CN105324225A - 纤维增强塑料、电梯用整风罩和纤维增强塑料的制造方法 - Google Patents
纤维增强塑料、电梯用整风罩和纤维增强塑料的制造方法 Download PDFInfo
- Publication number
- CN105324225A CN105324225A CN201480035249.4A CN201480035249A CN105324225A CN 105324225 A CN105324225 A CN 105324225A CN 201480035249 A CN201480035249 A CN 201480035249A CN 105324225 A CN105324225 A CN 105324225A
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- Prior art keywords
- resin
- fabric
- fiber
- reinforced plastic
- inorganic filler
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000005728 strengthening Methods 0.000 description 1
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Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
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- Textile Engineering (AREA)
Abstract
本发明涉及纤维增强塑料、电梯用整风罩和纤维增强塑料的制造方法。纤维增强塑料(1),具有:具有第1纤维织物(21)和含浸于第1纤维织物(21)的树脂(22)的第1纤维增强塑料层(2);具有内介质(31)和树脂(32)、重叠于第1纤维增强塑料层(2)的树脂流动层(3);具有第2纤维织物(41)和含浸于第2纤维织物(41)的树脂(42)、以在与第1纤维增强塑料层(2)之前配置树脂流动层(3)的方式重叠于树脂流动层(3)的第2纤维增强塑料层(4);具有粒径为20μm以上且50μm以下的无机填料(51)和树脂(52)、以在与树脂流动层(3)之间配置第2纤维增强塑料层(4)的方式重叠于第2纤维增强塑料层(4)的无机填料层(5),树脂(22)、树脂(32)、树脂(42)和树脂(52)各自由彼此相同的组成构成,相互一体地形成。
Description
技术领域
本发明涉及使树脂含浸于纤维织物的纤维增强塑料、由纤维增强塑料构成的电梯用整风罩(整風カバー)和纤维增强塑料的制造方法。
背景技术
作为轻质、高强度的原材料,纤维增强塑料(FRP:FiberReinforcedPlastics)在各种产业领域中受到关注。近年来,作为低价地制造风车的叶片、航空器部件或船等的比较大形的纤维增强塑料成型体的方法,被称为真空含浸成型法(VaRTM:VacuumassistResinTransferMolding)的制造方法在广泛地普及。该真空含浸成型法具有如下等的特征:不需要高压釜(压力釜)等的大型的设备,大型结构物的一体成型容易,以及有机溶剂的挥发少,作业环境好。
以往,已知具有以下的纤维增强塑料的制造方法:在成型模上以将内介质(インナーメダィア)配置于纤维织物之间的方式将多个纤维织物与多个内介质交替地进行层叠的纤维织物内介质层叠工序;然后在最上层的纤维织物将可剥保护层进行层叠的可剥保护层层叠工序;然后在可剥保护层将流动介质进进行层叠的流动介质层叠工序;将真空泵的空气抽吸口和树脂罐的树脂注入口安装于成型模、用装袋膜将全体覆盖、用密封剂将装袋膜的周围粘接于成型模的安装工序;和通过由真空泵产生的空气的抽吸来使装袋膜内成为了真空状态后,从树脂罐将树脂注入的真空含浸工序(例如,参照专利文献1)。
现有技术文献
专利文献
专利文献1:日本特开2009-248552号公报
发明内容
发明要解决的课题
