阅读说明：本技术 碳纤维片材、预浸料、成型体、碳纤维片材的制造方法、预浸料的制造方法以及成型体的制造方法 (Carbon fiber sheet, prepreg, molded body, method for producing carbon fiber sheet, method for producing prepreg, and method for producing molded body ) 是由 近藤彻 于 2019-08-23 设计创作，主要内容包括：本发明的碳纤维片材为包括多根碳纤维与结合所述碳纤维的粘合剂的碳纤维片材,其特征在于,作为所述碳纤维,包括作为原始的碳纤维的第一碳纤维与作为回收再利用的碳纤维的第二碳纤维。当所述第一碳纤维的平均长度为L-(VCF)[mm],所述第二碳纤维的平均长度为L-(RCF)[mm]时,优选满足1.1≤L-(VCF)/L-(RCF)≤30的关系。(The carbon fiber sheet of the present invention is a carbon fiber sheet including a plurality of carbon fibers and a binder for binding the carbon fibers, and is characterized in that the carbon fibers include first carbon fibers as virgin carbon fibers and second carbon fibers as recycled carbon fibers. When the average length of the first carbon fiber is L VCF [mm]The second carbon fiber has an average length L RCF [mm]When it is preferable that 1.1. ltoreq.L is satisfied VCF /L RCF The relationship is less than or equal to 30.)

1. A carbon fiber sheet comprising a plurality of carbon fibers and a binder for binding the carbon fibers, characterized in that the carbon fibers include a first carbon fiber as a virgin carbon fiber and a second carbon fiber as a recycled carbon fiber.

2. The carbon fiber sheet according to claim 1, wherein an average length of the second carbon fibers is shorter than an average length of the first carbon fibers.

3. The carbon fiber sheet according to claim 2, wherein when the average length of the first carbon fibers is L_VCF[mm]The second carbon fiber has an average length L_RCF[mm]When it is 1.1. ltoreq. L_VCF/L_RCFThe relationship is less than or equal to 30.

4. The carbon fiber sheet according to any one of claims 1 to 3, wherein the second carbon fibers have an average length of 1.0mm or more and 10mm or less.

5. The carbon fiber sheet according to any one of claims 1 to 4, wherein when the content ratio of the first carbon fibers is X_VCF[ mass% ]]The content of the second carbon fiber is X_RCF[ mass% ]]When it is not less than 0.006X_VCF/X_RCFThe relation of less than or equal to 1.0.

6. The carbon fiber sheet according to any one of claims 1 to 5, wherein the second carbon fibers have an organic component derived from a recycled raw material of the second carbon fibers and/or a carbide of the organic component as an adherent substance adhered to the surface thereof.

7. The carbon fiber sheet according to claim 6, wherein a coverage of the surface of the second carbon fiber with the attached matter is 2% or more and 40% or less.

8. The carbon fiber sheet according to claim 6 or 7, comprising a bundle body obtained by combining a plurality of the second carbon fibers by the attachment and forming a bundle shape.

9. The carbon fiber sheet according to claim 8, wherein an aspect ratio, which is a ratio of a length to a width of the bundle, is 2 or more and 500 or less.

10. A prepreg produced by impregnating the carbon fiber sheet according to any one of claims 1 to 9 with a resin material.

11. A prepreg comprising a plurality of carbon fibers, a plurality of resin fibers, and a binder for binding the carbon fibers and the resin fibers, characterized in that the carbon fibers include first carbon fibers as virgin carbon fibers and second carbon fibers as recycled carbon fibers.

12. The prepreg according to claim 11, wherein an average length of the resin fiber is 2.0mm or more and 20mm or less.

13. The prepreg according to claim 11 or 12, wherein when the content of the carbon fiber is X_CF[ mass% ]]The content of the resin fiber is X_RF[ mass% ]]When, X is 0.30. ltoreq_CF/X_RFRelationship ≦ 28.

14. A prepreg according to any one of claims 11 to 13, wherein when the average length of the carbon fibres is L_CF[mm]The average length of the resin fiber is L_RF[mm]When it is 0.10. ltoreq. L_RF/L_CFA relationship of ≦ 18.

15. A prepreg according to any one of claims 11 to 14, wherein the average length of the second carbon fibres is shorter than the average length of the first carbon fibres.

16. The prepreg of claim 15, wherein when the first carbon fibers have an average length L_VCF[mm]The second carbon fiber has an average length L_RCF[mm]When it is 1.1. ltoreq. L_VCF/L_RCFThe relationship is less than or equal to 30.

17. The prepreg according to any one of claims 11 to 16, wherein an average length of the second carbon fibers is 1.0mm or more and 10mm or less.

18. The prepreg according to any one of claims 11 to 17, wherein when the content ratio of the first carbon fibers is X_VCF[ mass% ]]The content of the second carbon fiber is X_RCF[ mass% ]]When it is not less than 0.006X_VCF/X_RCFThe relation of less than or equal to 1.0.

19. The prepreg according to any one of claims 11 to 18, wherein an organic component derived from a recycled raw material of the second carbon fiber and/or a carbide of the organic component is attached as an attached matter to a surface of the second carbon fiber.

20. The prepreg according to claim 19, wherein a coverage of the surface of the second carbon fiber with the attachment is 2% or more and 40% or less.

21. The prepreg according to claim 19 or 20, which comprises a bundle obtained by bonding a plurality of the second carbon fibers by the attachment and forming a bundle.

22. The prepreg according to claim 21, wherein an aspect ratio which is a ratio of a length to a width of the bundle is 2 or more and 500 or less.

23. A molded body characterized by being produced by subjecting the prepreg according to any one of claims 10 to 22 to heat and pressure molding.

24. A method for producing a carbon fiber sheet, characterized by comprising the steps of: first carbon fibers as virgin carbon fibers, second carbon fibers as recycled carbon fibers, and a binder that binds the first carbon fibers and the second carbon fibers are mixed.

25. A method for producing a prepreg, comprising the steps of: a carbon fiber sheet produced by the method according to claim 24, wherein the carbon fiber sheet is impregnated with a resin material.

26. A method for producing a prepreg, comprising the steps of: a first carbon fiber as a virgin carbon fiber, a second carbon fiber as a recycled carbon fiber, a resin fiber, and a binder that binds the first carbon fiber, the second carbon fiber, and the resin fiber are mixed.

27. A method for producing a molded article, comprising the steps of: a prepreg manufactured by the method of claim 25 or 26 is subjected to heat and pressure molding.

Technical Field

The present invention relates to a carbon fiber sheet, a prepreg, a molded body, a method for producing a carbon fiber sheet, a method for producing a prepreg, and a method for producing a molded body.

Background

Fiber-reinforced sheets and fiber-reinforced resin molded articles using the same are used in various fields such as vehicles and aircrafts. In particular, in the case of Fiber Reinforced Plastics (FRP), since the plastic is reinforced by the embedded reinforcing fiber, it is possible to achieve excellent strength which cannot be achieved by the plastic alone at all.

Among them, Carbon Fiber Reinforced Plastics (Carbon Fiber Reinforced Plastics: CFRP) using Carbon fibers having particularly excellent physical properties have been attracting attention (see patent document 1).

In the conventional CFRP, in order to effectively utilize the excellent physical properties of carbon fibers, there are many cases where long carbon fibers are used and carbon fibers are used as a fabric.

However, such CFRP has a problem of poor moldability when a molded article having a predetermined three-dimensional structure is produced from a sheet such as a prepreg. In addition, the following problems are present in the produced molded article: for example, a region where many carbon fibers are exposed and a region where the amount of exposed carbon fibers is small and many resin materials are exposed may be present in the vicinity of the surface of the molded body, and thus local strength may be lowered.

