Patent Application
20150048555
The present invention relates to a carbon fiber preform.
Carbon fiber-reinforced plastic has been known widely as the composite material of the enhanced resin strength. The carbon fiber-reinforced plastic is manufactured, for example, by impregnating a carbon fiber-containing base material (hereinafter referred to as “carbon fiber preform” or simply as “preform”) with a thermosetting resin and applying heat. One known type of carbon fiber preform is manufactured by stacking a plurality of carbon fiber sheets and bonding adjacent layers of the respective sheets to each other. Techniques employable to bond the plurality of stacked carbon fiber sheets include method of locating a layered structure of a plurality of carbon fiber sheets in a heated mold and applying a pressure, conduction heating method, induction heating method and ultrasonic welding method. In these techniques, a general procedure heats and melts a resin located between adjacent layers of the carbon fiber sheets, a resin located on the surface of the carbon fiber sheet or a resin with which the carbon fiber sheet is impregnated, and subsequently cools and solidifies the melted resin, so as to bond the carbon fiber sheets to each other.
The various techniques described above have both advantages and drawbacks. Conventionally, the method of bonding the plurality of stacked carbon fiber sheets to one another should thus be selected according to the application of the carbon fiber preform. For example, the method using the heated mold needs a long time and a large amount of energy to increase the temperature of the mold and subsequently decrease the temperature of the mold. The conduction heating method, the induction heating method and the ultrasonic welding method, on the other hand, achieve bonding in a relative short time. The ultrasonic welding method, however, needs a device (horn) as the source of ultrasonic wave, and the induction heating method needs a device (coil) as the source of magnetic field. This increases the equipment cost. The ultrasonic welding method is readily employed to bond carbon fiber sheets in a planar shape but has difficulty in arrangement of carbon fiber sheets in a three-dimensional shape in a mold and accordingly has restrictions.
The conduction heating method, on the other hand, uses the mold itself as the electrodes and generates heat by taking advantage of the contact resistance between adjacent layers of the plurality of carbon fiber sheets. The equipment used accordingly has the simplified configuration. The conduction heating method is, however, unsuitable for manufacturing a certain type of preform having an insulating material in the middle of the current application pathway (for example, a preform having a glass fiber sheet located between adjacent layers of carbon fiber sheets or on the surface layer of a layered structure). This is because the presence of the insulating material interferes with application of electric current in the stacking direction and thus fails to heat and melt a resin used as adhesive resin by using heat of resistance. In this case, the electric current may be applied in the surface direction of the carbon fiber sheets to generate heat by using the intrinsic resistance of the carbon fiber sheets, so as to heat and melt the resin. This procedure, however, needs electrodes for each of the plurality of carbon fiber sheets, thus complicating the configuration of the equipment.
Additionally, in the case of bonding the entire surface of the carbon fiber sheets by the conduction heating method, high current flows through the carbon fiber sheets, due to the low electric resistance. This instantaneously requires an extremely large amount of energy. This results in difficulty in bonding carbon fiber sheets of large areas. Additionally, in the case of bonding the entire surface of the carbon fiber sheets, the entire surface is fixed. The resulting preform is unlikely to have sufficient repulsive force in the thickness direction (stacking direction) required when the preform is located in a mold in a resin molding process after manufacture of the preform. The insufficient repulsive force of the preform in the thickness direction in the mold forms a gap between the preform and an upper mold and a gap between the preform and a lower mold. This leaves a large amount of the resin injected for molding in the gaps and may thus cause some failure.
By taking into account the foregoing, there is a need to manufacture a preform having an insulating material by equipment of the simplified configuration. There is also a need to manufacture the preform in a short time by taking into account the time required for post-process after manufacture of the preform. There is also a need to provide a preform having the repulsive force in the stacking direction of carbon fiber sheets. There is further a need to reduce energy required for manufacturing the preform.
The present invention is made to solve at least part of the problems described above and may be implemented by the following aspects or embodiments.
