CN109866435A - 纤维增强树脂体及其制造方法 - Google Patents

纤维增强树脂体及其制造方法 Download PDF

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CN109866435A
CN109866435A CN201811321112.1A CN201811321112A CN109866435A CN 109866435 A CN109866435 A CN 109866435A CN 201811321112 A CN201811321112 A CN 201811321112A CN 109866435 A CN109866435 A CN 109866435A
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fiber
reinforced resin
transparent membrane
substrate sheets
slot
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CN109866435B (zh
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松元正太
河合功介
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Subaru Corp
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    • B29C70/48—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements in the closed mould, e.g. resin transfer moulding [RTM], e.g. by vacuum
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    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/06—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts
    • B29K2105/08—Condition, form or state of moulded material or of the material to be shaped containing reinforcements, fillers or inserts of continuous length, e.g. cords, rovings, mats, fabrics, strands or yarns
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Abstract

本发明涉及纤维增强树脂体及其制造方法，提供一种能够减少纤维增强树脂体表面产生的凹凸、提高生产率的纤维增强树脂体及其制造方法。该纤维增强树脂体的制造方法，在成型模具的下模(74)中，以透明薄膜(20)为最外层，在其上重叠由纤维织物制成的基材片(50)，关闭上模(72)并在上下模内注入基体树脂(40)。透明薄膜(20)在与基材片(50)相对的表面具有多个槽(22)，当载置在下模(74)上时以槽(22)位于基材片(50)的相邻织眼(55)之间的方式进行层叠。

Description

纤维增强树脂体及其制造方法
技术领域
本发明涉及一种包括透明薄膜和由纤维织物制成的基材片的纤维增强树脂体及其制造方法。
背景技术
在树脂中混入有碳纤维等纤维材料的纤维增强树脂体(FRP：Fiber－ReinforcedPlastics)用于包括汽车、航空器等领域的各种工业领域。纤维增强树脂体因为重量轻且强度高，因而适合作为轻量化零件。特别是，使用纤维织物例如碳纤维织物作为纤维材料的纤维增强树脂体构成为使织眼从表面侧可见，由此发挥出较高的设计性，因此，近年来需求不断增长。