In addition, from the viewpoint of effective utilization of resources, it is required to recover and reuse carbon fibers.

However, conventionally, there has been a problem that satisfactory strength and reliability cannot be obtained in the case of using recycled carbon fibers.

Documents of the prior art

Patent document

Patent document 1: japanese patent laid-open publication No. 2014-077209

Disclosure of Invention

(problems to be solved by the invention)

The purpose of the present invention is to provide a molded body having excellent strength and reliability; provided is a prepreg which can be used for producing a molded body having excellent strength and reliability with excellent moldability; provided is a carbon fiber sheet which has excellent strength and reliability and can be used for producing a molded body having excellent strength and reliability with excellent moldability; and to provide a manufacturing method capable of stably manufacturing these.

(means for solving the problems)

This object is achieved by the present invention described in the following (1) to (27).

(1) A carbon fiber sheet comprising a plurality of carbon fibers and a binder for binding the carbon fibers, characterized in that the carbon fibers include a first carbon fiber as a virgin carbon fiber and a second carbon fiber as a recycled carbon fiber.

(2) The carbon fiber sheet according to the above (1), wherein an average length of the second carbon fibers is shorter than an average length of the first carbon fibers.

(3) The carbon fiber sheet according to item (2) above, wherein when the average length of the first carbon fibers is L_VCF[mm]The second carbon fiber has an average length L_RCF[mm]When the number is 1, the number is 1.1≤L_VCF/L_RCFThe relationship is less than or equal to 30.

(4) The carbon fiber sheet according to any one of (1) to (3), wherein the second carbon fibers have an average length of 1.0mm or more and 10mm or less.

(5) The carbon fiber sheet according to any one of the above (1) to (4), wherein when the content of the first carbon fibers is X_VCF[ mass% ]]The content of the second carbon fiber is X_RCF[ mass% ]]When it is not less than 0.006X_VCF/X_RCFThe relation of less than or equal to 1.0.

(6) The carbon fiber sheet according to any one of (1) to (5) above, wherein the second carbon fibers have an organic component derived from a recycled raw material of the second carbon fibers and/or a carbide of the organic component as an adherent substance adhered to the surfaces thereof.

(7) The carbon fiber sheet according to item (6) above, wherein a coating rate of the deposit on the surface of the second carbon fibers is 2% or more and 40% or less.

(8) The carbon fiber sheet according to the above (6) or (7), which comprises a bundle body obtained by binding the plurality of second carbon fibers with the attached matter to form a bundle.

(9) The carbon fiber sheet according to item (8) above, wherein an aspect ratio, which is a ratio of a length to a width of the bundle, is 2 to 500.

(10) A prepreg produced by impregnating a carbon fiber sheet described in any one of (1) to (9) above with a resin material.

(11) A prepreg comprising a plurality of carbon fibers, a plurality of resin fibers, and a binder for binding the carbon fibers and the resin fibers, characterized in that the carbon fibers include first carbon fibers as virgin carbon fibers and second carbon fibers as recycled carbon fibers.

(12) The prepreg according to the above (11), wherein the resin fibers have an average length of 2.0mm to 20 mm.

(13) The prepreg according to the above (11) or (12), whereinWhen the content of the carbon fiber is X_CF[ mass% ]]The content of the resin fiber is X_RF[ mass% ]]When, X is 0.30. ltoreq_CF/X_RFRelationship ≦ 28.

(14) The prepreg according to any one of (11) to (13) above, wherein when the average length of the carbon fibers is L_CF[mm]The average length of the resin fiber is L_RF[mm]When it is 0.10. ltoreq. L_RF/L_CFA relationship of ≦ 18.

(15) The prepreg according to any one of (11) to (14) above, wherein an average length of the second carbon fibers is shorter than an average length of the first carbon fibers.

(16) The prepreg according to the above (15), wherein when the average length of the first carbon fibers is L_VCF[mm]The second carbon fiber has an average length L_RCF[mm]When it is 1.1. ltoreq. L_VCF/L_RCFThe relationship is less than or equal to 30.

(17) The prepreg according to any one of (11) to (16) above, wherein the second carbon fibers have an average length of 1.0mm or more and 10mm or less.

(18) The prepreg according to any one of (11) to (17) above, wherein the content of the first carbon fibers is X_VCF[ mass% ]]The content of the second carbon fiber is X_RCF[ mass% ]]When it is not less than 0.006X_VCF/X_RCFThe relation of less than or equal to 1.0.

(19) The prepreg according to any one of (11) to (18) above, wherein the second carbon fibers have an organic component derived from a recycled raw material of the second carbon fibers and/or a carbide of the organic component as an adherent substance adhered to the surfaces thereof.

(20) The prepreg according to the above (19), wherein a coverage of the surface of the second carbon fibers with the deposit is 2% or more and 40% or less.

(21) The prepreg according to the above (19) or (20), which comprises a bundle body obtained by bonding a plurality of the second carbon fibers by the attachment and forming a bundle shape.

(22) The prepreg according to the above (21), wherein an aspect ratio, which is a ratio of a length to a width of the bundle, is 2 to 500.

(23) A molded article produced by subjecting the prepreg according to any one of the above (10) to (22) to heat and pressure molding.

(24) A method for producing a carbon fiber sheet, characterized by comprising a step of mixing first carbon fibers as virgin carbon fibers, second carbon fibers as recycled carbon fibers, and a binder for bonding the first carbon fibers and the second carbon fibers.

(25) A method for producing a prepreg, which comprises a step of impregnating a carbon fiber sheet produced by the method described in (24) above with a resin material.

(26) A method for producing a prepreg, comprising a step of mixing first carbon fibers as virgin carbon fibers, second carbon fibers as recycled carbon fibers, resin fibers, and a binder for bonding the first carbon fibers, the second carbon fibers, and the resin fibers.

(27) A method for producing a molded article, which comprises the step of subjecting a prepreg produced by the method of (25) or (26) to heat-pressure molding.

(Effect of the invention)

According to the present invention, a molded body excellent in strength and reliability can be provided; a prepreg which can be used for producing a molded body having excellent strength and reliability with excellent moldability; a carbon fiber sheet which is excellent in strength and reliability and can be used for producing a molded article excellent in strength and reliability with excellent moldability; further, a manufacturing method capable of stably manufacturing these can be provided.

Drawings

Fig. 1 is a plan view schematically showing a preferred embodiment of the carbon fiber sheet of the present invention.

Fig. 2 is a longitudinal sectional view schematically showing a preferred embodiment of the carbon fiber sheet of the present invention.

Fig. 3 is a plan view schematically showing a first embodiment of the prepreg of the present invention.

Fig. 4 is a plan view schematically showing a second embodiment of the prepreg of the present invention.

Description of the reference numerals

100 … carbon fiber sheet

200 … prepreg

1 … carbon fiber

11 … first carbon fiber

12 … second carbon fiber

2 … attachment

10 … bundle body

20 … adhesive

30 … resin Material (impregnated resin)

40 … resin fibers.

Detailed Description

Hereinafter, preferred embodiments of the present invention will be described in detail.

In the following description, the same names and symbols denote the same or homogeneous members, and detailed description thereof will be omitted as appropriate. In the present specification, the term "sheet" is used in the following sense: the sheet material may be in the form of a laminate, a mat, or a block, which is obtained by laminating a plurality of single sheet materials.

[ carbon fiber sheet ]

First, the carbon fiber sheet of the present invention will be explained.

Fig. 1 is a plan view schematically showing a preferred embodiment of the carbon fiber sheet of the present invention, and fig. 2 is a longitudinal sectional view schematically showing a preferred embodiment of the carbon fiber sheet of the present invention. In fig. 2, the attached matter 2 and the adhesive 20 are not shown.

