flexural strength among the examples, a flexural strength of 1409 MPa (strength ratio of 95%) was ensured. In other words, in Examples 1 to 9 heated at a temperature of 290 to 320°C and for a time of 5 to 20 minutes, it was found that the flexural strength according to JIS K7074 was ensured to be 1200 MPa or more.

[0044] From the above, Examples 1 to 9 have a relatively high strength with a flexural strength of 1200 MPa or more according to JIS K7074, and at the same time, the fire resistance evaluation according to Test Method I for non-metallic materials for railway vehicles in accordance with Article 83 of Section 5, Chapter 8, "Measures against Vehicle Fires, etc." of the Ordinance of the Ministry of Land, Infrastructure, Transport and Tourism No. 151 of 2001 is "non-combustible". It can be said that they are excellent composite materials with both high fire resistance and strength.

[0045] [Modification Example] In the above embodiment, the plate-shaped fireproof composite material 1 (Figure 1) having a rectangular cross-section was formed, but the shape of the fireproof composite material is not limited to this, and it is possible to form fireproof composite materials with various cross-sectional shapes.

[0046] In the above-described embodiment, continuous fibers extending in the same direction along the longitudinal direction X of the fireproof composite material 1 are used as the reinforcing fibers 3 contained in the fireproof composite material 1. However, the reinforcing fibers that can be contained in the fireproof composite material do not have to be continuous fibers, and may be long fibers or short fibers. Further, the reinforcing fibers may be oriented in two or more directions. For example, in order to form a fireproof composite material containing reinforcing fibers oriented in two or more directions using the drawing device 20 shown in FIG. 2, the directions of the reinforcing fibers 3 of each fiber sheet 3A fed out from the plurality of feed rollers 31 may be staggered. That is, while setting the fiber direction of the fiber sheet 3A fed out from some of the feed rollers 31 to be the same direction as the feed direction, the fiber direction of the fiber sheet 3A fed out from the other feed rollers 31 is set to be a direction different from the feed direction. In order to make the direction of the reinforcing fibers of the fiber sheet 3A different from the feed direction as described above, for example, a fiber sheet 3A in which bundles (fiber bundles) of reinforcing fibers extending in a direction different from the feed direction (for example, a direction orthogonal to the feed direction) are combined by means such as stitching may be prepared.

[0047] Furthermore, the direction of the reinforcing fibers contained in each of the fiber sheets 3A fed out from the plurality of feed rollers 31 may be set to two or more. That is, the fiber sheet used as the material before drawing on the upstream side of the drawing device 20 may be a multi-axis fiber sheet containing reinforcing fibers oriented in two or more directions. Also, as the fiber sheet, a woven fabric in which the reinforcing fibers are woven together can be used. Furthermore, as the material before drawing, a tape-shaped roving material containing reinforcing fibers can also be used.

[0048] In the above-described embodiment, the steps of introducing the fiber sheet 3A sent from the fiber feeder 21 into the resin impregnation tank 22 to form the prepreg sheet 3B, introducing the formed prepreg sheet 3B into the forming die 23 for draw forming, and heating the formed body 11 obtained by the draw forming in the heating furnace 24 were continuously performed in one production line. However, at least one step may be separated from the production line and a plurality of steps may be performed independently. For example, instead of the method (in-line format) of the above-described embodiment in which the formed body 11 discharged from the forming die 23 is directly charged into the heating furnace 24, a fireproof composite material similar to that of the above-described embodiment can also be manufactured by an off-line format in which the formed body 11 discharged from the forming die 23 is first cut to a predetermined length by a cutting machine and then charged into the heating furnace.

Explanation of Reference Numerals

[0049] 1 Fireproof composite material 2 Base material 3 Reinforcing fiber 3C Prepreg sheet (prepreg material) 23 Forming die (mold) 24 Heating furnace

Claims

Claim 1 A composite material having fire resistance, comprising: a base material made of a vinyl ester resin; and reinforcing fibers contained in the base material, wherein the concentration of styrene gas generated from the vinyl ester resin in the composite material is 287 ppm or more and 550 ppm or less in measurement by gas chromatograph analysis at 300°C. A fire-resistant composite material characterized by this. Claim 2 The fire-resistant composite material according to Claim 1, characterized in that the evaluation by Test Method I for non-metallic materials for railway vehicles in accordance with Article 83 of Section 5, Chapter 8, "Measures against Vehicle Fires, etc." of Ministry of Land, Infrastructure, Transport and Tourism Ordinance No. 151 is non-combustible. Claim 3 The fire-resistant composite material according to Claim 1 or 2, characterized in that the flexural strength according to JIS K7074 is 1200 MPa or more. Claim 4 A step of molding a prepreg material in which reinforcing fibers are impregnated with a vinyl ester resin; a step of introducing the molded prepreg material into a mold and performing drawing molding; and a step of heating the molded body obtained by the drawing molding in a heating furnace at 290°C or more and 320°C or less for 5 minutes or more and 20 minutes or less. A method for manufacturing a fire-resistant composite material characterized by this.

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