作为纤维增强树脂体的制造方法，专利文献1中记载了一种方法，其是在成型用模具的下模中载置薄膜片，在其上载置纤维织物片并关闭上模合膜后，注入基体树脂使其固化。
这样，通过在成型时在最外层配设薄膜片，省略在成型后在表面另外涂布保护用胶衣的工序，并且能够在保持设计性的同时提高表面的保护性能。
现有技术文献
专利文献
专利文献1：日本特开平8－156116号公报
发明内容
发明要解决的技术问题
通常，由纤维织物制成的纤维增强树脂体由于纤维织物的织眼造成的表面的凹凸形状和进入其的基体树脂的收缩，会在成型制品的表面产生沿织眼的高度差。具体而言，在表面凹陷的织眼部分，基体树脂的壁厚增加，因此，若基体树脂固化、收缩，则在织眼部分形成凹部。
如专利文献1，在使薄膜片与纤维织物片一体成型的制品中，伴随基体树脂的收缩，层叠于其上的薄膜片被拉伸，从而薄膜片的表面形成凹凸。
因此，为了使成型制品的表面平滑以提高外观设计性，在纤维增强树脂体成型后，需要在表面涂布填孔剂并抛光，或涂敷多层透明涂料。
然而，由于抛光处理和涂敷处理需要时间和成本，因此，需要一种能够减少成型时产生的表面的凹凸以提高生产率，并降低成本的制造方法。
本发明是鉴于上述课题而完成的，其目的在于，提供一种能够减少纤维增强树脂体表面产生的凹凸，从而提高生产率的纤维增强树脂体及其制造方法。
用于解决问题的技术方案
为了实现上述目的，本发明第一方面提供一种纤维增强树脂体的制造方法，包括：载置工序，在成型模具的下模中，以透明薄膜为最外层，在其上重叠载置由纤维织物制成的基材片；以及树脂注入工序，关闭上模并在上下模内注入基体树脂，其中，所述透明薄膜在与所述基材片相对的表面具有多个槽，在所述载置工序中，以所述槽位于所述基材片的相邻织眼之间的方式进行层叠。
根据该结构，由于透明薄膜的槽位于基材片的相邻织眼之间，因此，在注入基体树脂时，在基材片的织眼部分、和位于织眼之间的透明薄膜的槽部分，基体树脂的壁厚增加。这样，在织眼之间也形成壁厚较厚的部分，由此在基体树脂固化、收缩时，表面形成的凹凸变得微细，整体上能够加工成凹凸较小的平滑表面。这样，通过由一体成型的透明薄膜的构造抑制成型纤维增强树脂体时在表面产生的凹凸，能够省去成型后进行的抛光处理，或减少涂敷处理的次数，其结果，可以抑制制造成本并提高生产率。
另外，本发明第二方面的纤维增强树脂体的制造方法在本发明第一方面的基础上，其特征在于，所述透明薄膜在表面具有多个微细的贯通孔。
根据该结构，在成型纤维增强树脂体时，可以使基体树脂内产生的气泡从透明薄膜的贯通孔脱气，因此，能够抑制成型时产生气泡。另外，可以通过进入透明薄膜的槽部分及贯通孔部分的基体树脂的凝聚力将基体树脂固化时在基材片的织眼部分产生的凝聚力分散，因此，能够抑制表面产生凹凸。
另外，本发明第三方面的纤维增强树脂体的制造方法在本发明第一或第二方面的基础上，其特征在于，所述透明薄膜的槽形成为网格状，网格的宽度设定为等于所述基材片的织眼的宽度或小于织眼的宽度。
根据该结构，通过将透明薄膜的槽的形状设为网格状，能够使基体树脂容易沿槽流动。另外，能够容易将透明薄膜的槽配置在基材片的织眼之间。
另外，本发明第四方面的纤维增强树脂体的制造方法在本发明第一至第三方面中任一方面的基础上，其特征在于，所述透明薄膜在形成为网格状的槽的交叉部具有贯通孔。
根据该结构，在网格状的槽中，在基体树脂容易流入的槽的交叉部形成有贯通孔，因此，可以更有效地使基体树脂内产生的气泡从透明薄膜的贯通孔脱气。
另外，本发明第五方面提供一种纤维增强树脂体，其具备：纤维增强树脂层，其在表层具有由纤维织物制成的基材片，并且填充有基体树脂；以及透明薄膜，其覆盖该纤维增强树脂层的表层形成最外层，并与所述纤维增强树脂层一体成型，其中，所述透明薄膜在与所述基材片相对的表面具有多个槽，该槽至少位于所述基材片的相邻织眼之间，且在内部填充有所述基体树脂。
根据该结构，由于透明薄膜的槽位于基材片的相邻织眼之间，因此，在一体成型透明薄膜和纤维增强树脂层时，在基材片的织眼部分、和位于织眼之间的透明薄膜的槽部分，形成纤维增强树脂层的基体树脂的壁厚增大，因此，由于基体树脂的固化、收缩而在表面形成的凹凸变得微细，所以整体上能够加工成凹凸较小的平滑表面。这样，通过由一体成型的透明薄膜的构造抑制成型纤维增强树脂体时在表面产生的凹凸，能够省去成型后进行的抛光处理，或减少涂敷处理的次数，其结果，可以抑制制造成本并提高生产率。