The carbon fiber sheet 100 includes a plurality of carbon fibers 1 and a binder 20 that binds the carbon fibers 1. The carbon fibers 1 include first carbon fibers 11 as virgin carbon fibers and second carbon fibers 12 as recycled carbon fibers.

With such a configuration, the carbon fiber sheet 100 having excellent strength and reliability can be provided. In addition, such a carbon fiber sheet 100 can be suitably used for producing a molded body having excellent strength and reliability with excellent moldability.

As described in more detail below. That is, by including the first carbon fibers 11 as virgin carbon fibers that are less likely to suffer quality degradation or the like and have higher quality, the strength and reliability of the carbon fiber sheet 100 as a whole can be made excellent, and the strength of a molded body manufactured using the carbon fiber sheet 100 can also be made excellent. In addition, the recycled carbon fibers are generally excellent in affinity with resin materials such as binders, and therefore, the carbon fiber sheet can be made excellent in processability and moldability as compared with the case of using virgin carbon fibers, and moreover, occurrence of defects in molded articles produced using the carbon fiber sheet can be appropriately prevented, and the reliability of the molded articles can be made excellent. Further, since molding defects are less likely to occur, the method can be suitably applied to the production of a molded article having a microstructure or a molded article having a portion with a small radius of curvature. In addition, in the recovered and reused carbon fibers, in general, the broken portions formed during recovery and reuse are likely to be in a relatively rough state, and entanglement, hooking, and the like between the fibers are likely to occur, and the adhesion to the resin material such as the binder 20 is likely to be excellent. Further, the recovered and reused carbon fibers can be appropriately controlled in accordance with the recovery and reuse conditions, such as the amount of adhesion (coverage) of the adherent 2, the constituent material, and the formation of the bundle 10 having a predetermined shape, which will be described later, and thus the quality of the carbon fiber sheet 100, the molded article, and the like can be stabilized and the quality of the carbon fiber sheet 100, the molded article, and the like can be easily improved.

In addition, since excellent moldability is obtained in the production of the molded article, the production conditions (e.g., temperature, pressure, etc.) of the molded article can be relaxed. Therefore, it is possible to use a device having a simple structure as a manufacturing device, and to suppress a load on the manufacturing device and to extend the life of the manufacturing device. In addition, it is also advantageous from the viewpoint of suppressing the production cost of the molded article.

In addition, since the excellent moldability can be maintained even if the content of the carbon fibers is increased, the content of the resin material can be reduced, and the excellent properties (for example, strength, thermal conductivity, and electrical conductivity) of the carbon fibers can be more effectively exhibited in the molded article.

Further, the use of the second carbon fibers 12 that are recovered and reused is also preferable from the viewpoints of resource saving, reduction in environmental load, and the like.

In contrast, if the conditions described above are not satisfied, the excellent effects described above cannot be obtained.

For example, in the case of using only virgin carbon fibers without using recycled carbon fibers as carbon fibers, it is difficult to sufficiently excel the adhesion between the carbon fibers and a resin material such as a binder, and it is also difficult to sufficiently excel the moldability of a carbon fiber sheet and a prepreg manufactured using the carbon fiber sheet, and the reliability of the carbon fiber sheet and a molded article manufactured using the carbon fiber sheet, and the like.

In addition, when only recycled carbon fibers are used without using virgin carbon fibers as carbon fibers, it is difficult to sufficiently improve the strength of a carbon fiber sheet, a molded article produced using the carbon fiber sheet, and the like.

(first carbon fiber)

As described above, the carbon fiber sheet 100 includes the original carbon fiber (first carbon fiber 11) as the carbon fiber 1.

By including the first carbon fibers 11 as the original carbon fibers that are less likely to suffer quality degradation or the like and have higher quality, the strength and reliability of the carbon fiber sheet 100 as a whole can be made excellent, and the strength of a molded body manufactured using the carbon fiber sheet 100 can also be made excellent.

Further, by including the first carbon fibers 11 (virgin carbon fibers) together with the second carbon fibers 12 (recycled carbon fibers) described later in detail, for example, the ratio of the bundled body obtained by combining a plurality of carbon fibers into a bundle shape to the carbon fibers not bundled, and the distribution of the lengths of the carbon fibers can be appropriately adjusted as compared with the case of not using virgin carbon fibers. As a result, the properties of the carbon fiber sheet 100 and the molded body can be appropriately controlled.

The average length of the first carbon fibers 11 (the average length of the first carbon fibers 11 included in the prepreg 200 and the molded body described later is the same) is preferably 1.5mm to 30mm, more preferably 2.0mm to 20mm, and further preferably 4.0mm to 16 mm.

This can further improve the strength of the carbon fiber sheet 100, the molded article, and the like, can effectively prevent a defect or the like during molding, and can further improve the reliability of the carbon fiber sheet 100, the molded article, and the like.

In the present invention, as the average length of the fibers, for example, 100 randomly selected fibers included in the field of view observed by a microscope may be randomly extracted, and the average of the lengths of these fibers may be used. In addition, when 100 fibers are not included in one field, a total of 100 fibers may be randomly extracted in a plurality of different fields, and the average of the lengths of these fibers may be used as the average length.

The average width of the first carbon fibers 11 (the average width of the first carbon fibers 11 included in the prepreg 200 and the molded body described later is also the same) is preferably 1.0 μm to 20 μm, more preferably 2.0 μm to 18 μm, and further preferably 3.0 μm to 15 μm.

This can sufficiently improve the strength of the carbon fiber sheet 100, the molded body, and the like, and can particularly improve the processability and moldability of the carbon fiber sheet 100 and the like. In addition, it is possible to more effectively prevent the occurrence of undesirable irregularities on the surfaces of the carbon fiber sheet 100, the molded body, and the like.

In the present specification, as the average width of the fibers, for example, 100 randomly selected fibers included in the field of view observed by a microscope may be randomly extracted, and the average value of the widths of these fibers may be used. In addition, when 100 fibers are not included in one field of view, a total of 100 fibers may be randomly extracted in a plurality of different fields of view, and the average value of the widths of these fibers may be used as the average width.

The content of the first carbon fibers 11 in the carbon fiber sheet 100 is preferably 0.5 mass% or more and 40 mass% or less, more preferably 1.0 mass% or more and 30 mass% or less, and further preferably 1.5 mass% or more and 20 mass% or less.

By satisfying such a condition, the effect (synergistic effect) of the first carbon fibers 11 and the second carbon fibers 12 being present together can be more remarkably exhibited.

Further, as the first carbon fibers 11, a plurality of kinds of carbon fibers manufactured under different conditions may be used.

(second carbon fiber)

As described above, the carbon fiber sheet 100 includes recycled carbon fibers (second carbon fibers 12) as the carbon fibers 1.

The average length of the second carbon fibers 12 is not particularly limited, and is preferably shorter than the average length of the first carbon fibers 11.

This can further improve the moldability of the carbon fiber sheet 100, the prepreg, and the like. In addition, the occurrence of defects at the time of molding (for example, a local strength decrease due to an unexpected variation in the distribution of the fibers and the resin material, a defective appearance, and the like) can be more effectively prevented. Further, since molding defects are less likely to occur, the method can be more suitably applied to the production of molded articles having a fine structure and molded articles having a portion with a small radius of curvature.

When the average length of the first carbon fibers 11 is L_VCF[mm]The second carbon fibers 12 have an average length L_RCF[mm]When it is preferable that 1.1. ltoreq.L is satisfied_VCF/L_RCFA relationship of 30 or less, more preferably 1.3 or less L_VCF/L_RCFA relationship of not more than 12, more preferably 1.8 not more than L_VCF/L_RCFThe relation of less than or equal to 7.0.