There is provided a carbon fiber preform having a plurality of carbon fiber sheets that are stacked and are bonded to each other by means of an adhesive resin having thermal plasticity. The carbon fiber preform comprises a partial-conducting layer configured to have a resistance area which has higher electric resistance than electric resistance of the carbon fiber sheet in a stacking direction of the carbon fiber sheets, and a conductive area which has lower electric resistance than the electric resistance of the resistance area in the stacking direction. The resistance area and the conductive area are distributed in a surface direction orthogonal to the stacking direction. The partial-conducting layer is arranged at least in one of a location between at least one pair of adjacent carbon fiber sheets out of the plurality of carbon fiber sheets and a location on a surface layer of the carbon fiber preform. The plurality of carbon fiber sheets are bonded to each other by means of the adhesive resin in the conductive area provided in the partial-conducting layer and in an area corresponding to periphery of the conductive area.
The carbon fiber preform of this configuration may be manufactured by conduction heating method. More specifically, the conduction heating method applies electric current to the carbon fiber sheets in the stacking direction through the conductive area of the partial-conducting layer, so as to bond the carbon fiber sheets to each other. This enables the carbon fiber preform to be manufactured in a relatively short time. Only one pair of electrodes provided in the stacking direction are sufficient for the conduction heating method. This enables the carbon fiber preform to be manufactured by equipment of the simplified configuration. The conductive area having lower electric resistance in the stacking direction than that of the resistance area may be regarded as “current-carrying area” or “readily conducting area”. The electric resistance of the conductive area in the stacking direction may be lower than the electric resistance of the carbon fiber sheet or may be higher than the electric resistance of the carbon fiber sheet. The partial-conducting layer may further include an area having medium electrical resistance between the electrical resistance of the resistance area and the electrical resistance of the conductive area.
In the carbon fiber preform according to Aspect 1, the plurality of carbon fiber sheets may be not bonded to each other by means of the adhesive resin in at least part of the resistance area.
The carbon fiber sheets may be bonded to each other by means of the adhesive resin in another part of the resistance area.
This configuration ensures the repulsive force of the carbon fiber sheets in the stacking direction, compared with the configuration of bonding the entire surface of the carbon fiber sheets.
In the carbon fiber preform according to either Aspect 1 or Aspect 2, the partial-conducting layer may be made of an insulating sheet, and the conductive area may include an opening formed to pass through the insulating sheet in the stacking direction.
The carbon fiber preform of this configuration simplifies the structure of the partial-conducting layer. This results in reducing the cost of the carbon fiber preform and simplifying the manufacturing process of the carbon fiber preform.
In the carbon fiber preform according to any one of Aspects 1 to 3, the conductive area may have an area that is greater than 1% of an entire area of the carbon fiber sheet.
In the carbon fiber preform of this configuration, the conductive area of greater than 1% causes the carbon fiber sheets to be bonded to each other to such an extent that retains the shape of the preform.
In the carbon fiber preform according to any one of Aspects 1 to 4, the conductive area may have an area that is not greater than 20% of an entire area of the carbon fiber sheet.
The carbon fiber preform of this configuration reduces the energy required in the manufacturing process. More specifically, this reduces the amount of electric power required for conduction heating.
The invention may be implemented as a carbon fiber-reinforced plastic according to any of Aspects 6 to 9 described below. The carbon fiber-reinforced plastic according to Aspects 6 to 9 has the similar advantageous effects to those of the corresponding carbon fiber preform according to Aspects 1 to 4.
There is provided a carbon fiber-reinforced plastic having a plurality of carbon fiber sheets that are stacked. The carbon fiber-reinforced plastic comprises a partial-conducting layer configured to have a resistance area which has higher electric resistance than electric resistance of the carbon fiber sheet in a stacking direction of the carbon fiber sheets, and a conductive area which has lower electric resistance than the electric resistance of the resistance area in the stacking direction. The resistance area and the conductive area are distributed in a surface direction orthogonal to the stacking direction. The partial-conducting layer is arranged at least in one of a location between at least one pair of adjacent carbon fiber sheets out of the plurality of carbon fiber sheets and a location on a surface layer of the carbon fiber-reinforced plastic.
