Method for producing composite material

Abstract

In this method for producing a composite material, a fiber bundle containing a plurality of fibers is provided with an auxiliary component containing a resin, the auxiliary component being placed along the fiber bundle. The fiber bundle is then formed into a laminate, with the auxiliary component being heat-denatured and thereby immobilizing the fiber bundle.

Description

Composite material manufacturing method

[0001] The present disclosure relates to a method for manufacturing a composite material.

[0002] Patent Document 1 discloses a technology in which impregnated fiber bundles, in which a curable resin is continuously coated around the fiber bundles, are extruded and laminated onto the main surface of a substrate, the curable resin is cured to form a composite part, and then the curable resin is melted and infiltrated into the composite part to form a ceramic matrix composite (CMC).

[0003] U.S. Pat. No. 1,559,918

[0004] According to the technology described in Patent Document 1, the layered fibers are prone to disorder such as meandering, floating, and breakage due to the amount of resin coated on the fiber bundle, unevenness during coating, the shape and flexibility of the fiber bundle after coating, etc. Therefore, the technology described in Patent Document 1 has a problem in that it is not possible to efficiently form a shape by layering the fiber bundles.

[0005] The present disclosure has been made in view of the above-mentioned problems, and an object of the present disclosure is to provide a method for producing a composite material that can efficiently form a shape by laminating fiber bundles.

[0006] The method for producing a composite material according to the present disclosure involves placing an auxiliary member containing a resin on a fiber bundle containing a plurality of fibers, and stacking the fiber bundles while fixing the position of the fiber bundles during stacking by thermal modification of the auxiliary member.

[0007] The auxiliary member may be in the form of a fiber or a film.

[0008] The resin may be a thermoplastic resin. The auxiliary members may be fused together to position the fiber bundles when they are stacked.

[0009] The resin may be a thermosetting resin. After the fiber bundles are positioned when stacked, the auxiliary member may be cured.

[0010] An auxiliary member may be entangled with the fiber bundle.

[0011] An auxiliary member may be wound around the fiber bundle.

[0012] When at least two or more auxiliary members are wound around the fiber bundle, the direction in which one auxiliary member is wound may be opposite to the direction in which the other auxiliary members are wound.

[0013] The fiber bundles may be surrounded by a woven mesh structure formed by the auxiliary members.

[0014] The fibers may be bound by a ring of auxiliary material.

[0015] An auxiliary member may be provided along the outer peripheral surface of the fiber bundle.

[0016] An auxiliary member may be embedded inside the fiber bundle.

[0017] The density of the arrangement of the auxiliary members in the extending direction of the fiber bundles may be set based on the radius of curvature of the fiber bundles when stacked.

[0018] The fiber bundle may be interface coated.

[0019] The structural material obtained by laminating the fiber bundles may be combined with a matrix material to form a ceramic matrix composite material.

[0020] The treatment may be chemical vapor infiltration, polymer impregnation and baking, or melt impregnation.

[0021] According to the present disclosure, a method for producing a composite material can be provided that can efficiently form a shape by stacking fiber bundles.

[0022] FIG. 1 is a diagram showing a flowchart of a method for manufacturing a composite material according to an embodiment of the present disclosure; FIG. 2 is a diagram showing an example of a structural material obtained by stacking fiber bundles; FIG. 3 is a diagram showing a first example of an arrangement of auxiliary members relative to fiber bundles; FIG. 4 is a diagram showing a second example of an arrangement of auxiliary members relative to fiber bundles; FIG. 5 is a diagram showing a third example of an arrangement of auxiliary members relative to fiber bundles; FIG. 6 is a diagram showing a fourth example of an arrangement of auxiliary members relative to fiber bundles; FIG. 7 is a diagram showing a fifth example of an arrangement of auxiliary members relative to fiber bundles; and FIG. 8 is a diagram showing a sixth example of an arrangement of auxiliary members relative to fiber bundles.

[0023] Hereinafter, several exemplary embodiments will be described with reference to the drawings. Note that common parts in the drawings are given the same reference numerals, and duplicated explanations will be omitted.

[0024] [Method for Producing Composite Material] FIG. 1 is a flowchart illustrating a method for producing a composite material according to an embodiment of the present disclosure.