This can provide the above-described effects more remarkably, and can further improve the strength of the carbon fiber sheet 100, the molded body, and the like.

Specific values of the average length of the second carbon fibers 12 (the average length of the second carbon fibers 12 included in the prepreg 200 and the molded body described later is also the same) are not particularly limited, but are preferably 1.0mm to 10mm, more preferably 1.5mm to 9.0mm, and further preferably 2.0mm to 8.0 mm.

This can provide the carbon fiber sheet 100, the molded body, and the like with more excellent strength while more remarkably exhibiting the above-described effects. In addition, even when subjected to heat history, internal stress is hard to accumulate, dimensional accuracy can be made excellent, and undesired deformation or the like is hard to occur when the molded article is used.

The average width of the second carbon fibers 12 (the same applies to the average width of the second carbon fibers 12 included in the prepreg 200 and the molded body described later) is preferably 1.0 μm to 20 μm, more preferably 2.0 μm to 18 μm, and still more preferably 3.0 μm to 15 μm.

This can sufficiently improve the strength of the carbon fiber sheet 100, the molded body, and the like, and can particularly improve the processability and moldability of the carbon fiber sheet 100 and the like. In addition, it is possible to more effectively prevent the occurrence of undesirable irregularities on the surfaces of the carbon fiber sheet 100, the molded body, and the like.

The second Carbon fibers 12 may be recycled, and are preferably Carbon fibers recycled from Carbon Fiber Reinforced Plastics (CFRP).

The CFRP generally uses high-quality carbon fibers, and the second carbon fibers 12 recovered and reused by the CFRP can further improve the quality of the carbon fiber sheet 100, the molded body, and the like. Further, by using CFRP as a raw material for recycling, the formation of the bundles 10, the composition of the deposits 2, the amount of deposits, and the like, which will be described later, can be controlled more appropriately.

The second carbon fibers 12 can be recovered and reused by any method, and can be obtained by, for example, subjecting a crushed and pulverized recovered and reused raw material to heat treatment.

The conditions of the heat treatment performed on the recovered and reused raw material are not particularly limited, and for example, the second carbon fibers 12 satisfying the above conditions can be suitably obtained by performing a first heat treatment (heat treatment mainly aimed at thermal decomposition of the resin material) at a temperature of 300 ℃ to 400 ℃ in an air atmosphere and a second heat treatment (heat treatment mainly aimed at removal of the carbonized residue) at a temperature of 400 ℃ to 600 ℃ in an air atmosphere.

Further, as the second carbon fibers 12, a plurality of kinds of carbon fibers recovered and reused under different conditions may be used.

In the present embodiment, the organic component derived from the recycled raw material (for example, CFRP or the like) of the second carbon fibers 12 and/or the carbide of the organic component is attached to the surfaces of the second carbon fibers 12 as the attachments 2.

In general, such a deposit 2 has excellent adhesion to carbon fibers as compared with a deposit deposited on virgin carbon fibers as a post-treatment. The attached matter 2 has excellent affinity with the binder 20, the resin material (impregnated resin) 30, and the like. Therefore, it is advantageous to further improve the strength and reliability of the carbon fiber sheet 100, the molded body, and the like. Further, since the deposit 2 adheres to the surface of the second carbon fibers 12, the bundle 10 described later can be formed more appropriately, and the strength and stability of the bundle 10 can be further improved.

Examples of the organic component include a sizing agent and a matrix resin.

The coverage of the surface of the second carbon fibers 12 with the deposit 2 (the same applies to the coverage of the surface of the second carbon fibers 12 included in the prepreg 200 and the molded article described later with the deposit 2) is not particularly limited, but is preferably 2% to 40%, more preferably 4% to 30%, and still more preferably 6% to 20%.

This can further improve the strength and reliability of the carbon fiber sheet 100 and the molded body.

In addition, the present embodiment includes a bundle 10 obtained by bonding a plurality of second carbon fibers 12 into a bundle.

This can further improve the strength and reliability of the carbon fiber sheet 100 and the molded body.

Specifically, in the present embodiment, a bundle body 10 obtained by combining a plurality of second carbon fibers 12 into a bundle by the attachments 2 is included.

This can improve the strength and stability of the bundle 10 itself, and can further improve the strength and reliability of the carbon fiber sheet 100 and the molded body.

The aspect ratio (the same applies to the prepregs 200 and the bundles 10 included in the molded body described later) which is the ratio (L/W) of the length L to the width W of the bundles 10 is preferably 2 to 500, more preferably 10 to 450, and further preferably 20 to 400.

By satisfying such conditions, the carbon fiber sheet 100 and the molded article can be further improved in strength and reliability while the moldability (processability such as bending) and the like at the time of production of the molded article are further improved.

When the carbon fiber sheet 100 (the same applies to the prepreg 200 and the molded body described later) includes a plurality of bundles 10, the average value of the aspect ratios of the plurality of bundles 10 preferably satisfies the aforementioned condition.

Further, as for the average value of the aspect ratio, for example, the following average value may be adopted: 100 randomly selected bundles 10 included in the field of view observed by the microscope are randomly extracted, the aspect ratios of the bundles 10 are obtained, and the average value of the aspect ratios in this case is calculated. In addition, when 100 beam-shaped bodies are not included in one field of view, a total of 100 beam-shaped bodies 10 may be randomly extracted in a plurality of different fields of view, and an average value of aspect ratios of the beam-shaped bodies 10 may be used.

In the illustrated configuration, the carbon fiber sheet 100 (the same applies to the prepreg 200 and the molded body described later) includes the second carbon fibers 12 that do not form the bundle 10 in addition to the second carbon fibers 12 that form the bundle 10.

This makes it possible to achieve both excellent strength and ease of handling (including moldability) at a higher level.

When in the carbon fiber sheet 100The content of the first carbon fibers 11 is X_VCF[ mass% ]]The content of the second carbon fibers 12 is X_RCF[ mass% ]]When it is used, it is preferable that X is 0.006. ltoreq._VCF/X_RCFA relationship of not more than 1.0, more preferably 0.015 not more than X_VCF/X_RCFA relationship of 0.60 or less, more preferably 0.020 or less and X_VCF/X_RCFThe relation of less than or equal to 0.33.

By satisfying such a condition, the effect (synergistic effect) of the first carbon fibers 11 and the second carbon fibers 12 being present together can be more remarkably exhibited.

The content of the second carbon fibers 12 in the carbon fiber sheet 100 is preferably 40 mass% or more and 99 mass% or less, more preferably 50 mass% or more and 98 mass% or less, and further preferably 60 mass% or more and 97 mass% or less.

By satisfying such a condition, the effect (synergistic effect) of the first carbon fibers 11 and the second carbon fibers 12 being present together can be more remarkably exhibited.

The content of the carbon fibers 1 in the carbon fiber sheet 100 (the sum of the content of the first carbon fibers 11 and the content of the second carbon fibers 12) is preferably 50 mass% or more and 99.5 mass% or less, more preferably 54 mass% or more and 99 mass% or less, and still more preferably 63 mass% or more and 98.5 mass% or less.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more effectively exhibited, and the strength, reliability, and the like of the carbon fiber sheet 100 and the molded body can be further improved.

(Binder)

The binder 20 has a function of binding the carbon fibers 1 (the first carbon fibers 11 and the second carbon fibers 12). In addition, in the case where the binder 20 remains in the molded body produced using the carbon fiber sheet 100, the binder 20 may constitute a part of the matrix resin in the molded body.

