成果報告書詳細
管理番号20120000000720
タイトル*平成23年度中間年報 サステナブルハイパーコンポジット技術の開発
公開日2012/7/19
報告書年度2011 - 2011
委託先名国立大学法人東京大学 三菱レイヨン株式会社 東洋紡績株式会社 東レ株式会社 株式会社タカギセイコー
プロジェクト番号P08024
部署名電子・材料・ナノテクノロジー部
和文要約和文要約等以下本編抜粋:
1. 研究開発の内容及び成果等
研究開発項目1)「易加工性CFRTP中間基材の開発」
1)-1「等方性CFRTP中間基材」
1)-1-1「マトリックス樹脂の開発」
研究開発項目1)-1-2 と連動して樹脂を改質し、耐衝撃性に特化した材料を開発した。また、アロイ化により強度を15%向上させたマトリックス樹脂を開発した。
1)-1-2「熱可塑樹脂用の炭素繊維界面技術の開発」
研究開発項目1)-1-1 と連動し、界面特性を制御する事で、耐衝撃性に特化した材料を開発した。また、界面処理の程度と力学特性の関連性を定量化し、求める材料物性に応じて自在に界面処理を行なうための方針を定めた。
1)-1-3「繊維等方分散技術の開発」
均一分散を達成可能な繊維長および繊維目付けのスクリーニングを実施し、安定・均一分散する繊維長の範囲を特定した。
1)-1-4「中間基材化技術の開発」
ダブルベルトプレスによる含浸工程を精査し、生産性向上のためのボトルネックを精査した。ボトルネックは冷却工程およびベルトからの材料離形性であり、含浸には余力がある事が分かった。
1)-1-5「ミクロ構造解析」
長期耐久性の解析を深化し、等方性CFRTP 材料の疲労破壊メカニズムを明らかとした。等方性CFRTP 材料では疲労破壊でも繊維破断を伴うため、優れた疲労強度を示す事が分かった。
英文要約Title : Development of Sustainable Hyper Composite Materials Technology (FY2008-FY2012) FY2011 Annual Report
This project aims to reduce the energy consumption of automobiles and other vehicles and help to establish a recycling-oriented society by reducing the weight of such vehicles through the development of composite materials that are highly formable, processable and recyclable utilizing carbon fiber and thermoplastic resins. In FY2011, following four topics were performed.
[1] Development of high-processability CFRTP intermediate substrates
In the 4th fiscal year of this project, the development of several principle technologies applied to the new composite material composed of carbon fiber and thermoplastic resin, including highly-impregnation of thermoplastic resin, control of carbon fiber volume fraction and acid-treatment of thermoplastic resin, and so on, resulted in improvement of performance, variety and formability of the new material, CFRTP, and by applying such approaches to the new material, this project received vision of achievement for its final targets of bending strength in both cases of isotropic and unidirectional CFRTP.
[2] Development of molding technology
This project has developed high-speed-heating techniques, pre-forming techniques and mold-flow simulation technologies for press-molding process and internal-pressure-molding process. As a result, high-speed stamping was achieved so that the molding cycle time is approaching close to 1 minute and high-speed internal pressure molding was achieved so that its cycle time is 3-minutes. They mean that the molding processes are capable to be applied to high-volume production of automobiles. Furthermore, aiming to construct the database of molding conditions, we have investigated how complicated shapes are formed from the developed materials.
[3] Development of joining technology
Various joining methods were investigated, including ultrasonic-welding, vibrated-welding and mechanical fastening. In case of welding technologies, their interfacial shear strength on joint surfaces was found to be affected by the strength of the matrix and/or the interfacial shear strength between carbon fiber and matrix resin. Meanwhile, the fracture behavior of fastening joint of CFRTP was found to show the prospective aspects of the junction of CFRTP with metal.
[4] Development of recycling technology
This project aims to conduct R&D for the improvement of 3R technologies in the life cycle by making use of the properties of the developed CFRTP. The recycling efficiency was investigated by means of comparing the mechanical properties of specimens re-formed by using crushed pieces or offcuts of CFRTP obtained from timber offcuts at molding and virgin specimens. And then, some advanced methods for improving the performance of recycled materials were demonstrated. As for repairing techniques, some basic mechanisms of strengthening broken specimen were shown by means of simple repair design and equipment.
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