发明效果
根据本发明的纤维增强树脂体及其制造方法，能够减少纤维增强树脂体表面产生的凹凸，提高生产率。
附图说明
图1是示意性表示本发明一实施方式的纤维增强树脂体表面的俯视图。
图2是沿着图1中的II－II线的剖视图。
图3是沿着图1中的III－III线的剖视图。
图4是从内表面侧观察透明薄膜的俯视图。
图5是示意性表示纤维增强树脂体的成型工序的制造装置的剖面示意图。
图6(a)和图6(b)是示意性表示纤维增强树脂体的成型工序的剖面示意图。
图7是表示透明薄膜的变形例1的与图4同样的俯视图。
图8是表示透明薄膜的变形例2的与图4同样的俯视图。
图9是表示透明薄膜的变形例2的与图2同样的剖视图。
图10是表示透明薄膜的变形例3的与图4同样的俯视图。
图11是表示现有的纤维增强树脂体的与图2同样的剖视图。
具体实施方式
图1是示意性表示本发明一实施方式的纤维增强树脂体10表面的俯视图，图2是沿着图1中的II－II线的示意性剖视图，图3是沿着图1中的III－III线的示意性剖视图。
纤维增强树脂体10具有形成最外层的透明薄膜20和与透明薄膜20相邻层叠的纤维增强树脂层30。透明薄膜20在与纤维增强树脂层30相对的内表面具有多个槽22。纤维增强树脂层30是通过将基体树脂40浸渍在一个以上的纤维片的层叠体中并使其固化而形成的层，至少在与透明薄膜20相对的一侧的面上具有由纤维织物制成的基材片50。
作为构成纤维增强树脂层30的增强纤维，例如，可以使用碳纤维或玻璃纤维，从轻量化和高强度、高刚性的观点出发，特别优选使用碳纤维。本实施方式中，作为基材片50使用平纹编织由碳纤维的纤维束制成的经线52及纬线54而成的纤维织物。此外，基材片50不限于平纹，例如，还可以为斜纹或缎纹织物。如图1～图3所示，基材片50具有织眼55(即，经线52和纬线54的间隙部分)。
此外，在本实施方式中，纤维增强树脂层30由以基材片50为最外层的多个纤维片的层叠体构成，但各图中仅记载纤维片层叠体中的基材片50，省略其他纤维片的记载。层叠于基材片50的纤维片不限于织物，例如，也可以为使纤维在一个方向上排列的单向材料、针织品、无纺布等。
构成纤维增强树脂层30的基体树脂40可以适当应用热塑性树脂及热固性树脂中的任何一种。作为热固性树脂，例如，可以使用环氧树脂、不饱和聚酯树脂、酚醛树脂、聚氨酯树脂等。作为热塑性树脂，例如，可以使用聚乙烯树脂、聚丙烯树脂、聚氯乙烯树脂、ABS树脂、聚苯乙烯树脂、AS树脂、尼龙6或尼龙66等聚酰胺树脂、聚缩醛树脂、聚碳酸酯树脂、热塑性聚酯树脂、PPS(聚苯硫醚)树脂、氟树脂、聚醚酰亚胺树脂、聚醚酮树脂、聚酰亚胺树脂等。另外，这些热塑性树脂可以分别单独使用，也可以两种以上并用。
图4是从内表面侧观察透明薄膜20的俯视图，并用虚拟线示出了基材片50的经线52及纬线54，以理解相对于基材片50的层叠状态，具体而言，理解层叠状态中的织眼55和透明薄膜22的槽22及贯通孔26的位置关系。
透明薄膜20可以适当应用热塑性树脂及热固性树脂中的任何一种，但从与纤维增强树脂层30一体成型的观点出发，优选使用热塑性树脂。作为热塑性树脂，例如，可以使用丙烯酸树脂、聚碳酸酯树脂、聚对苯二甲酸乙二醇酯树脂等。透明薄膜20在与纤维增强树脂层30相对的面即内表面具有槽22，外表面为没有槽22的平滑面。
槽22具有沿纵向呈直线状连续延伸的多个纵槽22A和沿横向呈直线状连续延伸的多个横槽22B，整体上形成为大致正方形的网格状。如图4所示，槽22形成的网格的宽度X1设定为与基材片50的相邻织眼55的宽度X2相同的大小。宽度X2可根据编织纱线适当设定，例如，可以为2mm～1.5cm。另外，由槽22形成的网格形状、和通过由经线52及纬线54的两侧边缘形成的编织纱线形成的网格状的图案(参考图4的虚拟线)在纵向及横向上错位配置，以在纵向及横向上至少一个槽22配置于相邻织眼55之间。
在本实施方式中，纵槽22A及横槽22B的宽度W1分别设定为与织眼55的宽度W2大致相同的大小。此外，宽度W1、W2可以适当设定，例如，也可以将槽22的宽度W1设定为大于或小于织眼55的宽度W2。