The binder 20 may directly bond the carbon fibers 1, or may bond the carbon fibers 1 to each other via another component (for example, the attached matter 2 and another component described later).

Examples of the binder 20 include polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polylactic acid; polyolefins such as polyethylene and polypropylene; polyamides such as nylon 6 and nylon 6, 6; examples of the thermosetting resin include thermoplastic resins such as polyvinyl alcohol (PVA), polyvinyl acetate, polyphenylene sulfide, polyether ketone, polycarbonate, and phenoxy resin, thermosetting resins such as epoxy resin, phenol resin, melamine resin, and unsaturated polyester resin, copolymers thereof, modified resins thereof, and polymer alloys thereof.

Among them, the binder 20 is preferably polyvinyl alcohol.

This allows the binder 20 to more appropriately bind and fix the carbon fibers 1 to each other, and to impart appropriate drapability (ドレープ property) to the carbon fiber sheet 100.

The content of the binder 20 in the carbon fiber sheet 100 is preferably 0.5 mass% to 50 mass%, more preferably 1.0 mass% to 45 mass%, and still more preferably 1.5 mass% to 35 mass%.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more effectively exhibited, and the strength, reliability, and the like of the carbon fiber sheet 100 and the molded body can be further improved.

(other Components)

The carbon fiber sheet 100 may include components (other components) other than the foregoing.

Examples of such components include plasticizers, colorants, antioxidants, ultraviolet absorbers, light stabilizers, softeners, modifiers, rust inhibitors, fillers, surface lubricants, corrosion inhibitors, heat stabilizers, lubricants, primers, antistatic agents, polymerization inhibitors, crosslinking agents, catalysts, leveling agents, thickening agents, dispersants, aging inhibitors, flame retardants, hydrolysis inhibitors, corrosion inhibitors, carbon nanotubes, carbon nanofibers, cellulose nanofibers, fullerenes, and graphite.

The thickness of the carbon fiber sheet 100 is not particularly limited, but is preferably 0.15mm to 2.5mm, more preferably 0.20mm to 2.0mm, and further preferably 0.25mm to 1.5 mm.

This can further improve the ease of handling the carbon fiber sheet 100, the ease of producing the prepreg 200 and the like, and the moldability in forming a molded body.

The application of the carbon fiber sheet 100 is not particularly limited, and for example, the carbon fiber sheet can be used for the production of a prepreg and a molded article described later, or can be used as a heat sink, a fin, a conductive sheet, an electromagnetic wave shielding material, an electrode material, and the like.

[ prepreg ]

Next, the prepreg of the present invention will be explained.

The prepreg of the present invention is a sheet-like member that can be used for producing a molded body having a predetermined shape by heat and pressure molding, and includes first carbon fibers as virgin carbon fibers, second carbon fibers as recycled carbon fibers, and a resin material. The resin material may be any of a thermoplastic resin and a thermosetting resin. In the present invention, the concept of the prepreg also includes a semi-prepreg which is not completely impregnated with a resin material.

< first embodiment >

Fig. 3 is a plan view schematically showing a first embodiment of the prepreg of the present invention.

The prepreg 200 of the present embodiment is produced by impregnating the carbon fiber sheet 100 with a resin material (impregnated resin) 30.

This makes it possible to provide a prepreg 200 that can be used to produce a molded body having excellent strength and reliability with excellent moldability.

In addition, since excellent moldability can be obtained in the production of the molded article, the production conditions (e.g., temperature, pressure, etc.) of the molded article can be relaxed. Therefore, it is possible to use a device having a simple structure as a manufacturing device, and to suppress a load on the manufacturing device and to extend the life of the manufacturing device. In addition, it is also advantageous from the viewpoint of suppressing the production cost of the molded article.

In addition, since the excellent moldability can be maintained even if the content of the carbon fibers is increased, the content of the resin material can be reduced, and the excellent properties (for example, strength, thermal conductivity, and electrical conductivity) of the carbon fibers can be more effectively exhibited in the molded article.

Further, the use of the second carbon fibers 12 that are recovered and reused is also preferable from the viewpoints of resource saving, reduction in environmental load, and the like.

The resin material (impregnated resin) 30 constitutes a matrix resin in the molded body.

Examples of the resin material (resin-impregnated) 30 include polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polylactic acid; polyolefins such as polyethylene and polypropylene; polyamides such as nylon 6 and nylon 6, 6; examples of the thermosetting resin include thermoplastic resins such as polyvinyl alcohol (PVA), polyvinyl acetate, polyphenylene sulfide, polyether ketone, polycarbonate, and phenoxy resin, thermosetting resins such as epoxy resin, phenol resin, melamine resin, and unsaturated polyester resin, copolymers thereof, modified resins thereof, and polymer alloys thereof.

Among them, the resin material (impregnated resin) 30 is preferably a thermosetting resin.

This makes it possible to obtain a molded article having particularly excellent strength, durability, and the like.

The content of the resin material (impregnated resin) 30 in the prepreg 200 is preferably 3.0 mass% or more and 70 mass% or less, more preferably 4.0 mass% or more and 68 mass% or less, and further preferably 5.0 mass% or more and 65 mass% or less.

By satisfying such conditions, the strength and reliability of the molded article produced using the prepreg 200 can be sufficiently improved, and the moldability in producing the molded article can be further improved.

The content of the carbon fibers 1 in the prepreg 200 (the sum of the content of the first carbon fibers 11 and the content of the second carbon fibers 12) is preferably 16 mass% to 96 mass%, more preferably 17.5 mass% to 95 mass%, and still more preferably 23 mass% to 93 mass%.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more effectively exhibited, and the molded body produced using the prepreg 200 can be made sufficiently excellent in strength and reliability, and excellent in moldability in producing the molded body.

When the content of the carbon fibers 1 in the prepreg 200 (the sum of the content of the first carbon fibers 11 and the content of the second carbon fibers 12) is X_CF[ mass% ]]The content of the resin material (impregnated resin) 30 in the prepreg 200 is X_IR[ mass% ]]When it is preferable that X is 0.035. ltoreq._IR/X_CFA relationship of not more than 4.3, more preferably 0.045 not more than X_IR/X_CFA relationship of not more than 3.8, and more preferably satisfies 0.055 not more than X_IR/X_CFA relation less than or equal to 2.8.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more effectively exhibited, and the molded body produced using the prepreg 200 can be made sufficiently excellent in strength and reliability and also excellent in moldability in producing the molded body.

The prepreg 200 may include components (other components) other than the foregoing ones.

Examples of such components include plasticizers, colorants, antioxidants, ultraviolet absorbers, light stabilizers, softeners, modifiers, rust inhibitors, fillers, surface lubricants, corrosion inhibitors, heat stabilizers, lubricants, primers, antistatic agents, polymerization inhibitors, crosslinking agents, catalysts, leveling agents, thickening agents, dispersants, aging inhibitors, flame retardants, hydrolysis inhibitors, corrosion inhibitors, carbon nanotubes, carbon nanofibers, cellulose nanofibers, fullerenes, and graphite.

The thickness of the prepreg 200 is not particularly limited, but is preferably 0.15mm to 2.5mm, more preferably 0.20mm to 2.0mm, and still more preferably 0.25mm to 1.5 mm.

This can further improve the ease of handling the prepreg 200, the ease of production, and the moldability in the case of forming a molded article.

< second embodiment >

Fig. 4 is a plan view schematically showing a second embodiment of the prepreg of the present invention. In the following description, the differences from the above-described embodiments will be emphasized, and descriptions of the same matters will be omitted.