但是,在该方法中,在制造一个目标的纤维增强塑料时,需要规定的面积的可剥保护层、流动介质和装袋膜的一整套,树脂固化后废弃,因此存在制造效率差这样的问题。另外,平面形状的可剥保护层、流动介质和装袋膜各自难以形成曲面形状,其结果,存在纤维增强塑料的制造效率差这样的问题。
本发明提供可以使制造效率提高的纤维增强塑料及其制造方法。
用于解决课题的手段
本发明涉及的纤维增强塑料具备:具有第1纤维织物和含浸于第1纤维织物的第1纤维织物用树脂的第1纤维增强塑料层;具有树脂扩散介质和树脂扩散介质用树脂、重叠于第1纤维增强塑料层的树脂流动层;具有第2纤维织物和含浸于第2纤维织物的第2纤维织物用树脂、以在与第1纤维增强塑料层之间配置树脂流动层的方式重叠于树脂流动层的第2纤维增强塑料层;具有粒径为20μm以上且50μm以下的无机填料和无机填料用树脂、以在与树脂流动层之间配置第2纤维增强塑料层的方式重叠于第2纤维增强塑料层的无机填料层,第1纤维织物用树脂、树脂扩散介质用树脂、第2纤维织物用树脂和无机填料用树脂各自由彼此相同的组成构成,相互一体地形成。
发明的效果
根据本发明涉及的纤维增强塑料,具备:具有第1纤维织物和含浸于第1纤维织物的第1纤维织物用树脂的第1纤维增强塑料层;具有树脂扩散介质和树脂扩散介质用树脂、重叠于第1纤维增强塑料层的树脂流动层;具有第2纤维织物和含浸于第2纤维织物的第2纤维织物用树脂、以在与第1纤维增强塑料层之间配置树脂流动层的方式重叠于树脂流动层的第2纤维增强塑料层;具有粒径为20μm以上且50μm以下的无机填料和无机填料用树脂、以在与树脂流动层之间配置第2纤维增强塑料层的方式重叠于第2纤维增强塑料层的无机填料层,第1纤维织物用树脂、树脂扩散介质用树脂、第2纤维织物用树脂和无机填料用树脂各自由彼此相同的组成构成,相互一体地形成,因此在将目标的纤维增强塑料进行成型时,不需要可剥保护层、流动介质和装袋膜。其结果,可以使纤维增强塑料的制造效率提高。
附图说明
图1为表示本发明的实施方式1涉及的纤维增强塑料的剖面图。
图2为表示图1的第1纤维增强塑料层的放大图。
图3为表示图1的树脂流动层的放大图。
图4为表示图1的无机填料层的放大图。
图5为表示图1的第2纤维增强塑料层和无机填料层的放大图。
图6为表示图1的纤维增强塑料的制造方法中的赋型工序的示意图。
图7为表示图1的纤维增强塑料的制造方法中的附着工序的示意图。
图8为表示图1的纤维增强塑料的制造方法中的装袋工序的示意图。
图9为表示图1的纤维增强塑料的制造方法中的树脂含浸工序的示意图。
图10为表示图1的纤维增强塑料的制造工序中的脱模工序及除去工序的示意图。
图11为表示本发明的实施方式1涉及的纤维增强塑料的变形例的剖面图。
图12为表示本发明的实施方式2涉及的电梯用整风罩的透视图。
具体实施方式
实施方式1.
图1为表示本发明的实施方式1涉及的纤维增强塑料的剖面图。在图中,纤维增强塑料1具备第1纤维增强塑料层2、树脂流动层3、第2纤维增强塑料层4和无机填料层5。将树脂流动层3重叠于第1纤维增强塑料层2。将第2纤维增强塑料层4以与第1纤维增强塑料层2之间配置树脂流动层3的方式重叠于树脂流动层3。将无机填料层5以与树脂流动层3之间配置第2纤维增强塑料层4的方式重叠于第2纤维增强塑料层4。换言之,将第1纤维增强塑料层2、树脂流动层3、第2纤维增强塑料层4和无机填料层5依次层叠。
图2为表示图1的第1纤维增强塑料层2的放大图。第1纤维增强塑料层2具有第1纤维织物21和含浸于第1纤维织物21的树脂(第1纤维织物用树脂)22。作为第1纤维织物21,例如可列举碳纤维、玻璃纤维、ザイロン纤维、ケプラー纤维等的织物。在本例中,使用了纤维直径为7μm的碳纤维。第2纤维增强塑料层4形成与第1纤维增强塑料层2同样的构成,具有第2纤维织物41和含浸于第2纤维织物41的树脂(第2纤维织物用树脂)42。
图3为表示图1的树脂流动层3的放大图。树脂流动层3具有内介质(树脂扩散介质)31和浸入了内介质31的树脂(树脂扩散介质用树脂)32。流动介质是用于使树脂扩散的副材料,由于从纤维增强塑料1中除去·废弃,因此对材质并无特别限定,而内介质同样具有使树脂扩散的功能,且在制品中作为增强基材残留、发挥功能,因此作为内介质31,只要是流动阻力小的材料,则并无特别限定,与尼龙等的热塑性树脂制相比,优选作为增强纤维的玻璃纤维或碳纤维。