基材片50或包含其的纤维片层叠体的厚度，例如为0.5mm以上，透明薄膜20的厚度(未形成槽22的部分的厚度)，例如可以设为0.2mm～0.5mm。
如图3及图4所示，在透明薄膜20的表面形成有多个微细的贯通孔26，基体树脂40进入该贯通孔26。贯通孔26优选配置于不与织眼55重合的位置。在本实施方式中，在纵槽22A和横槽22B的交叉部分23分别形成有贯通孔26。贯通孔26的直径优选设为小于或等于槽22的宽度W1的大小。
上述纤维增强树脂体10例如使用树脂传递模塑(RTM)成型等所使用的已知成型用模具70制造。图5是示意性表示具有模具70的纤维增强树脂体10的制造装置80的图。模具70具备上模72和下模74，并安装于未图示的压制装置。上模72是可动模，并构成为可上下移动，以通过压制装置的升降机构接近或远离作为固定模的下模74。通过上模72接近下模74，模具70关闭而在内部形成腔室(成型模具的内部空间)。腔室具有对应成型后的纤维增强树脂体10的形状的凹凸形状。在上模72上安装有向腔室内注入基体树脂40的注入器76。
下面，使用图5及图6(a)和图6(b)说明纤维增强树脂体10的制造方法。
首先，如图6(a)所示，在上模72远离下模74的状态下，将透明薄膜20以形成有槽22的表面面向腔室内的方式载置在下模74的腔室形成面75上。
其次，如图6(b)所示，在透明薄膜20上重叠载置基材片50(载置工序)。此外，在纤维增强树脂层30由包含基材片50的多个纤维片的层叠体构成的情况下，以基材片50与透明薄膜20相邻层叠的方式载置纤维片层叠体。基材片50以在相邻织眼55之间配置透明薄膜20的槽22的方式层叠。另外，以基材片50的织眼55不与透明薄膜20的贯通孔26重合的方式层叠。
此外，基材片50或纤维片层叠体可以预成型为成型制品的形状，也可以不预成型。另外，纤维片层叠体可以为将多个纤维片通过由热固性树脂或热塑性树脂制成的粘合剂相互粘合而成的半固化物(プリプレグ)。
载置透明薄膜20及基材片50后，通过升降机构使上模72接近下模74而合膜。腔室内由设于模具70的密封材料78密封。在图5所示的合膜状态下，通过未图示的真空装置将模具70内抽成真空状态后，从注入器76将基体树脂40注入腔室内，并浸渍到纤维片中(树脂注入工序)。在本实施方式中，作为基体树脂40，使用熔点及粘度比构成透明薄膜20的热塑性树脂低的热塑性树脂，注入基体树脂40时，模具70内以等于或高于基体树脂40的熔点且低于透明薄膜20的熔点的温度加热。
注入的基体树脂40进入透明薄膜20的槽22的内部及贯通孔26的内部。由此，基体树脂40内的气泡通过槽22或贯通孔26促进脱泡。
之后，使基体树脂40固化，打开模具取出所成型的纤维增强树脂体10。
基体树脂40固化时，在基体树脂40的壁厚较厚的部位产生比壁厚较薄的部分大的凝聚力，基体树脂40在厚度方向大幅收缩，从而与较薄的部分相比更凹陷，整体上表面呈凹凸状。
如图11所示，在透明薄膜120未形成有槽及贯通孔的现有纤维增强树脂体100中，由于基体树脂140的固化、收缩，在纤维增强树脂层130上，在由基材片150的经线152及纬线154形成的织眼155的部分表面产生较大的凹陷(凹痕)157。换言之，在作为织物的基材片150的凹凸的凸部，表层的基体树脂140变薄，在基材片的凹部(即织眼155的部分)，基体树脂140变厚，因此，在基体树脂140固化、收缩时，基体树脂155的较厚部分比较薄部分更凹陷。随着该收缩，表面的透明薄膜120被拉伸，在纤维增强树脂体100的表面形成凹部127，并且表面变成凹凸状。
在本实施方式的纤维增强树脂体10中，如图2所示，在现有的、基体树脂40的厚度变薄的基材片50的凸部配置有透明薄膜20的槽22和贯通孔26，由此，除织眼55的部分外，还在基材片50的凸部也形成基体树脂40的壁厚较厚的部分。由此，通过填充于槽22和/或贯通孔26的基体树脂40的凝聚力分散了填充于织眼55的基体树脂40的凝聚力，伴随基体树脂40收缩的透明薄膜20的表面的拉力比现有的小。其结果，形成于透明薄膜20的外表面的凹部与现有相比凹陷量变小，且变细，透明薄膜20的外表面整体上成为平滑的平面状。