According to one embodiment, the partial-conducting layer may be arranged at least in one of the location between at least one pair of adjacent carbon fiber sheets out of the plurality of carbon fiber sheets and a location on a surface layer of one or more carbon fiber sheets out of the plurality of carbon fiber sheets.
In the carbon fiber-reinforced plastic according to Aspect 6, the partial-conducting layer may be made of an insulating sheet, and the conductive area may include an opening formed to pass through the insulating sheet in the stacking direction.
In the carbon fiber-reinforced plastic according to either Aspect 6 or Aspect 7, the conductive area may have an area that is greater than 1% of an entire area of the carbon fiber sheet.
In the carbon fiber-reinforced plastic according to any one of Aspects 6 to 8, the conductive area may have an area that is not greater than 20% of an entire area of the carbon fiber sheet.
The invention may be implemented as a manufacturing method of a carbon fiber preform according to any one of Aspects 10 to 13 described below. The manufacturing method according to Aspects 10 to 13 has the similar advantageous effects to those of corresponding Aspect 3, Aspect 2, Aspect 4 and Aspect 5. The invention may also be implemented as a manufacturing method of a carbon fiber-reinforced plastic.
There is provided a manufacturing method of a carbon fiber preform, comprising: providing a layered structure formed by stacking an insulating sheet and a plurality of carbon fiber sheets by means of an adhesive resin having thermal plasticity; placing the layered structure between two molds that are arranged to face each other and serve as electrodes to apply a voltage to the layered structure of the insulating sheet and the plurality of carbon fiber sheets; and transferring a mold shape defined by the two molds to the layered structure. The manufacturing method of the carbon fiber preform comprises the steps of: providing the layered structure using, as the insulating sheet, an insulating sheet having an opening formed to pass through the insulating sheet in a direction of the stacking, and locating the layered structure between the two molds; and applying a pressure to the layered structure in the direction of the stacking with the two molds, while applying a voltage to the two molds to apply electric current to the layered structure and cause the plurality of carbon fiber sheets to generate heat, so as to melt and fix the adhesive resin in a conductive area including the opening and in an area corresponding to periphery of the conductive area and thereby bond the plurality of carbon fiber sheets to each other by means of the adhesive resin.
In the manufacturing method of the carbon fiber preform according to Aspect 10, the step of bonding the plurality of carbon fiber sheets to each other may be performed without melting the adhesive resin in at least a partial area other than the conductive area.
The step of bonding the plurality of carbon fiber sheets to each other may melt the adhesive resin in another part of the conductive area.
In the manufacturing method of the carbon fiber perform according to either Aspect 10 or Aspect 11, the opening may have an opening area that is greater than 1% of an entire area of the carbon fiber sheet.
In the manufacturing method of the carbon fiber preform according to any one of Aspects 10 to 12, the opening may have an opening area that is not greater than 20% of an entire area of the carbon fiber sheet.
The flat portion 21 is a flat plate-like section. The outer periphery of the flat portion 21 has a rectangular shape. The protruded portion 22 is a section protruded in one direction from the flat portion 21. The protruded portion 22 of the preform 20 has a thickness substantially equal to the thickness of the flat portion 21. Accordingly, the preform 20 has a cavity formed on the other surface opposite to the protruded surface where the protruded portion 22 is formed to have a shape corresponding to the shape of the protruded portion 22. The protruded portion 22 has a nearly circular flat top surface protruded concentrically from a clearly circular base end 23. In other words, the protruded portion 22 has a nearly circular truncated cone shape. The boundary between the top surface and a side surface of the protruded portion 22 is called top end 24. The preform 20 may be in any desired shape.
The carbon fiber sheets 31 to 34 are sheet-like members of woven carbon fiber according to this embodiment. The carbon fiber sheet is a woven fabric made of carbon fiber according to this embodiment. The carbon fiber sheet is, however, not limited to the form of this embodiment. For example, the form of the carbon fiber sheet may be any of: (i) woven fabric; (ii) knitted fabric; (iii) braided fabric; (iv) nonwoven fabric; (v) unidirectional sheet obtained by stabilizing a reinforcing fiber sheet of aligned in one direction with a binder, an adhesive nonwoven fabric or stitching yarn; and (vi) mat made of randomly-oriented short fiber.