[0025] In step S101, a fiber bundle FB is prepared. The fiber bundle FB includes a plurality of fibers. The fibers may be reinforcing fibers. For example, the fibers may be fibers containing silicon carbide. Specifically, commercially available silicon carbide fibers such as Tyranno Fiber (registered trademark) (manufactured by Ube Industries), Hi-Nicalon (registered trademark) (manufactured by Nippon Carbon), and Sylramic (registered trademark) (manufactured by COI Ceramics), as well as carbon fibers and alumina fibers, can be used. The fiber bundle may have a diameter of, for example, about 0.1 mm to 5 mm, and may contain, for example, about 500 to 10,000 fibers.

[0026] The prepared fiber bundle FB may be interface coated. For example, when a structural material containing the fiber bundle FB is combined with a base material to form a ceramic matrix composite material, an interface coating layer may be provided on the surfaces of the fiber bundle FB and the fibers to prevent cracks in the base material from propagating to the fibers. The interface coating layer may be a coating layer containing graphite or a coating layer containing boron nitride. Alternatively, the fiber bundle FB itself may be coated with a resin.

[0027] In step S103, a support member containing a resin is placed on the fiber bundle. Here, the resin contained in the support member SF may be a thermoplastic resin or a non-thermoplastic resin.

[0028] There are various arrangements of the auxiliary member SF relative to the fiber bundle. The arrangements will be described later. The auxiliary member SF may be fibrous or film-like. More specifically, the auxiliary member SF may be a thin, long thread, or a tape-like member having a predetermined width. If the auxiliary member SF is fibrous, its diameter may be, for example, approximately 0.01 mm to 1 mm. If the auxiliary member SF is film-like, its thickness may be approximately 0.01 mm to 0.5 mm and its width may be approximately 1 mm to 10 mm. Examples of thermoplastic resins included include polyamide, polyether ether ketone (PEEK), and polyphenylene sulfide (PPS). Examples of thermosetting resins include epoxy resin, phenolic resin, and cyanate ester resin. The auxiliary member SF has a predetermined shape under normal conditions, such as room temperature. Powders, liquids, and other materials whose shape can change freely are not considered to be auxiliary members SF.

[0029] In step S105, the fiber bundles FB are positioned. Specifically, the fiber bundles FB are stacked while the positions of the fiber bundles FB during stacking are fixed by thermal modification of the auxiliary members SF.

[0030] Fig. 2 is a diagram showing an example of a structural material obtained by stacking fiber bundles. In Fig. 2, fiber bundles FB are stacked adjacent to each other on a support stand ST to form a structural material 10. The structure of the structural material 10 formed by the fiber bundles FB is not limited to the structure shown in Fig. 2, and may be a more complex structure.

[0031] When forming the structural material 10, in order to suppress disturbances such as meandering, floating, and breakage of the fiber bundles FB, the auxiliary members SF are heat-modified so that the positional relationship between adjacent fiber bundles FB is fixed.

[0032] For example, if the resin contained in the auxiliary member SF is a thermoplastic resin, the thermoplastic resin is heated to soften it, and the softened thermoplastic resin is fused together. By fusing the auxiliary members SF in this manner, the fiber bundles FB may be positioned when stacked. The heating temperature may be set to a temperature equal to or higher than the glass transition temperature of the thermoplastic resin used, or near its melting point. For example, polyamide may be heated to approximately 200°C to 250°C, and PEEK may be heated to approximately 300°C to 350°C. The heating time may be, for example, approximately 1 second to 10 minutes. The conditions regarding the heating temperature and heating time are not limited to the examples given here. The fused thermoplastic resin suppresses deformation of the auxiliary member SF. As a result, disturbances such as meandering, lifting, and breakage of the fiber bundles FB are suppressed.

[0033] Furthermore, if the resin contained in the auxiliary member SF is a thermosetting resin, the thermosetting resin may be heated to harden the auxiliary member SF after positioning the fiber bundles FB during lamination. The hardened thermosetting resin suppresses deformation of the auxiliary member SF. As a result, disturbances such as meandering, lifting, and breakage of the fiber bundles FB are suppressed.