图4为表示图1的无机填料层5的放大图。无机填料层5具有多个无机填料51和无机填料51进入其中的树脂(无机填料用树脂)52。作为无机填料51,并无特别限定,与碳酸钙、二氧化硅、氧化铝等相比,从阻燃性的观点出发,优选氢氧化铝、三氧化锑或它们的混合物等。
无机填料51的平均粒径优选比第2纤维织物41的纤维直径(系径)大。在无机填料51的粒径比第2纤维织物41的纤维直径小的情况下,后述的有机硅袋62(图8)与第2纤维织物41相接。一般地,第2纤维织物41的纤维直径为10μm以下,因此无机填料51的平均粒径优选为第2纤维织物41的纤维直径的2倍即20μm以上。
另外,无机填料51的平均粒径优选为50μm以下。是因为:在无机填料51的粒径比50μm大的情况下,由于无机填料51的自重,从有机硅袋62(图7)脱落,作为结果,有机硅袋62与第2纤维织物41相接的部分增大。
在该例中,作为无机填料51,使用平均粒径为27μm的氢氧化铝。
树脂22、树脂32、树脂42和树脂52各自由彼此相同的组成构成、相互一体地形成。作为树脂22、树脂32、树脂42和树脂52,只要是环氧树脂、聚酯树脂、乙烯基酯树脂等的低粘度的树脂,则并无特别限定,但优选常温下可固化的乙烯基酯树脂。
图5为表示图1的第2纤维增强塑料层4和无机填料层5的放大图。第2纤维织物41被无机填料层5覆盖,没有露出。无机填料51没有从位于树脂52中的第2纤维增强塑料层4侧的相反侧的表面53突出。
在制造多个纤维增强塑料1的情况下,制造了成型模后,只进行1次制造有机硅袋62的工序,只反复进行规定次数的成型纤维增强塑料1的工序。对于这些构成分别说明。首先,对纤维增强塑料1的制造方法进行说明。首先,图6为表示图1的纤维增强塑料1的制造方法中的赋型工序的示意图。首先,在用特氟隆(注册商标)涂覆被脱模了的成型模(铝制、厚3mm)61上重叠2片第1纤维织物21。层叠方向为纤维增强塑料1的厚度方向。接着,在第1纤维织物21上重叠内介质31。然后,在内介质31上重叠2片第2纤维织物41。通过以上,赋型工序完成。
图7为表示图1的纤维增强塑料1的制造方法中的附着工序的示意图。赋型工序之后,使无机填料51附着于以规定的形状形成了的有机硅袋62。具体地,首先,使无机填料51附着于海绵(未图示),从该海绵使无机填料51转印于有机硅袋62(附着工序)。在有机硅袋62形成曲面,构成有机硅袋62的有机硅具有使杂质(例如灰尘等)吸附的性质,因此可以不使用粘接剂、粘结剂等地适度且容易地使无机填料51附着于有机硅袋62。予以说明,也可以通过使无机填料51附着于成型模61(图6)来将无机填料层5层叠于第1纤维增强塑料层2和第2纤维增强塑料层4这两者。
图8为表示图1的纤维增强塑料1的制造方法中的装袋工序的示意图。附着工序之后,将真空泵的空气抽吸口63和树脂罐的树脂注入口64安装于成型模61,以无机填料51与第2纤维织物41对置的方式有机硅袋62与成型模61一起将第1纤维织物21、内介质31和第2纤维织物41覆盖。接着,以空气不从成型模61与有机硅袋62之间泄漏的方式使有机硅袋62的周围密合于成型模61(装袋工序)。作为使有机硅袋62密合于成型模61的方法,一般使用被称为密封剂的粘合剂,但由于构成有机硅袋62的有机硅具有脱模性,因此使用密封剂使成型模61与有机硅袋62之间成为真空是困难的。因此,优选使用有机硅粘接剂而使O型环形状的有机硅制的阻塞材料65粘接于成型模61,使用框66而得到有机硅袋62与阻塞材料65的密合。
图9为表示图1的纤维增强塑料1的制造方法中的树脂含浸工序的示意图。在装袋工序之后,驱动真空泵而使成型模61与有机硅袋62之间的密闭空间成为真空状态,然后,从树脂罐将树脂100(树脂22、树脂32、树脂42和树脂52)注入成型模61与有机硅袋62之间的密闭空间。由于成型模61与有机硅袋62之间的密闭空间成为真空状态,因此树脂100向流路阻力比较小的内介质31的全面扩展后,向第1纤维织物21和第2纤维织物41的厚度方向、即、层叠方向浸入,使树脂100含浸于第1纤维织物21和第2纤维织物41中(树脂含浸工序)。此时,如果孔格粗的内介质31从树脂注入口64连接到空气抽吸口63,则树脂100没有浸透于网眼被堵塞了的流动阻力高的第1纤维织物21和第2纤维织物41,因此必须将空气抽吸口63附近的内介质31切除。