The prepreg 200 of the present embodiment includes a plurality of carbon fibers 1, a plurality of resin fibers 40, and a binder 20 that bonds the carbon fibers 1 and the resin fibers 40. The carbon fiber 1 includes a first carbon fiber 11 as an original carbon fiber and a second carbon fiber 12 as a recycled carbon fiber.

Thus, a prepreg 200 can be provided, and the prepreg 200 can be used for manufacturing a molded body having excellent strength and reliability with excellent moldability.

In addition, since excellent moldability is obtained in the production of the molded article, the production conditions (e.g., temperature, pressure, etc.) of the molded article can be relaxed. Therefore, it is possible to use a device having a simple structure as a manufacturing device, and to suppress a load on the manufacturing device and to extend the life of the manufacturing device. In addition, it is also advantageous from the viewpoint of suppressing the production cost of the molded article.

In addition, since the excellent moldability can be maintained even if the content of the carbon fibers is increased, the content of the resin material can be reduced, and the excellent properties (for example, strength, thermal conductivity, and electrical conductivity) of the carbon fibers can be more effectively exhibited in the molded article.

Further, the use of the second carbon fibers 12 that are recovered and reused is also preferable from the viewpoints of resource saving, reduction in environmental load, and the like.

Further, the resin fibers 40 constitute a matrix resin in the molded body.

In the prepreg 200 of the present embodiment, it is preferable that the carbon fibers 1 (first carbon fibers 11, second carbon fibers 12), the deposit 2, and the adhesive 20 satisfy the same conditions as those described for the carbon fiber sheet 100, except for the conditions described below.

Examples of the material constituting the resin fiber 40 include polyesters such as polyethylene terephthalate, polybutylene terephthalate, and polylactic acid; polyolefins such as polyethylene and polypropylene; polyamides such as nylon 6 and nylon 6, 6; polyether ketones such as polyether ether ketone; examples of the thermoplastic resin include thermoplastic resins such as polyvinyl acetate, polyphenylene sulfide, polycarbonate, polystyrene, acrylonitrile-butadiene-styrene resin (ABS resin), polyvinyl chloride resin, and phenoxy resin, thermosetting resins such as epoxy resin, phenol resin, melamine resin, and unsaturated polyester resin, copolymers thereof, modified resins thereof, and polymer alloys thereof.

Among them, polypropylene, polycarbonate, polyamide, polyether ether ketone, and polyphenylene sulfide are preferable as the material constituting the resin fiber 40.

This makes handling of the prepreg 200 easier, and at the same time, can achieve both moldability at the time of production of the molded body and the characteristics (strength, reliability, etc.) of the molded body at a high level.

The average length of the resin fibers 40 is not particularly limited, but is preferably 2.0mm to 20mm, more preferably 3.0mm to 18mm, and further preferably 4.0mm to 16 mm.

This makes it possible to further improve the ease of handling the prepreg 200, the strength and reliability of a molded body produced using the prepreg 200, and the moldability during production of the molded body.

When the average length of the carbon fiber 1 is L_CF[mm]The resin fiber 40 has an average length L_RF[mm]When it is used, it is preferable that 0.10. ltoreq.L is satisfied_RF/L_CFA relationship of not more than 18, more preferably 0.25 not more than L_RF/L_CFA relationship of not more than 11, more preferably 0.45 not more than L_RF/L_CFThe relation of less than or equal to 7.0.

This makes it possible to further improve the ease of handling the prepreg 200, the strength and reliability of a molded body produced using the prepreg 200, and the moldability during production of the molded body.

The content of the carbon fibers 1 in the prepreg 200 (the sum of the content of the first carbon fibers 11 and the content of the second carbon fibers 12) is preferably 16 mass% to 96 mass%, more preferably 17.5 mass% to 95 mass%, and still more preferably 23 mass% to 93 mass%.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more effectively exhibited, and the molded body produced using the prepreg 200 can be made sufficiently excellent in strength and reliability and also excellent in moldability in producing the molded body.

When the content of the first carbon fibers 11 in the prepreg 200 is X_VCF[ mass% ]]The content of the second carbon fibers 12 is X_RCF[ mass% ]]When it is used, it is preferable that X is 0.006. ltoreq._VCF/X_RCFA relationship of not more than 1.0, more preferably 0.015 not more than X_VCF/X_RCFA relationship of 0.60 or less, more preferably 0.020 or less and X_VCF/X_RCFThe relation of less than or equal to 0.33.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more significantly exhibited, and the molded body produced using the prepreg 200 can be made sufficiently excellent in strength and reliability, and can be made more excellent in moldability at the time of producing the molded body.

The content of the binder 20 in the prepreg 200 is preferably 0.2 mass% to 20 mass%, more preferably 0.3 mass% to 15 mass%, and still more preferably 0.6 mass% to 10 mass%.

This makes it possible to further improve the ease of handling the prepreg 200, the strength and reliability of a molded body produced using the prepreg 200, and the moldability during production of the molded body.

The content of the resin fibers 40 in the prepreg 200 is preferably 3.0 mass% to 75 mass%, more preferably 4.0 mass% to 72 mass%, and still more preferably 5.0 mass% to 70 mass%.

This makes it possible to further improve the ease of handling the prepreg 200, the strength and reliability of a molded body produced using the prepreg 200, and the moldability during production of the molded body.

When the content of the carbon fibers 1 in the prepreg 200 (the sum of the content of the first carbon fibers 11 and the content of the second carbon fibers 12) is X_CF[ mass% ]]The resin fiber 40 has a content of X_RF[ mass% ]]When it is used, it is preferable that X is 0.30. ltoreq_CF/X_RFA relationship of 28 or less, more preferably 0.40 or less X_CF/X_RFA relationship of not more than 20, more preferably 0.50 not more than X_CF/X_RFThe relationship is less than or equal to 15.

By satisfying such conditions, the inherent characteristics of the carbon fiber 1 can be more significantly exhibited, and the molded body produced using the prepreg 200 can be made sufficiently excellent in strength and reliability, and can be made more excellent in moldability at the time of producing the molded body.

The prepreg 200 may include components (other components) other than the foregoing ones.

Examples of such components include plasticizers, colorants, antioxidants, ultraviolet absorbers, light stabilizers, softeners, modifiers, rust inhibitors, fillers, surface lubricants, corrosion inhibitors, heat stabilizers, lubricants, primers, antistatic agents, polymerization inhibitors, crosslinking agents, catalysts, leveling agents, thickening agents, dispersants, aging inhibitors, flame retardants, hydrolysis inhibitors, corrosion inhibitors, carbon nanotubes, carbon nanofibers, cellulose nanofibers, fullerenes, and graphite.

The resin material (impregnated resin) described in the first embodiment may be impregnated into the gaps between the fibers.

[ molded article ]

Next, the molded article of the present invention will be explained.

The molded article of the present invention is produced by molding the prepreg of the present invention under heat and pressure.

This provides a molded article having excellent strength and reliability.

The molded article of the present invention may have a portion formed by molding the prepreg of the present invention under heat and pressure, and may have a structure such as a coating film.

The molded article of the present invention can be used in any applications, and examples of the applications of the molded article of the present invention include components of vehicles (e.g., automobiles, bicycles, trains, aircrafts, rockets, elevators, etc.), components of electronic and electric parts (e.g., housing parts for portable terminals such as personal computers, mobile phones (including smartphones, PHS, etc.), tablet computers, etc.), components for buildings and civil engineering structures, furniture, and the like.

[ method for producing carbon fiber sheet ]

Next, a method for producing a carbon fiber sheet of the present invention will be described.

The carbon fiber sheet 100 can be produced, for example, by a method including a step (paper-making step) of mixing first carbon fibers 11 as virgin carbon fibers, second carbon fibers 12 as recycled carbon fibers, and a binder 20 for bonding the first carbon fibers 11 and the second carbon fibers 12.