The insulating sheet 40 is a sheet-like member made of an insulating material according to this embodiment. The insulating sheet 40 used according to this embodiment is a mat made of glass fiber. The insulating sheet may, however, be, for example, a natural fiber such as cotton, linen, or bamboo or synthetic fiber such as polyester or nylon. The material of the insulating sheet 40 is not limited to these materials, but any of various other insulating materials may be used for the material of the insulating sheet 40. The form of the insulating material is preferably a sheet form such as woven fabric, nonwoven fabric or film. The form of the insulating material is, however, not limited to the sheet form. Any of various insulating materials that has deformation capability and lets the sheet itself be flexibly deformable in shape may be employed. The insulating material may not be a completely insulating material but may be a material having higher resistance than that of the carbon fiber sheet. According to this embodiment, the insulating sheet 40 is located between the carbon fiber sheet 32 and the carbon fiber sheet 33, i.e., in the middle (third layer) of the five-layered structure of the carbon fiber sheets 31 to 34 and the insulating sheet 40.
The insulating sheet 40 has a plurality of openings 41 formed therein. According to this embodiment, the openings 41 are through holes formed to pass through the insulating sheet 40 in the thickness direction (stacking direction).
An adhesive resin 50 is present between the respective layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40. In
In the preform 20, the respective layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40 are bonded to one another in the surface direction at the positions corresponding to the openings 41 and their peripheries by means of the adhesive resin 50. More specifically, the adhesive resin 50 present at the positions corresponding to the openings 41 and their peripheries are melted and cooled to be solidified, so as to exert the adhesive function. Substantially no electric current is applied to other areas having high electric resistance, due to the high electric resistance, so that the adhesive resin 50 is substantially not melted. In these other areas, the respective layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40 are not bonded at all or are only partly bonded. Such partial bonding, however, does not reach the level that exerts the adhesive force to retain the shape of the preform 20. In
In the illustration of
Inside of an opening 41a formed in the insulating sheet 40, the carbon fiber sheet 32 and the carbon fiber sheet 33 located on both sides of the insulating sheet 40 are bonded to each other by means of the adhesive resin 50 exerting the adhesive function. Inside of an opening 41b, on the other hand, the carbon fiber sheet 32 and the carbon fiber sheet 33 are not bonded to each other. This is attributed to the absence of the adhesive resin 50 exerting the adhesive function inside of the opening 41b. In other words, the carbon fiber sheet 32 and the carbon fiber sheet 33 may not be necessarily bonded to each other by means of the adhesive resin 50 inside of all the openings 41 according to this embodiment. The configuration that the adjacent carbon fiber sheets are bonded to each other in only part of the openings is implemented by reducing the amount of the adhesive resin used or by unevenly distributing the adhesive rein in the surface direction between layers.
The carbon fiber sheets 31 to 34 have the unit area weight or the weight per unit area of 200 g/m2 according to this embodiment. The insulating sheet 40 has the weight per unit area of 60 g/m2 according to this embodiment. The unit area weights of the carbon fiber sheets 31 to 34 and the insulating sheet 40 may be set in the range of such relationship between the unit area weights of the carbon fiber sheets 31 to 34 and the insulating sheet 40 that the carbon fiber sheet 32 and the carbon fiber sheet 34 are brought into contact with each other inside of the openings 41 to have electrical continuity at step S150 described later. For example, this relationship is achieved by setting the unit area weight of the carbon fiber sheets 31 to 34 to 70 to 500 g/m2 and the unit area weight of the insulating sheet 40 to 30 to 180 g/m2.