[0034] In step S107, the structural material obtained by laminating the fiber bundles is combined with a base material. For example, a ceramic matrix composite may be formed by combining the structural material 10 with a base material. Examples of the base material include ceramic materials such as silicon carbide, silicon nitride, alumina, zirconia, and mullite. The process for combining the structural material 10 with the base material may be at least one of chemical vapor infiltration, polymer impregnation and sintering, and melt impregnation. In the chemical vapor infiltration method, a source gas such as methyltrichlorosilane may be supplied at a temperature range of, for example, 800°C to 1200°C to precipitate silicon carbide or the like within the pores of the structural material. In the polymer impregnation and sintering method, silicon carbide or the like may be formed by impregnating a precursor such as polycarbosilane and then sintering at 1000°C to 1500°C. In the melt impregnation method, for example, metallic silicon or the like may be melted at 1400° C. to 1600° C. and impregnated into the structural material.

[0035] [Examples of Arrangement of Auxiliary Members] Next, examples of arrangement of auxiliary members will be described with reference to Figures 3 to 8. Note that although Figures 3 to 8 show the auxiliary members SF having a fibrous shape, the auxiliary members SF may also have a film-like shape. For example, the auxiliary members SF may have a predetermined width. When arranging the auxiliary members SF, the surfaces of the fiber bundles FB and the auxiliary members SF do not need to be in close contact with each other.

[0036] When the auxiliary members SF are film-like, the auxiliary members SF may be adjacent to each other with no gaps while overlapping each other on the surface of the fiber bundle FB. In other words, the surface of the fiber bundle FB may be covered with the film-like auxiliary members SF. Also, the auxiliary members SF may be adjacent to each other with gaps between them on the surface of the fiber bundle FB. When the auxiliary members SF are arranged, a gap may be provided between the surface of the fiber bundle FB and the auxiliary members SF.

[0037] For example, the auxiliary member SF may be entangled with the fiber bundle FB. Figures 3 to 5 show an example in which the auxiliary member SF is entangled with the fiber bundle FB.

[0038] 3 is a diagram showing a first example of the arrangement of auxiliary members with respect to a fiber bundle. In Fig. 3, an auxiliary member SF is wound around a fiber bundle FB. The number of auxiliary members SF wound around one fiber bundle FB is not limited to one, and may be multiple.

[0039] Furthermore, the arrangement density of the auxiliary members SF in the extending direction of the fiber bundles FB may be set based on the radius of curvature of the fiber bundles FB when stacked. In Fig. 3, the arrangement density of the auxiliary members SF can be defined by the number of turns of the auxiliary members SF per unit length of the fiber bundles FB and the number of auxiliary members SF. The greater the number of turns of the auxiliary members SF per unit length, the higher the arrangement density. Also, the greater the number of auxiliary members SF, the higher the arrangement density.

[0040] Fig. 4 is a diagram showing a second example of the arrangement of auxiliary members with respect to the fiber bundle. In Fig. 4, the direction around the central axis of the fiber bundle FB when the auxiliary member SF is wound around the fiber bundle FB is opposite to the direction around the central axis of the fiber bundle FB when the auxiliary member SF2 is wound around the fiber bundle FB.

[0041] In this way, when at least two or more auxiliary members are wound around the fiber bundle FB, the winding direction of one auxiliary member SF may be opposite to the winding direction of another auxiliary member SF2. This makes the distribution of the auxiliary members on the outer peripheral surface of the fiber bundle FB closer to a uniform state. As a result, the thermal denaturation of the auxiliary members makes it easier to position the fiber bundle FB.

[0042] In Fig. 4, the arrangement density of the auxiliary members can be defined by the number of turns of the auxiliary members per unit length of the fiber bundle FB and the number of auxiliary members. The greater the number of turns of the auxiliary members per unit length, the higher the arrangement density. Also, the greater the number of auxiliary members, the higher the arrangement density.

[0043] Fig. 5 is a diagram showing a third example of the arrangement of auxiliary members relative to the fiber bundle. In Fig. 5, auxiliary members SF and SF2 are entangled with fiber bundle FB. At this time, fiber bundle FB and fiber bundle FB2 are woven together to form a net structure. For example, in regions R1 and R2, fiber bundle FB and fiber bundle FB2 form nodes. The nodes may or may not have knots. In this way, the fiber bundle may be surrounded by a net structure woven by the auxiliary members.

[0044] In Fig. 5, the arrangement density of the auxiliary members can be defined by the number of nodes formed by the auxiliary members and the number of auxiliary members per unit length of the fiber bundle FB. The greater the number of nodes per unit length, the higher the arrangement density. Also, the greater the number of auxiliary members, the higher the arrangement density.