进而，基体树脂40从贯通孔26到达纤维增强树脂体10的表层，由此可以释放内部应力，与仅有槽22的情况相比，可以加工成更平滑的表面。另外，填充于贯通孔26的柱状的基体树脂40支撑透明薄膜20而减轻表面的凹凸。
这样，在成型纤维增强树脂体10时，通过将表面形成为比现有更平滑的平面状，能够省去成型后进行的表面的抛光处理，或者减少涂敷处理的次数，可以抑制制造成本并提高生产率。
进而，在上述纤维增强树脂体10中，在注入基体树脂40时，通过促进从槽22和贯通孔26的脱泡，能够提高质量。特别是，由于将贯通孔26设置在基体树脂40容易流入集聚的槽22的交叉部分23，因此能够有效地进行脱气。
另外，由于基体树脂40为熔点及粘度低于透明薄膜20的热塑性树脂，因此，能够防止成型时透明薄膜20熔化。
下面，使用图7～图10说明纤维增强树脂体10中的透明薄膜20的变形例。此外，在图7～图10中，与上述实施方式同样的要素标注相同的符号，并省略其说明。
(变形例1)
在图7所示的变形例1中，由槽22形成的网格的宽度X1设定为小于基材片50的织眼的宽度X2。这样，通过将槽22的网格宽度X1设定为小于织眼宽度X2，能够在相邻织眼55之间可靠地配置一个或多个槽22。此外，图7中，虽然所有的槽22以不与织眼55重合的方式配置，但槽22的一部分也可以与织眼55重合配置。此外，在经线52的方向(或纬线54的方向)上，每单位长度的横槽22B(或纵槽22A)的数量优选为织眼数量的2倍以上。
(变形例2)
在图8及图9所示的变形例2中，槽22沿与经线52及纬线54延伸的方向不同的两个方向延伸。具体而言，具有沿与纵向及横向交叉的第一方向延伸的多个第一槽24A和沿与第一方向垂直的第二方向延伸的多个第二槽24B。在图示例中，以第一槽24A及第二槽24B相对于纵向及横向倾斜约45度的角度，槽22的交叉部分23在纵向及横向上位于相邻织眼55之间的方式配置。
(变形例3)
在图10所示的变形例3中，网格状的槽22在交叉部分23是非连续的，在该非连续部分形成有贯通孔26。如变形例3所示，槽22可以在非连续状态下沿两个方向延伸。这样，通过将槽22设为非连续的直线状，能够在使基体树脂40沿槽22的延伸方向容易流动的同时，调节流入量。
此外，本发明不限于上述实施方式及变形例，在不脱离本发明的主旨的范围内可以进行各种变更。例如，透明薄膜22可以不具有贯通孔26。
另外，例如，透明薄膜20的槽22的形状可以不为网格状，只要以一个或多个槽22位于相邻织眼55之间的方式配置即可。
另外，透明薄膜20的贯通孔26的配置位置不限于槽22的交叉部分23，例如，可以仅配置于槽22的非形成区域中，也可以配置于槽22的形成区域和非形成区域的两者中。
符号说明
10 纤维增强树脂体
20 透明薄膜
22 槽
26 贯通孔
30 纤维增强树脂层
40 基体树脂
50 基材片
52 经线
54 纬线
55 织眼
70 模具
72 上模
74 下模

Claims (5)

1.一种纤维增强树脂体的制造方法，包括：
载置工序，在成型模具的下模中以透明薄膜为最外层，在所述透明薄膜上重叠载置由纤维织物制成的基材片；以及
树脂注入工序，关闭上模并在上下模内注入基体树脂，
其中，所述透明薄膜在与所述基材片相对的表面具有多个槽，
在所述载置工序中，以所述槽位于所述基材片的相邻织眼之间的方式进行层叠。
2.根据权利要求1所述的纤维增强树脂体的制造方法，其中，
所述透明薄膜在表面具有多个微细的贯通孔。
3.根据权利要求1或2所述的纤维增强树脂体的制造方法，其中，
所述透明薄膜的槽形成为网格状，网格的宽度设定为等于所述基材片的织眼的宽度或小于织眼的宽度。
4.根据权利要求1～3中任一项所述的纤维增强树脂体的制造方法，其中，
所述透明薄膜在形成为网格状的槽的交叉部具有贯通孔。
5.一种纤维增强树脂体，包括：
纤维增强树脂层，其在表层具有由纤维织物制成的基材片，并且填充有基体树脂；以及
透明薄膜，其覆盖该纤维增强树脂层的表层形成最外层，并与所述纤维增强树脂层一体成型，
其中，所述透明薄膜在与所述基材片相对的表面具有多个槽，
该槽至少位于所述基材片的相邻织眼之间，且在内部填充有所述基体树脂。
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