According to this embodiment, the ratio of the total area of the respective openings 41 to the area of each of the carbon fiber sheets 31 to 34 (area of one sheet) (hereinafter referred to as “opening area ratio”) is 6%. It is desirable to control the opening area ratio to greater than 1%. It is also desirable to control the opening area ratio to not greater than 20%. The reason of such control will be described later. When the area of the insulating sheet 40 is smaller than the area of the carbon fiber sheets 31 to 34, the sum of the total area of the respective openings 41 and a difference (positive value) between the area of the carbon fiber sheets 31 to 34 and the area of the insulating sheet 40 to the area of each of the carbon fiber sheets 31 to 34 is specified as the “opening area ratio.”
The description is now returned to the manufacturing process of the preform 20 (
After locating the layered structure 60 in the mold 70, the process applies a pressure to the layered structure 60 in the stacking direction, while applying a voltage to the upper mold 71 and the lower mold 72 (step S150 in
Applying the voltage to the upper mold 71 and the lower mold 72 causes electric current to flow through the layered structure 60 in the stacking direction. The electric current flowing through the layered structure 60 causes the carbon fiber sheets 31 to 34 to generate heat by the contact resistance. The application of pressure to the upper mold 71 and the lower mold 72 in the mold 70 in the stacking direction increases the contact between the carbon fiber sheet 31 and the carbon fiber sheet 32 and ensures the electrical continuity between the carbon fiber sheet 31 and the carbon fiber sheet 32 in the stacking direction. The same is applied to between the carbon fiber sheet 33 and the carbon fiber sheet 34. Application of the pressure to the layered structure 60 across the upper mold 71 and the lower mold 72 causes parts of the carbon fiber sheet 32 and the carbon fiber sheet 33 located on both sides of the insulating sheet 40 to enter inside of the openings 41 formed in the insulating sheet 40. As a result, the carbon fiber sheet 32 and the carbon fiber sheet 33 are certainly brought into contact with each other inside of the openings 41. This ensures the electrical continuity between the carbon fiber sheet 32 and the carbon fiber sheet 33 in the stacking direction.
As clearly understood from the above description, at step S150, electric current is flowed through the layered structure 60 in the stacking direction by pathways going through the openings 41 formed in the insulating sheet 40 as shown by thick black arrows in
After applying the voltage for the required time, the process subsequently leaves to stand the layered structure 60 and the mol 70 for a specified time (step S160). The specified time here is a time required to cool and solidify the molten adhesive resin 50. This specified time is generally about several seconds. While the specified time has elapsed, the adhesive resin 50 is solidified to bond the adjacent layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40 to each other in the areas corresponding to the openings 41 and their peripheries on the entire surface. The description of “the areas corresponding to the openings 41 and their peripheries” means any of “only the areas corresponding to the openings 41,” “only the areas corresponding to the peripheries of the openings 41” and “both the areas corresponding to the openings 41 and the areas corresponding to their peripheries.”. For example, the following situation may be expected according to some application density of the adhesive resin 50 and some opening area of the openings 41: the adhesive resin 50 is not present in the areas corresponding to the openings 41 but is present only in the areas corresponding to the peripheries of the openings 41. In such cases, the adjacent layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40 may be bonded to each other only in the areas corresponding to the peripheries of the openings 41.
The adjacent layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40 are bonded to each other as described above, so that the preform 20 is completed. This method causes the layered structure 60 to generate heat by applying electric current and does not need to heat the mold 70. The mold can thus be removed immediately after completion of the preform 20.
Area of carbon fiber sheets 31 to 34: 40000 mm2
Area of one opening 41: about 16 mm2 (diameter of 4.5 mm)
Current application time: 3 seconds
According to the experiment data shown in
According to the calculation results, the required electric current was 2560A at the opening area ratio of 20%. The calculation results also showed that the required electric current was 3840 A and 6400 A respectively at the opening area ratios of 30% and 50%. When the required electric current exceeds 3000 A, upgrading the capacity of the power source used is needed. This results in size expansion of the equipment and increase in energy consumption. The opening area ratio is thus preferably not greater than 20%. This reduces the power consumption required for conduction heating and contributes to reduction of cost and saving of energy consumption. The calculation result gave the required electric current of or over 10000A at the opening area ratios of or greater than 75%. Such setting is unpractical in terms of saving of the cost and the energy consumption.
