고무 치공구와 필름 함침공정을 이용한 열가소성 장섬유 복합재료 성형공정 연구

김동욱; 안영선; 이영관; 김성우; 남재도; Dong-wook Kim; Young sun An; Young-kwan Lee; Seong-woo Kim; Jae-do Nam

Polymer(Korea), Vol.25, No.1, 122-132, January, 2001

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고무 치공구와 필름 함침공정을 이용한 열가소성 장섬유 복합재료 성형공정 연구

Thermoplastic Film Infusion Process for Long Fiber Reinforced Composites Using Rubber Expandable Tools

김동욱, 안영선¹, 이영관², 김성우³, 남재도 ^{1, †}

(주)오리엔탈 공업
¹성균관대학교 고분자공학과
²성균관대학교 화학공학과
³경기대학교 화학공학과

Dong-wook Kim, Young sun An¹, Young-kwan Lee², Seong-woo Kim², and Jae-do Nam^{1, †}

Oriental Industry Co, Ltd., Korea
¹Department of Polymer Science and Engineering, Sungkyunkwan University, Korea
²Department of Chemical Engineering, Kyunggi University, Korea

E-mail:

초록

본 연구에서는 온도의 상승에 의하여 팽창하는 열팽창 기능을 가지고 있으면서 부피의 감소에 의하여 발생하는 압력의 손실을 상쇄시킬 수 있는 고무 치공구를 열가소성 고분자의 필름 함침공정에 적용하였다. 일반적인 압축성형공정에서는 온도의 상승에 의하여 수지가 용융되고 이에 수지가 함침됨에 따라 압력이 감소하지만, 고무 치공구를 사용한 경우에는 수지의 함침을 보상한 고무 치공구가 팽창하여 감소된 압력을 보상하기 때문에 급격한 압력의 강하를 억제할 수 있었다. 이렇게 수지의 함침에 따른 고무 치공구의 부피 팽창 그리고 이에 따른 수지 함침속도의 변화를 고려하여 고무 치공구를 이용한 필름 함침공정 모델을 제안하였다. 또한 고무 치공구를 사용하지 않는 일반적인 압축공정에 있어서 수지의 함침에 따른 섬유층 탄성력의 변화를 실험적으로 측정하여 단계적인 압축공정에 있어서 수지의 함침속도를 예측할 수 있는 모델을 제안하였다.

Thermoplastic film infusion process was investigated by using a rubber tool, which intrinsically contains a thermally-expandable characteristic and effectively compensates for the pressure loss caused by thermoplastic polymer infusion. Increasing temperature up to the melting temperature of matrix, the polymer melt subsequently infused into the dry fabric, but the pressure was successfully sustained by the rubber tool. Even with the decreased resin volume, the rubber tool produced sufficiently high elastic force for continuous resin infusion. Combining D''Arcy''s law with the compressibility of rubber tool and elastic fiber bed, a film infusion model was developed to predict the resin infusion rate and pressure change as a function of time. In addition, the film infusion process without the rubber tool was viewed and analyzed by a compression process of the elastic fiber bed and viscous resin melt. The compressibility of fiber bed was experimentally measured and the multiple-step resin infusion was well described by the developed model equations.

Keywords:thermoplastic composite;film infusion;rubber expandable tool;long fiber reinforced composite

[References]

Kocsis JK, "Polypropylene: Structure, Blends and Composites", Chapman & Hall, London (1995)
Jang BZ, "Advanced Polymer Composites: Principles and Applications", ASM International (1994)
Filbert C, Proc. SPE Ann. Conf., 394 (1968)
Price RV, U.S. Patent, 3,742,106 (1973)
Klein AJ, Advanced Composites, 2(3), 37 (1987)
Van West BP, Pipes RB, Advani SG, Polym. Compos., 12, 417 (1991)
Silverman EM, Polym. Compos., 8, 8 (1987)
Bigg DM, Bradbury EJ, Polym. Eng. Sci., 32, 287 (1992)
Atochem Product Brochure, "Thermoplastic Polymers in Powders for Composites", 1984
Thiede-Smet M, Liu M, Ho V, 34th Int'l. SAMPE Symp., 1223 (1989)
Handermann AC, 20th Int'l. SAMPE Conf., 681 (1988)
Clemans SR, Western ED, Handerman AC, Mater. Eng., 27 (1988)
Silverman EM, Jones RJ, SAMPE J., 33 (1988)
Hiscock DF, Bigg DM, Polym. Compos., 10, 145 (1989)
Bigg DM, Preston JR, Polym. Compos., 10, 261 (1989)
Letterman LE, U.S. Patent, 4,622,091 (1986)
Carlsson LA, Pipes RB, "Experimental Characterization of Advanced Composite Materials", Prentice Hall, New Jersey (1987)
Peterson AL, Cull RA, McMahon DF, 36th Int'l. SAMPE Symp., 959 (1991)
Erik S, Robert M, J. Adv. Mat., 26, 2 (1994)
Cull RA, Jacobson L, MaMahon DF, 36th Int'l. SAMPE Symp., 944 (1991)
Ku MK, Keum SW, Lee YK, Nam JD, Hah JM, Choi HS, Lee SH, Suh MH, HWAHAK KONGHAK, 36(4), 536 (1998)
Coldicott RJ, Longdon T, Green S, Ives PJ, 34th Int'l. SAMPE Symp., 2206 (1989)
Hogan PA, 14th SAMPE Tech. Conf., New York (1980)
Lin HH, Ranganathan S, Advani SG, "Consolidation of Continuous-Fiber System", ed. by S.G. Advani, Elsevier Science (1994)
Lee SY, Springer GS, J. Comp. Mater., 24, 1270 (1990)
Calius EP, Lee SY, Springer GS, J. Comp. Mater., 24, 1299 (1990)
D'Arcy H, Les Fontaines Publiques de la Ville de Dijon, Dalmont, Paris, 306 (1856)
Gutowski TG, Cai Z, Proc. Manufacturing International, 4, 13 (1988)
Gutowski TG, Morigaki T, Cai Z, J. Comp. Mater., 21(7), 172 (1987)
Gutowski TG, SAMPE Q., 16(4), 58 (1985)
Gutowski TG, Cai Z, Bauer S, Boucher D, Kingery J, Wineman SJ, J. Comp. Mater., 21(7), 650 (1987)
Lee WI, Springer GS, J. Comp. Mater., 33, 661 (1988)
Alan N, "Engineering with Rubber", Oxford University Press, New York, 1992
Brandup J, Immergut EH, "Polymer HandBook", 3rd ed., Wiley, New York (1989)
Ku MK, Nam JD, Hah JM, Choi HS, Kim BS, Proc. Polym. Soc. Korea, 22(1), 210 (1997)
Kim DW, "Thermoplastic Composite Molding Process Using Thermally Expandable Rubber Tool and Film Stacking Method", Master Thesis, Sungkyunkwan University, 1999