This makes it possible to provide a production method that can stably produce a carbon fiber sheet 100, and that can be used to produce a molded product having excellent strength and reliability with excellent moldability while having excellent strength and reliability of the carbon fiber sheet 100.

In the paper making step, for example, the surface of at least a part of the carbon fibers 1 (the first carbon fibers 11 and the second carbon fibers 12) may be treated with a sizing agent or the like.

This can improve the adhesion between the binder 20 and the resin material, and can further improve the strength and reliability of the carbon fiber sheet 100 and the molded body.

Examples of the sizing agent include epoxy resins, phenol resins, polyethylene glycols, polyurethanes, polyesters, emulsifiers, surfactants, and the like.

The content of the carbon fibers 1 (the sum of the content of the first carbon fibers 11 and the content of the second carbon fibers 12) in the papermaking composition is not particularly limited, and the bundle 10 can be efficiently formed by setting the content to 0.01 mass% or more and 0.3 mass% or less.

[ method for producing prepreg ]

Next, a method for producing a prepreg of the present invention will be described.

< first embodiment >

The prepreg 200 according to the first embodiment can be stably manufactured, for example, by a method including a step (impregnation step) of impregnating the carbon fiber sheet 100 obtained through the paper-making step with a resin material (impregnated resin) 30.

Examples of the impregnation step include a method of thermally transferring a sheet made of a material including a thermosetting resin or a thermoplastic resin in an uncured state (B stage) as the resin material (impregnating resin) 30 onto the carbon fiber sheet 100, and a method of impregnating the carbon fiber sheet 100 with a liquid resin material (impregnating resin) 30.

< second embodiment >

The prepreg 200 according to the second embodiment described above can be stably manufactured, for example, by a method including a step (paper-making step) of mixing the first carbon fibers 11 as virgin carbon fibers, the second carbon fibers 12 as recycled carbon fibers, the resin fibers 40, and the binder 20 for bonding the first carbon fibers 11, the second carbon fibers 12, and the resin fibers 40.

In the manufacturing method of the first embodiment described above, the impregnation step is performed on the carbon fiber sheet 100 obtained through the paper making step, whereas in the manufacturing method of the present embodiment, the carbon fibers 1 (the first carbon fibers 11 and the second carbon fibers 12), the resin fibers 40, and the binder 20 are used in the paper making step, and the subsequent impregnation step is not required. Therefore, the productivity of the prepreg 200 can be improved.

[ method for producing molded article ]

Next, a method for producing a molded article of the present invention will be described.

The molded body can be stably produced by a method including a step (molding step) of performing heat and pressure molding on the prepreg 200 produced as described above, for example.

When a molded body is manufactured, a plurality of prepregs 200 may be stacked.

The number of stacked sheets is not particularly limited, but is preferably two or more and fifty or less, and more preferably three or more and thirty or less.

When a plurality of prepregs 200 are used, the prepregs 200 may be under different conditions or may be under the same condition.

In addition, an intermediate layer may be provided between adjacent prepregs 200.

Further, the joining process may be performed on a plurality of prepregs 200 before the joining step. Examples of a method for joining a plurality of prepregs 200 include fusion bonding (including solvent fusion bonding, polymerization fusion bonding, and the like), melting, and adhesion.

The heating temperature in the molding step is not particularly limited, and varies depending on the type, content, and the like of the resin material (impregnated resin) 30 or the resin fiber 40, and is preferably 100 ℃ to 380 ℃, more preferably 110 ℃ to 350 ℃, and still more preferably 120 ℃ to 300 ℃.

The molding pressure in the molding step is not particularly limited, and varies depending on the type, content, and the like of the resin material (impregnated resin) 30 or the resin fiber 40, but is preferably 0.1MPa to 15MPa, more preferably 0.2MPa to 12MPa, and further preferably 0.3MPa to 10 MPa.

When the prepreg 200 includes a thermosetting resin, the curing reaction of the thermosetting resin is performed by heating in the molding step, and the obtained molded article is excellent in heat resistance and the like.

The preferred embodiments of the present invention have been described above, but the present invention is not limited to these embodiments.

For example, the method for producing a carbon fiber sheet, the method for producing a prepreg, and the method for producing a molded body may include other steps (pretreatment step, intermediate treatment step, post-treatment step, etc.) in addition to the above-described steps.

The carbon fiber sheet, prepreg, and molded body of the present invention are not limited to those produced by the above-described methods, and can be produced by any method.

In the above-described embodiment, the carbon fiber sheet, the prepreg, and the molded body are typically described as including not only the carbon fibers constituting the bundle but also carbon fibers not constituting the bundle, but may be configured to include only one of these.

Examples

The present invention will be described in detail below with reference to examples and comparative examples, but the present invention is not limited thereto. The treatment and measurement, which do not particularly show the temperature conditions, were carried out at 20 ℃.

Production of "1" carbon fiber sheet

The carbon fiber sheets of the respective examples and comparative examples were produced as follows.

(example A1)

First, 20 parts by mass of virgin carbon fibers (first carbon fibers having an average fiber diameter (average width) of 7.0 μm and an average length of 6.0mm), 75 parts by mass of recycled carbon fibers (second carbon fibers having an average fiber diameter (average width) of 7.0 μm and an average length of 5.0mm), and 5.0 parts by mass of polyvinyl alcohol fibers (fineness of 1.1 dtex, average length of 3.0mm, weighted average density of 1.20 g/cm) as a binder were mixed³) The composition was mixed and dispersed in water to prepare a papermaking slurry containing 0.03 mass% of solid content.

Next, 0.001 parts by mass of anionic polyacrylamide as a dispersant was added to 100 parts by mass of the papermaking slurry to obtain a dispersion, and the dispersion was guided to the paper-making surface of a mesh conveyor having a mesh gap of 0.2mm and stacked into a sheet (papermaking step).

Then, the sheet in a wet state produced in the paper making process was heated and dried at 120 ℃, and the polyvinyl alcohol fibers were melted, and then the carbon fibers were bonded at the intersection points to obtain a carbon fiber sheet.

Further, as the recycled carbon fibers, those obtained by subjecting crushed/pulverized CFRP to a first heat treatment at 350 ℃ in an air atmosphere and then further subjecting the same to a second heat treatment at 550 ℃ in an air atmosphere are used.

(examples A2, A3)

A carbon fiber sheet was produced in the same manner as in example a1, except that the conditions of the first carbon fibers, the second carbon fibers, and the binder were changed as shown in table 1.

Comparative example A1

A carbon fiber sheet was produced in the same manner as in example a1, except that only the first carbon fibers were used as the carbon fibers and the compounding ratios of the respective components were as shown in table 1.

Comparative example A2

A carbon fiber sheet was produced in the same manner as in example a1, except that only the second carbon fibers were used as the carbon fibers and the compounding ratios of the respective components were as shown in table 1.

Table 1 shows the structures of the carbon fiber sheets of the examples and comparative examples. In addition, the second carbon fibers used in the above examples and comparative example a2 have a deposit derived from a recycled raw material attached to a part of the surface thereof. In the carbon fiber sheets of the above examples and comparative example a2, bundles including a plurality of carbon fibers were included, and carbon fibers not constituting bundles were also included. The carbon fiber sheets of the examples and comparative examples each had a thickness of 0.5mm to 0.8 mm.

[ Table 1]

Watch slave

Production of prepreg

Prepregs of each example and each comparative example were produced as follows.

(example B1)

First, a methanol solution (40 mass%) of a phenol resin as an uncured thermosetting resin was prepared.