According to the above description, the evaluation grade is “C” (fair) at the opening area ratio of 1% and in the range of not less than 30% and less than 75%. The evaluation grade is “D” (unpractical) at the opening area ratio of not less than 75%. The evaluation grade is “B” (good) at the opening area ratio in the range of greater than 1% and not greater than 20%. The evaluation grade is “A” (excellent) at the opening area ratio in the range of not less than 5% and not greater than 6%, which certainly provides the adhesive force and the shape retaining force while reducing the required electric current to some extent.
The preform 20 described above may be manufactured by conduction heating method. More specifically, the insulating sheet 40 has the openings 41, and the electric current is applied to the layered structure 60 in the stacking direction via the openings 41, so as to melt the adhesive resin 50 and bond the adjacent layers of the carbon fiber sheets 31 to 34 and the insulating sheet 40 to each other. The conduction heating method achieves bonding in a relatively short time and thereby shortens the manufacturing time of the preform 20. The temperature of the molten adhesive resin 50 decreases in a short time, so that no additional cooling step is needed. Only one pair of electrodes provided in the stacking direction are sufficient for the conduction heating method. Accordingly, the upper mold 71 and the lower mold 72 can be used as the electrodes for the conduction heating method. This enables the preform 20 to be manufactured by the equipment of the simplified configuration. Additionally, the conduction heating method does not require any special equipment, unlike the induction heating method or the ultrasonic welding method. This manufacturing method preferably enables the preform 20 in a three-dimensional shape to be manufactured.
The openings 41 serve as “the conductive area having the lower electric resistance in the stacking direction than the resistance area” and as the “current-carrying conductive area”. Here “current-carrying” is not limited to the current-carrying configuration without application of an external force to the preform 20. For example, the configuration that the carbon fiber sheet 32 and the carbon fiber sheet 33 are not in contact with each other inside of the openings 41 but are brought into contact with each other to have electrical continuity by application of a pressure to the preform 20 in the stacking direction is included in the “current-carrying” configuration. When the area (S1) of the insulating sheet 40 is smaller than the area (S2) of the carbon fiber sheets 31 to 34, a difference area (area of S2−S1) that is included in the location (area) of the carbon fiber sheets 31 to 34 but is outside of the insulating sheet 40 may also be regarded as “current-carrying conductive area.”
In the preform 20, the carbon fiber sheets 31 to 34 and the insulating sheet 40 are bonded to one another in the surface direction in the areas corresponding to the openings 41 formed in the insulating sheet 40 and in the areas corresponding to their peripheries but are not bonded to one another in the other areas. Compared with the configuration of bonding the entire surface of the carbon fiber sheets, this configuration ensures the repulsive force of the preform 20 in the stacking direction.
The plurality of openings 41 are formed to be distributed in the surface direction of the insulating sheet 40. This causes the carbon fiber sheets 31 to 34 and the insulating sheet 40 to be bonded to one another at the distributed locations and thereby facilitates retaining the shape of the preform 20.
In the preform 20, the amount of conduction heating, i.e., the amount of energy required for bonding the layered structure 60, can be controlled by adjusting the opening area ratio.
This preform 20 may be used to produce carbon fiber-reinforced plastic including the insulating sheet 40 between the adjacent layers of the carbon fiber sheets 31 to 34. In the case of producing carbon fiber-reinforced plastic by the RTM method using the preform 20, the insulating sheet 40 also serves to accelerate spread of the thermosetting resin injected into the mold in the surface direction. This results in increasing the impregnation rate of the thermosetting resin or enhancing the evenness of impregnation of the thermosetting resin.
In the embodiment described above, the insulating sheet 40 is located between the carbon fiber sheet 32 and the carbon fiber sheet 33. The location of the insulating sheet 40 is, however, not limited to this arrangement. The insulating sheet 40 may be arranged between any adjacent layers of the carbon fiber sheets 31 to 34. Moreover, the insulating sheet 40 may not be necessarily arranged between adjacent layers of the carbon fiber sheets 31 to 34. The insulating sheet 40 may be arranged on the surface of the carbon fiber sheets 31 to 34. For example, the layered structure 60 may be formed by stacking the insulating sheet 40 and the carbon fiber sheets 31 to 34 in this order. As long as the plurality of carbon fiber sheets are provided, the number of the carbon fiber sheets may be set to any number of not less than 2.
