scholarly journals Development of Molding Method of Carbon Fiber Reinforced Thermoplastics by Using Direct Resistance Heating and Induction Heating

2019 ◽  
Vol 68 (7) ◽  
pp. 565-571
Author(s):  
Kazuto TANAKA ◽  
Shun AKAMATSU ◽  
Tsutao KATAYAMA ◽  
Hideyuki KUWAHARA
Keyword(s):  
Carbon Fiber ◽  
Induction Heating ◽  
Resistance Heating ◽  
Fiber Reinforced ◽  
Molding Method ◽  
Carbon Fiber Reinforced ◽  
Reinforced Thermoplastics ◽  
Fiber Reinforced Thermoplastics

scholarly journals Carbon Fiber Reinforced Thermoplastics Molding by Using Direct Resistance Heating to Carbon Nanofilaments Grafted Carbon Fiber

2019 ◽  
Vol 3 (1) ◽  
pp. 14 ◽  
Author(s):  
Kazuto Tanaka ◽  
Ririko Habe ◽  
Masayoshi Tanaka ◽  
Tsutao Katayama
Keyword(s):  
Carbon Fiber ◽  
Void Content ◽  
Resistance Heating ◽  
Fiber Reinforced ◽  
Hot Press ◽  
Molding Method ◽  
Reinforced Thermoplastics ◽  
Reinforcing Fiber ◽  
Fiber Reinforced Thermoplastics ◽  
Press Molding

In the automobile industry, carbon fiber reinforced thermoplastics (CFRTP) have attracted attention as potential materials to reduce the weight of the automobile body. In order to apply CFRTP to mass-produced automobile parts, it is necessary to develop the reduction of molding time and the impregnation method into the carbon fiber (CF) for the thermoplastic resin, which has relatively high viscosity. Although the conventional hot press molding uses only the heat transfer from the mold to the molding materials, it is expected to develop a new molding method for CFRTP using heat generation of the materials themselves to overcome these issues. As a method of heating the carbon fiber, there is a direct resistance heating method, in which carbon fiber is directly energized and heated by Joule heat. We have developed resistance welding methods in which carbon nanotube (CNT) grafted carbon fiber (CNT-CF) is used for the heating elements, and revealed that the higher welded strength is obtained by using CNT-CF instead of CF. Therefore, the carbon nanofilaments (CNF) grafted carbon fiber (CNF-CF) including CNF-CF is expected not only to be used as a resistance heating medium at the time of joining but also as a reinforcing fiber and as a self-heating member at the time of molding. In this study, we develop the CFRTP molding method by using direct resistance heating to CNF-CF in the hot press molding. CFRTP ([0°]20) with the volume fractions (Vf) of 40% are molded by conventional hot press and hot press with direct resistance heating to reinforcing fiber. CF or CNF-CF is used for reinforcement. CFRTP molded by hot press with direct resistance heating to CNF-CF indicated lower void content than CFRTP molded by hot press with direct resistance heating to CF. Compared to CFRTP molding by only hot press, hot press molding with direct resistance heating to CNF-CF can mold CFRTP with low void content.

scholarly journals DEVELOPMENT OF RAPID PIPE MOULDING PROCESS FOR CARBON FIBER REINFORCED THERMOPLASTICS BY DIRECT RESISTANCE HEATING

2012 ◽  
Vol 06 ◽  
pp. 616-621 ◽  
Author(s):  
KAZUTO TANAKA ◽  
RYUKI HARADA ◽  
TOSHIKI UEMURA ◽  
TSUTAO KATAYAMA ◽  
HIDEYUKI KUWAHARA
Keyword(s):  
Carbon Fiber ◽  
Woven Fabric ◽  
Production Cycle ◽  
Resistance Heating ◽  
Fiber Reinforced ◽  
Heating Method ◽  
Moulding Process ◽  
Carbon Fiber Reinforced ◽  
Reinforced Thermoplastics ◽  
Fiber Reinforced Thermoplastics

To deal with environmental issues, the gasoline mileage of passenger cars can be improved by reduction of the car weight. The use of car components made of Carbon Fiber Reinforced Plastics (CFRP) is increasing because of its superior mechanical properties and relatively low density. Many vehicle structural parts are pipe-shaped, such as suspension arms, torsion beams, door guard bars and impact beams. A reduction of the car weight is expected by using CFRP for these parts. Especially, when considering the recyclability and ease of production, Carbon Fiber Reinforced Thermoplastics are a prime candidate. On the other hand, the moulding process of CFRTP pipes for mass production has not been well established yet. For this pipe moulding process an induction heating method has been investigated already, however, this method requires a complicated coil system. To reduce the production cost, another system without such complicated equipment is to be developed. In this study, the pipe moulding process of CFRTP using direct resistance heating was developed. This heating method heats up the mould by Joule heating using skin effect of high-frequency current. The direct resistance heating method is desirable from a cost perspective, because this method can heat the mould directly without using any coils. Formerly developed Non-woven Stitched Multi-axial Cloth (NSMC) was used as semi-product material. NSMC is very suitable for the lamination process due to the fact that non-crimp stitched carbon fiber of [0°/+45°/90°/-45°] and polyamide 6 non-woven fabric are stitched to one sheet, resulting in a short production cycle time. The use of the pipe moulding process with the direct resistance heating method in combination with the NSMC, has resulted in the successful moulding of a CFRTP pipe of 300 mm in length, 40 mm in diameter and 2 mm in thickness.

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