Next, the methanol solution was applied to the carbon fiber sheet of example a1 and impregnated therein. Then, the resin was heated to 80 ℃ to remove methanol, and further, heat treatment was performed at 150 ℃ for fifteen minutes to cure the phenol resin, thereby obtaining a prepreg.

(examples B2, B3)

Prepregs were produced in the same manner as in example B1, except that the carbon fiber sheets produced in examples a2 and A3 were used instead of the carbon fiber sheet produced in example a 1.

(example B4)

First, 5.0 parts by mass of virgin carbon fibers (first carbon fibers having an average fiber diameter (average width) of 7.0 μm and an average length of 6.0mm), 35.2 parts by mass of recycled carbon fibers (second carbon fibers having an average fiber diameter (average width) of 7.0 μm and an average length of 5.0mm), and 2.9 parts by mass of polyvinyl alcohol fibers (fineness of 1.1 dtex, average length of 3.0mm, weighted average density of 1.20 g/cm) as a binder were mixed together³) A composition comprising 56.9 parts by mass of nylon 6 fibers (fineness: 1.1 dtex, average length: 6.0mm) as resin fibers was mixed and dispersed in water to prepare a papermaking slurry having a solid content of 0.03% by mass.

Next, 0.001 parts by mass of anionic polyacrylamide as a dispersant was added to 100 parts by mass of the papermaking slurry to obtain a dispersion, and the dispersion was guided to the paper-making surface of a mesh conveyor having a mesh gap of 0.3mm and stacked into a sheet (papermaking step).

Then, the sheet in a wet state produced in the paper making process was heated and dried at 120 ℃, and the polyvinyl alcohol fibers were melted and then the carbon fibers were bonded at the intersection points to obtain a prepreg. In the obtained prepreg, nylon 6 was not melted and remained in a fibrous state.

Further, as the recycled carbon fibers, those obtained by subjecting crushed/pulverized CFRP to a first heat treatment at 350 ℃ in an air atmosphere and then further subjecting the same to a second heat treatment at 550 ℃ in an air atmosphere are used.

(examples B5, B6)

Prepregs were produced in the same manner as in example B4, except that the conditions of the first carbon fibers, the second carbon fibers, the binder, and the resin fibers were changed as shown in table 2.

Comparative examples B1 and B2

Prepregs were produced in the same manner as in example B1, except that the carbon fiber sheets produced in comparative examples a1 and a2 were used instead of the carbon fiber sheet produced in example a 1.

Comparative example B3

Prepregs were produced in the same manner as in example B4, except that only the first carbon fibers were used as the carbon fibers and the compounding ratios of the respective components were as shown in table 2.

Comparative example B4

Prepregs were produced in the same manner as in example B4, except that only the second carbon fibers were used as the carbon fibers and the compounding ratios of the respective components were as shown in table 2.

Table 2 shows the structures of the prepregs of the examples and comparative examples. In addition, the second carbon fibers used in the above examples and comparative examples B2 and B4 have a deposit derived from a recycled raw material adhered to a part of the surface thereof. The prepregs of each of the examples and comparative examples B2 and B4 included bundles including a plurality of carbon fibers and also included carbon fibers not constituting bundles. The thickness of the prepreg in each of the examples and comparative examples is 0.8mm to 1.4 mm.

[ Table 2]

Production of molded article

The molded bodies of the examples and comparative examples were produced as follows.

(example C1)

First, fifteen prepregs manufactured in the example B1 were stacked.

Next, at 50kg/cm²And heating and pressing the prepreg laminate at 150 ℃. Thereby, the thermosetting resin included in the prepreg is cured, and a plurality of prepregs are bonded to each other between the layersThus, a flat plate-like molded article A was obtained.

A molded article B was produced in the same manner as the molded article a except that the molded article B was formed into a curved plate having an L-shaped curvature radius of the outer peripheral surface.

(examples C2, C3)

Shaped articles (shaped articles a and B) were produced in the same manner as in example C1, except that the prepregs produced in examples B2 and B3 were used instead of the prepregs produced in example B1.

(example C4)

First, fifteen prepregs manufactured in the example B4 were stacked.

Next, at 50kg/cm²And heating and pressing the prepreg laminate at 250 ℃. As a result, the thermoplastic resin included in the prepreg is softened and melted, and a plurality of prepregs are bonded to each other between layers, thereby obtaining a flat plate-shaped molded body a.

A molded article B was produced in the same manner as the molded article a except that the molded article B was formed into a curved plate having an L-shaped curvature radius of the outer peripheral surface.

(examples C5, C6)

Shaped articles (shaped articles a and B) were produced in the same manner as in example C4, except that the prepregs produced in examples B5 and B6 were used instead of the prepregs produced in example B4.

Comparative examples C1 and C2

Shaped articles (shaped articles a and B) were produced in the same manner as in example C1, except that the prepregs produced in comparative examples B1 and B2 were used instead of the prepregs produced in example B1.

Comparative examples C3 and C4

Shaped articles (shaped articles a and B) were produced in the same manner as in example C4, except that the prepregs produced in comparative examples B3 and B4 were used instead of the prepregs produced in example B5.

In addition, the molded bodies of the examples and comparative examples C2 and C4 included bundles including a plurality of carbon fibers and also included carbon fibers not constituting bundles.

Evaluation of

Evaluation of bending Strength of 4-1

The molded articles a of examples C1 to C6 and comparative examples C1 to C4 were evaluated for flexural strength determined by a flexural test in accordance with JIS K7074, and according to the following criteria.

A: the bending strength is 250MPa or more.

B: the bending strength is 200MPa or more and less than 250 MPa.

C: the bending strength is 150MPa or more and less than 200 MPa.

D: the bending strength is 100MPa or more and less than 150 MPa.

E: the bending strength is less than 100 MPa.

Evaluation of appearance of 4-2

(evaluation by visual inspection)

The molded bodies B of examples C1 to C6 and comparative examples C1 to C4 were visually observed and evaluated according to the following criteria.

A: no appearance defects were observed at all.

B: poor appearance was hardly observed.

C: appearance defects were slightly observed.

D: the appearance was clearly confirmed to be poor.

E: poor appearance was clearly confirmed.

(evaluation by microscope)

The vicinity of the bent portions of the molded bodies B of the examples C1 to C6 and the comparative examples C1 to C4 were observed with a microscope and evaluated according to the following criteria.

A: the exposed amount of the carbon fibers was not confirmed to vary.

B: the areas where the carbon fibers were exposed in a large amount and the areas where the amount of carbon fibers exposed was small and the resin material was exposed in a large amount were present, and the variation in the amount of carbon fibers exposed was slightly observed.

C: the areas where the carbon fibers were exposed in a large amount and the areas where the amount of carbon fibers exposed was small and the resin material was exposed in a large amount were present, and variations in the amount of carbon fibers exposed were clearly confirmed.

D: the areas where the carbon fibers were exposed in a large amount and the areas where the amount of carbon fibers exposed was small and the resin material was exposed in a large amount were present, and variations in the amount of carbon fibers exposed were clearly observed.

These results are shown in Table 3.

[ Table 3]

TABLE 3

As is clear from table 3, excellent results were obtained in the present invention, and in contrast, satisfactory results were not obtained in the comparative examples.

(availability in industry)

The carbon fiber sheet of the present invention includes a plurality of carbon fibers and a binder that binds the carbon fibers, and includes, as the carbon fibers, a first carbon fiber that is a virgin carbon fiber and a second carbon fiber that is a recycled carbon fiber. Therefore, a carbon fiber sheet which is excellent in strength and reliability and which can be used for producing a molded article excellent in strength and reliability with excellent moldability can be provided. Therefore, the carbon fiber sheet of the present invention has industrial applicability.