In the embodiment described above, the layered structure 60 is produced by stacking a plurality of carbon fiber sheets 31 to 34 and one insulating sheet 40. The layered structure 60 may, however, include a plurality of the insulating sheets 40. For example, the insulating sheets 40 may be located between the carbon fiber sheet 31 and the carbon fiber sheet 32 and between the carbon fiber sheet 33 and the carbon fiber sheet 34.
In the embodiment described above, the plurality of openings 41 formed in the insulating sheet 40 are arranged to be equally distributed in the surface direction. The arrangement of the plurality of openings 41 is, however, not limited to this embodiment. The arrangement of the plurality of openings 41 may be set arbitrarily. The plurality of openings 41 may not necessarily have an identical opening area but may have arbitrarily set opening areas. The arrangement and the opening areas of the openings 41 may be set adequately according to the shape of the preform 20 manufactured.
In this manner, the openings may be arranged intensively in the periphery of the area that is deformed by processing from the initial state prior to shape transfer (shape of entirely flat sheet). This arrangement causes the periphery of the deformed area to be intensively bonded in the layered structure and thereby facilitates retaining the post-processing shape. Openings 141b formed in an inside area of the base end 23 which is a relatively narrow area are set to have a smaller area than the area of openings 141a formed in an outside area of the base end 23 which is a relatively wide area. Adjusting the areas of the openings according to the processing shape of the preform in this manner enhances the flexibility in arrangement of the bonding positions. In the structure of
In the embodiment described above, the openings 41 formed in the insulating sheet 40 have the circular shape. The shape of the openings 41 may, however, be set arbitrarily.
The above embodiment describes the configuration that the insulating sheet 40 is located between the adjacent layers of the carbon fiber sheets 31 to 34. The insulating sheet 40 may be replaced with a partial-conducting sheet. The “partial-conducting sheet” denotes a sheet including an insulating area made of an insulating material and a conductive area made of a conductive material in the total area of the sheet. The insulating area and the conductive area are located at different positions in the surface direction. For example, the partial-conducting sheet may be provided as a sheet using the conductive material at the positions of the openings 41 of the insulating sheet 40. Carbon fiber may be used as the conductive material.
The above embodiment describes the configuration that the insulating sheet 40 is located between the adjacent layers of the carbon fiber sheets 31 to 34. The insulating sheet 40 may be replaced with a material having higher electric resistance in the stacking direction than that of the carbon fiber sheet. The electric resistance of one layer of the carbon fiber sheet in the thickness direction is generally in the range of 10 to 300 Ω/cm2 (under the conditions of the carbon fiber weight per unit area of 330 g/m2, the number of carbon fibers of 1200, and pressing pressure of 0.1 to 0.5 MPa). This configuration ensures the advantageous effects described above to some extent. The partial-conducting sheet described in Modification 5 may be provided as a sheet having a high resistance area made of a material having the higher electric resistance in the stacking direction than that of the carbon fiber sheet and a conductive area.
The foregoing describes some embodiments of the invention. The invention is, however, not limited to these embodiments, but a multiplicity of variations and modifications may be made to the embodiments without departing from the scope of the invention. For example, the components of the respective aspects and the components of the embodiments described above may be adequately combined, omitted or conceptualized in a generic manner in any aspect to solve at least part of the objects described above or in any aspect to achieve at least part of the advantageous effects described above.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-061510 | Mar 2012 | JP | national |
This is the U.S. National Phase application of PCT/JP2013/001863, filed Mar. 19, 2013, which claims priority to Japanese Patent Application No. 2012-061510, filed Mar. 19, 2012, the disclosures of each of these applications being incorporated herein by reference in their entireties for all purposes.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2013/001863 | 3/19/2013 | WO | 00 |