图10为表示图1的纤维增强塑料1的制造工序中的脱模工序和除去工序的示意图。树脂含浸工序之后,停止从树脂罐的树脂100的注入,进而,通过只放置1天,使树脂100固化,形成纤维增强塑料主体11(固化工序)。然后,将有机硅袋62从成型模61取出,进而,将纤维增强塑料主体11从成型模61取出(脱模工序)。然后,通过研磨将在无机填料层5的表面53(与有机硅袋62对置的纤维增强塑料主体11的袋面)中无机填料51突出的部分除去(除去工序)。在除去工序中,可以使用砂纸。在无机填料层5中的无机填料51突出的部分中,由于树脂52没有附着,因此必须将该突出部分除去。通过将突出了的无机填料51的部分除去,形成纤维增强塑料1。另外,由于有机硅袋62的全体或表面由脱模性优异的有机硅树脂构成,因此在将纤维增强塑料1多次成型时可以再利用。
接着,对于有机硅袋62的制造方法进行说明。首先,在用特氟隆涂层进行了脱模的成型模61上只将2片第1纤维织物21层叠。然后,在第1纤维织物21上将内介质31重叠。然后,在内介质31上只将2片第2纤维织物41层叠。
接着,使可剥保护层、装袋膜重叠于第2纤维织物41、将空气抽吸口63和树脂注入口64安装于成型模61、进而使用密封剂来使装袋膜粘接于成型模61。
然后,将不饱和聚酯树脂100重量份、固化剂0.5重量份、固化促进剂仅仅0.5重量份进行混合,对其进行脱泡,制造含浸用树脂。
然后,驱动真空泵,使装袋膜与成型模61之间的密闭空间成为真空状态,将树脂从树脂注入口64注入装袋膜与成型模61之间的密闭空间,使树脂含浸于第1纤维织物21和第2纤维织物41。
含浸工序之后,停止树脂的注入,在室温下放置仅仅1天后,使树脂固化。
然后,将可剥保护层、装袋膜从成型模61中移除,进而,将纤维增强塑料主体11从成型模61移除。对纤维增强塑料主体11进行修剪而形成用于得到有机硅袋62的模拟材料。
接着,将2液型RTV橡胶混合,脱泡。然后,将模拟材料在成型模61上固定,在模拟材料上使液体状的2液型RTV橡胶垂流,放置仅仅1天,由此使其固化。由此,制造仅仅模拟材料的厚度偏移了的有机硅袋62。
如以上说明那样,根据本发明的实施方式1涉及的纤维增强塑料1,具有:具有第1纤维织物21和含浸于第1纤维织物21的树脂22的第1纤维增强塑料层2;具有内介质31和树脂32、重叠于第1纤维增强塑料层2的树脂流动层3;具有第2纤维织物41和含浸于第2纤维织物41的树脂42、以在与第1纤维增强塑料层2之间配置树脂流动层3的方式重叠于树脂流动层3的第2纤维增强塑料层4;具有粒径为20μm以上且50μm以下的无机填料51和树脂52、以在与树脂流动层3之间配置第2纤维增强塑料层4的方式重叠于第2纤维增强塑料层4的无机填料层5,树脂22、树脂32、树脂42和树脂52各自由彼此相同的组成构成、相互一体地形成,因此将目标的纤维增强塑料进行成型时,不需要可剥保护层、流动介质和装袋膜。其结果,可以使纤维增强塑料1的制造效率提高。
另外,无机填料51的粒径为20μm以上且50μm以下,因此可以防止有机硅袋62与第2纤维织物41相接,同时可以防止无机填料51由于自重而从有机硅袋62脱落。
另外,由于无机填料51为氢氧化铝、三氧化锑、或它们的混合物,因此可以使无机填料51为阻燃性。
另外,根据本发明的实施方式1涉及的纤维增强塑料1的制造方法,具有:使第1纤维织物21重叠于成型模61、使内介质31重叠于第1纤维织物21、使第2纤维织物41重叠于内介质31的赋型工序;使无机填料51附着于有机硅袋62的附着工序;以无机填料51与第2纤维织物41对置的方式有机硅袋62与成型模61一起将第1纤维织物21、内介质31和第2纤维织物41覆盖的装袋工序;以内介质31作为树脂流路而使液体状的树脂100含浸于第1纤维织物21和第2纤维织物41的含浸工序;在含浸工序之后使树脂100固化的固化工序;在固化工序之后将由树脂22、32、42、52一体成型了的纤维增强塑料主体11从成型模61和有机硅袋62中取出的脱模工序;在脱模工序之后通过研磨将在与有机硅袋62对置的纤维增强塑料主体11的表面53中无机填料51突出的部分除去的除去工序,因此制造纤维增强塑料1时,不需要可剥保护层、流动介质和装袋膜。其结果,可以使纤维增强塑料1的制造效率提高。另外,由于在第2纤维织物41与有机硅袋62之间存在无机填料51,因此可以防止第2纤维织物41与有机硅袋62的密合,可以使树脂42含浸于第2纤维织物41的全部区域。另外,由于通过研磨将在与有机硅袋62对置的纤维增强塑料主体11的表面53中无机填料51突出的部分除去,因此可以防止第2纤维织物41的损伤。