[0045] In addition to the above-mentioned examples, there are various other arrangements of the auxiliary members, some of which will be described with reference to FIGS.

[0046] Fig. 6 is a diagram showing a fourth example of the arrangement of auxiliary members relative to the fiber bundle. In Fig. 6, the fibers constituting the fiber bundle FB are bundled by rings made of auxiliary members SF. The rings made of auxiliary members SF are also arranged at predetermined intervals.

[0047] 6, the density of the arrangement of the auxiliary members can be defined by the number of loops made of the auxiliary members SF per unit length of the fiber bundle FB. The greater the number of loops per unit length, the higher the arrangement density.

[0048] Fig. 7 is a diagram showing a fifth example of the arrangement of auxiliary members relative to the fiber bundle. In Fig. 7, auxiliary members SF and SF2 are arranged along the outer peripheral surface of the fiber bundle FB. The number of auxiliary members arranged along the outer peripheral surface of the fiber bundle FB may be one or more.

[0049] 7, the density of the placement of the auxiliary members can be defined by the number of auxiliary members to be placed. The more auxiliary members to be placed, the higher the placement density.

[0050] Fig. 8 is a diagram showing a sixth example of the arrangement of auxiliary members relative to the fiber bundle. In Fig. 8, auxiliary members SF are embedded inside the fiber bundle FB. For example, the auxiliary members SF may be bundled together with the multiple fibers that make up the fiber bundle FB. The auxiliary members SF embedded in the fiber bundle FB may be partially exposed on the outer circumferential surface of the fiber bundle FB.

[0051] Effect of the embodiment As described above in detail, the method for producing a composite material according to the present disclosure places an auxiliary member containing a resin on a fiber bundle containing a plurality of fibers, and stacks the fiber bundles while fixing the positions of the fiber bundles during stacking by thermal modification of the auxiliary member.

[0052] This allows for efficient formation of a shape by laminating fiber bundles. In particular, when forming a structural material by laminating fiber bundles, it is possible to suppress disturbances such as meandering, floating, and breakage of the fiber bundles. As a result, it is also possible to reduce the working time and costs involved in laminating the fiber bundles.

[0053] The auxiliary member may be fibrous or film-like. This allows the auxiliary member to have a predetermined shape in a normal state and not to change shape freely like a powder, liquid, etc. Therefore, the auxiliary member can be easily arranged relative to the fiber bundle, and further, the fiber bundles can be stacked with the auxiliary member in place.

[0054] The resin may be a thermoplastic resin. The auxiliary members may be fused together to position the fiber bundles when stacking them. This makes it possible to easily position the fiber bundles when stacking them by simply heating the resin. The fused thermoplastic resin suppresses deformation of the auxiliary members. As a result, disturbances such as meandering, lifting, and breakage of the fiber bundles FB are suppressed.

[0055] The resin may be a thermosetting resin. The auxiliary member may be cured after positioning the fiber bundles when stacking. This allows for easy positioning of the fiber bundles when stacking by simply heating the resin. The cured thermosetting resin suppresses deformation of the auxiliary member. As a result, disturbances such as meandering, lifting, and breakage of the fiber bundles are suppressed.

[0056] An auxiliary member may be entangled with the fiber bundle. Alternatively, an auxiliary member may be wound around the fiber bundle. Furthermore, the fiber bundle may be surrounded by a mesh structure woven with auxiliary members. In this way, the movement of the fiber bundle can be restrained by the auxiliary member. As a result, disturbances such as meandering, floating, and breakage of the fiber bundle are suppressed.

[0057] When at least two or more auxiliary members are wound around a fiber bundle, the winding direction of one auxiliary member may be opposite to the winding direction of the other auxiliary members. This makes the distribution of the auxiliary members on the outer circumferential surface of the fiber bundle more uniform. As a result, the thermal modification of the auxiliary members makes it easier to position the fiber bundle.

[0058] The fibers may be bundled using a ring made of an auxiliary member. This allows the movement of the fiber bundle to be restrained by the auxiliary member. As a result, disturbances such as meandering, floating, and breakage of the fiber bundle are suppressed.