[Related Articles]

[1] Kocsis JK, "Polypropylene: Structure, Blends and Composites", Chapman & Hall, London (1995)

[2] Jang BZ, "Advanced Polymer Composites: Principles and Applications", ASM International (1994)

[3] Filbert C, Proc. SPE Ann. Conf., 394 (1968)

[4] Price RV, U.S. Patent, 3,742,106 (1973)

[5] Klein AJ, Advanced Composites, 2(3), 37 (1987)

[6] Van West BP, Pipes RB, Advani SG, Polym. Compos., 12, 417 (1991)

[7] Silverman EM, Polym. Compos., 8, 8 (1987)

[8] Bigg DM, Bradbury EJ, Polym. Eng. Sci., 32, 287 (1992)

[9] Atochem Product Brochure, "Thermoplastic Polymers in Powders for Composites", 1984

[10] Thiede-Smet M, Liu M, Ho V, 34th Int'l. SAMPE Symp., 1223 (1989)

[11] Handermann AC, 20th Int'l. SAMPE Conf., 681 (1988)

[12] Clemans SR, Western ED, Handerman AC, Mater. Eng., 27 (1988)

[13] Silverman EM, Jones RJ, SAMPE J., 33 (1988)

[14] Hiscock DF, Bigg DM, Polym. Compos., 10, 145 (1989)

[15] Bigg DM, Preston JR, Polym. Compos., 10, 261 (1989)

[16] Letterman LE, U.S. Patent, 4,622,091 (1986)

[17] Carlsson LA, Pipes RB, "Experimental Characterization of Advanced Composite Materials", Prentice Hall, New Jersey (1987)

[18] Peterson AL, Cull RA, McMahon DF, 36th Int'l. SAMPE Symp., 959 (1991)

[19] Erik S, Robert M, J. Adv. Mat., 26, 2 (1994)

[20] Cull RA, Jacobson L, MaMahon DF, 36th Int'l. SAMPE Symp., 944 (1991)

[21] Ku MK, Keum SW, Lee YK, Nam JD, Hah JM, Choi HS, Lee SH, Suh MH, HWAHAK KONGHAK, 36(4), 536 (1998)

[22] Coldicott RJ, Longdon T, Green S, Ives PJ, 34th Int'l. SAMPE Symp., 2206 (1989)

[23] Hogan PA, 14th SAMPE Tech. Conf., New York (1980)

[24] Lin HH, Ranganathan S, Advani SG, "Consolidation of Continuous-Fiber System", ed. by S.G. Advani, Elsevier Science (1994)

[25] Lee SY, Springer GS, J. Comp. Mater., 24, 1270 (1990)

[26] Calius EP, Lee SY, Springer GS, J. Comp. Mater., 24, 1299 (1990)

[27] D'Arcy H, Les Fontaines Publiques de la Ville de Dijon, Dalmont, Paris, 306 (1856)

[28] Gutowski TG, Cai Z, Proc. Manufacturing International, 4, 13 (1988)

[29] Gutowski TG, Morigaki T, Cai Z, J. Comp. Mater., 21(7), 172 (1987)

[30] Gutowski TG, SAMPE Q., 16(4), 58 (1985)

[31] Gutowski TG, Cai Z, Bauer S, Boucher D, Kingery J, Wineman SJ, J. Comp. Mater., 21(7), 650 (1987)

[32] Lee WI, Springer GS, J. Comp. Mater., 33, 661 (1988)

[33] Alan N, "Engineering with Rubber", Oxford University Press, New York, 1992

[34] Brandup J, Immergut EH, "Polymer HandBook", 3rd ed., Wiley, New York (1989)

[35] Ku MK, Nam JD, Hah JM, Choi HS, Kim BS, Proc. Polym. Soc. Korea, 22(1), 210 (1997)

[36] Kim DW, "Thermoplastic Composite Molding Process Using Thermally Expandable Rubber Tool and Film Stacking Method", Master Thesis, Sungkyunkwan University, 1999