应予说明,在上述实施方式1中,对于无机填料层5露出的纤维增强塑料1的构成进行了说明,但也可以是如图11中所示那样进一步具备在无机填料层5的表面53形成了的涂膜7的纤维增强塑料1的构成。作为涂膜7,可以使用氨基甲酸酯树脂等。在使用了碳纤维作为纤维织物41的情况下,相对于第2纤维增强塑料层4的面内的热膨胀率为约0ppm/K,涂膜7的面内的热膨胀率为约60ppm/K,因此如果实施热循环试验,由于热膨胀率差,存在涂膜7容易产生开裂的课题。但是,就纤维增强塑料1而言,由于在涂膜7与第2纤维增强塑料层4之间存在面内的热膨胀率为30ppm/K的无机填料层5,因此可以使涂膜7的耐开裂性提高。另外,由于无机填料层5承担涂膜7的基底的作用,因此在涂膜7产生了损伤的情况下,可以抑制第2纤维织物41露出。本申请的申请人对于具备30μm的涂膜7的纤维增强塑料1进行了热循环试验(-40℃~+85℃、500循环),结果在涂膜7没有开裂的发生等,可以获得良好的结果。
实施方式2.
图12为表示本发明的实施方式2涉及的电梯用整风罩的透视图。在电梯的筐体的上部安装有电梯用整风罩200。电梯用整风罩200由纤维增强塑料1构成。其他的构成与实施方式1相同。
如以上说明那样,根据本发明的实施方式2涉及的电梯用整风罩200,由于由纤维增强塑料1构成,因此可以低价地制造。
应予说明,在各上述实施方式中,以只2片层叠了的第1纤维织物21、第2纤维织物41为例进行了说明,但并不限于2片,也可以是只1片的第1纤维织物21、第2纤维织物41或3片以上层叠了的第1纤维织物21、第2纤维织物41。
Claims (4)
1.一种纤维增强塑料,其特征在于,具备:
具有第1纤维织物和含浸于所述第1纤维织物的第1纤维织物用树脂的第1纤维增强塑料层,
具有树脂扩散介质和树脂扩散介质用树脂、重叠于所述第1纤维增强塑料层的树脂流动层,
具有第2纤维织物和含浸于所述第2纤维织物的第2纤维织物用树脂、在与第1纤维增强塑料层之间配置所述树脂流动层地重叠于所述树脂流动层的第2纤维增强塑料层,和
具有粒径为20μm以上且50μm以下的无机填料和无机填料用树脂、在与所述树脂流动层之间配置所述第2纤维增强塑料层地重叠于所述第2纤维增强塑料层的无机填料层;
所述第1纤维织物用树脂、所述树脂扩散介质用树脂、所述第2纤维织物用树脂和所述无机填料用树脂各自由彼此相同的组成构成,相互一体地形成。
2.根据权利要求1所述的纤维增强塑料,其特征在于,所述无机填料为氢氧化铝、三氧化锑、或它们的混合物。
3.一种电梯用整风罩,其特征在于,由权利要求1或权利要求2所述的纤维增强塑料构成。
4.一种纤维增强塑料的制造方法,其特征在于,具有:
使第1纤维织物重叠于成型模、使树脂扩散介质重叠于所述第1纤维织物、使第2纤维织物重叠于所述树脂扩散介质的赋型工序,
使无机填料附着于有机硅袋的附着工序,
所述无机填料与所述第2纤维织物对置的方式所述有机硅袋与所述成型模一起将所述第1纤维织物、所述树脂扩散介质和所述第2纤维织物覆盖的装袋工序,
以所述树脂扩散介质作为树脂流路、使液体状的树脂含浸于所述第1纤维织物和所述第2纤维织物中的含浸工序,
所述含浸工序之后、使所述树脂固化的固化工序,
所述固化工序之后、将由所述树脂而一体成型了的纤维增强塑料主体从所述成型模和所述有机硅袋中取出的脱模工序,和
所述脱模工序之后、通过研磨将在与所述有机硅袋对置的所述纤维增强塑料主体的袋面中所述无机填料突出的部分进行除去的除去工序。
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