[0059] An auxiliary member may be arranged along the outer peripheral surface of the fiber bundle. This reduces the workload and costs involved in arranging the auxiliary member along the outer peripheral surface of the fiber bundle, and allows for efficient formation of a shape by stacking the fiber bundles. In particular, when forming a structural material by stacking fiber bundles, it is possible to suppress disturbances such as meandering, lifting, and breakage of the fiber bundles.

[0060] An auxiliary member may be embedded inside the fiber bundle. The movement of the fiber bundle can be restrained by the auxiliary member. As a result, disturbances such as meandering, floating, and breakage of the fiber bundle are suppressed.

[0061] The density of the arrangement of the auxiliary members in the extending direction of the fiber bundles may be set based on the radius of curvature of the fiber bundles when stacked, which allows the necessary amount of auxiliary members to be appropriately arranged around the fiber bundles to suppress disturbances such as meandering, lifting, and breakage of the fiber bundles.

[0062] The fiber bundles may be interface coated. This can prevent cracks in the matrix from propagating to the fibers, for example, when a structural material containing the fiber bundles is combined with a matrix to form a ceramic matrix composite. The interface coating layer may be a coating layer containing graphite or a coating layer containing boron nitride.

[0063] The structural material obtained by laminating the fiber bundles may be combined with a matrix material to form a ceramic matrix composite, which may be processed by at least one of chemical vapor infiltration, polymer impregnation and sintering, and melt impregnation.

[0064] As a result, the shape of the structural material contained in the composite material can be efficiently formed by laminating the fiber bundles, and the composite material can be efficiently formed. Also, the strength of various products made from the composite material can be improved.

[0065] According to the present disclosure, it is possible to improve the strength of various products made of composite materials, which can contribute to, for example, Goal 9 of the United Nations-led Sustainable Development Goals (SDGs), which is to "Build resilient infrastructure, promote inclusive and sustainable industrialization, and foster innovation."

[0066] Although several embodiments have been described, the embodiments can be modified or varied based on the above disclosure. All components of the above embodiments and all features described in the claims may be individually extracted and combined, unless they contradict each other.

[0067] The entire contents of Japanese Patent Application No. 2024-154901 (filing date: September 9, 2024) are incorporated herein by reference.

[0068] 10 Structural material FB Fiber bundle SF, SF2 Auxiliary member

Claims

1. A method for producing a composite material, comprising: placing an auxiliary member containing a resin on a fiber bundle containing a plurality of fibers; and stacking the fiber bundles while fixing the positions of the fiber bundles during stacking by thermal modification of the auxiliary member.

2. The method for producing a composite material according to claim 1, wherein the auxiliary member is in the form of a fiber or a film.

3. The method for producing a composite material according to claim 1, wherein the resin is a thermoplastic resin, and the auxiliary members are fused together to position the fiber bundles when stacked.

4. The method for producing a composite material according to claim 1, wherein the resin is a thermosetting resin, and the auxiliary member is cured after positioning of the fiber bundles during lamination.

5. The method for producing a composite material according to claim 1, wherein the auxiliary member is entangled with the fiber bundle.

6. The method for producing a composite material according to claim 1, wherein the auxiliary member is wound around the fiber bundle.

7. A method for producing a composite material as described in claim 6, wherein when at least two or more auxiliary members are wound around the fiber bundle, the direction in which one auxiliary member is wound is opposite to the direction in which the other auxiliary members are wound.

8. The method for manufacturing a composite material according to claim 1, wherein the auxiliary member surrounds the fiber bundles in a woven mesh structure.

9. The method for producing a composite material according to claim 1, wherein the fibers are bundled by a ring made of the auxiliary member.

10. The method for producing a composite material according to claim 1, wherein the auxiliary member is arranged along the outer peripheral surface of the fiber bundle.

11. The method for producing a composite material according to claim 1, wherein the auxiliary member is embedded inside the fiber bundle.

12. A method for producing a composite material according to claim 1, wherein the density of the arrangement of the auxiliary members in the direction in which the fiber bundles extend is set based on the radius of curvature of the fiber bundles when stacked.

13. The method for producing a composite material according to claim 1, wherein the fiber bundles are interface coated.

14. A method for producing a composite material according to any one of claims 1 to 13, wherein the structural material obtained by laminating the fiber bundles is combined with a base material to form a ceramic matrix composite material.

15. The method for producing a composite material according to claim 14, wherein the treatment is at least one of a chemical vapor infiltration method, a polymer impregnation and calcination method, and a melt impregnation method.

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