CN1921996A - Rtm molding method and device - Google Patents

Abstract

An RTM molding method comprising disposing and clamping a reinforced fiber base material in the cavity of a molding die consisting of a plurality of dies, and then injecting resin to complete molding, characterized in that divided areas with respect to the surface direction of the reinforcing fiber base material are assumed, respective divided areas are ones in which injected resin expands over the entire surface in the areas and can be substantially uniformly impregnated in the base material thickness direction, and injected resin introducing paths are formed into the respective divided areas for respective assumed divided areas; and an RTM molding device. When a comparatively large molded product is to be formed, a molding step from resin injection to impregnating/hardening can be implemented at high speed without producing a non-resin-flowing area, thereby enabling a high-quality molded product to be produced free from voids, etc., with a molding time shortened and a production speed/production volume increased.

Description

RTM forming method and device

Technical field

The present invention relates to be used for RTM (resin transfer molding (Resin Transfer Molding)) forming method and the device of moulding, particularly the RTM forming method and the device of energy high-speed molding and raising surface quality than relatively large FRP (fiber-reinforced resin).

Background technology

FRP, particularly CFRP (carbon fiber-reinforced resin) are applied to every field as lightweight and composite with high engineering properties.A kind of as the FRP forming method, known have in mould mounting by the reinforcing fiber base that the lamination material of reinforcing fiber fabric etc. constitutes, and behind the mold closing, reduces cavity pressure, injects liquid resin, the RTM forming method that heating makes it to solidify.Also propose in addition, in above-mentioned moulding in the past, by with about the excipient mould hold pressure under the arm, before being provided in shaping mould, give reinforcing fiber base shape (as patent documentation 1) to a certain degree in advance.

In RTM forming method in the past, inject resin from an inlet pressurization usually.Then, a plurality of resin outlets according to circumstances are set.But this method is owing to be difficult to set significantly the amount of mobile resin, and has only a resin inlet, so there is the problem of massive article RTM difficult forming.That is, exist following problems: in making resin flows, the gelation of resin aggravation (resin viscosity increase), resin can't flow into the whole zone of moulded products.In addition, prolong gelation time if in resin, add set retarder, though then elapsed time makes resin flow into whole zone, the resin flows holding time of regulation, thus speed of production, output reduce.And then, when the moulding massive article, particularly during bigger 3-D solid structure, if make resin flows from an inlet, the phenomenon in the zone that resin can not flow to can appear then producing because of shape.Even a plurality of resin outlets control resin flows are set, also there is certain limitation in labyrinth that can good moulding.

On the other hand, as whole the method for injecting resin simultaneously, RFI (resin molding soaks Resin Film Infusion) method is arranged from formed body.This method heats for the state with the resin film of bonding impregnation semi-solid preparation in the reinforcing fiber base of not impregnation, make the method for molten resin impregnation through pressurizations such as hot presses, but this method exists and is difficult to the shape of moulding complexity, generates problem such as not impregnation part easily in the part of reinforcing fiber base.

Method as also can impregnation in having certain complexity and large-scale moulded products for example has the method described in the patent documentation 2 etc.The matrix form resin carrier that this method is dipped in the sponge material for use for example makes molten resin contain replaces the method for the resin film impregnation in the above-mentioned RFI method, though be a kind of method through improvement, but as method by cheap and simple method pressurization impregnation massive article, employing covers at the packaging material film and reduces wherein under the state all by formed body that the method and the plus-pressure maximum of pressure can only reach 0.1Mpa, can not contain the problem that is dipped into slab or trickle part fully so exist.

Because said method all is not to make the matrix form resin flows limit of fusion make it to contain the method that is dipped into the reinforcing fiber base from beginning the limit at first, so the factor that generates not impregnation part is arranged.

In addition, as RTM forming method in the past, also known have from the method for a filling line pressurization injection resin.For example, when the moulding goods were made of polygonal shape (polygon), resin injected from going into (as patent documentation 3, patent documentation 4) to other marginal nots of subtend on one side.But, in this method, though resin is from flowing to opposite side limit impregnation reinforcing fiber base limit successively on one side, when but if moulded products becomes bigger, then there is following problems: the time that the resin flows needs are extremely many, and with the variation of situation, resin arrives gelation time and is stopping to flow before the impregnation fully in flowing.Therefore, proposed the method that the resin filling line also injects successively to be set as above-mentioned patent documentation 3 described many places at moulded products, but because this method is injected resin in the forming area of moulded products, so, can't inject from the shaping mould both sides and inapplicable for using core and disposing the interlayer moulded products of reinforcing fiber base on this core two sides.In addition, even be not the interlayer moulded products, be not suitable for the moulding of the moulded products of two face moulds and the high pattern of surface requirements yet.So above-mentioned RTM forming method in the past is difficult to the relatively large moulded products of moulding efficiently.

Usually, in by the RTM shaping mould that constitutes than multimode, so because of needing extremely many time to have the low big problem of productivity ratio in the moulding.On the other hand, when shaping mould is the formation of film up and down, have to die face and described reinforcing fiber base is installed than the advantage that is easier to and the set-up time is also short, on the contrary, general resin method for implanting, promptly in exert pressure with 0.2～1.0Pa, do not control especially under the situation of flow velocity injection resin, resin is to flow in the mould with the pressure flow rate corresponding, casting resin in mould in the short period of time, but reinforcing fiber base becomes chaotic because of resin flow, or flow velocity is fast and generate inhomogeneous resin flow, thereby produces space or pin hole easily on the surface of moulded products.

Particularly, in order to shorten molding time, the large-area moulded products of moulding at short notice, when being 0.5MPa or the high pressure more than the 0.5MPa (being high speed therefore) injection resin with the resin outflow pressure, because the braiding structure of reinforcing fiber base (particularly flat fabric) is chaotic easily, and resin flows in the mould at a high speed, part base material due to the small thickness inequality of the cavity dimension inequality of Yin Monei (especially uneven thickness) or base material or the mutual superposition between the base material etc. constitutes different, make flow resistance in flow region, disperse, can not keep uniform resin flow, so can produce part " trying to be the first of resin flow " etc., thereby generate bigger space.Also have following situation in addition: in fact resin has flowed in this base material part, but fast because of flow velocity, for example the gas in the fabric reticulate pattern does not have the time of discharging and is detained, thereby generates the defective of pin hole on the surface.Above-mentioned causing in the past the condition of molding or molding procedure that the presentation quality relevant with pattern such as base material confusion or space, pin hole etc. reduce is difficult to carry out guaranteeing when injecting at a high speed great surface quality in order to shorten molding time.The model of moulded products is big more, injects resin in any case at a high speed, and the defective on the above-mentioned presentation quality all easily takes place.

Because the resin flow state influences the above-mentioned space relevant with pattern or the generation of pin hole greatly, also becomes key factor so the density of fiber reinforced substrate is weight per unit area.That is to say,, therefore must set the suitable weight per unit area of being satisfied with the resin flows condition because the weight per unit area of every layer of fiber-reinforced resin influences the discharge difficulty or ease of resin flow resistance or bubble.Not only consider from the surface quality aspect separately, also consider also to need suitably to set this weight per unit area from viewpoints such as preformed operability or rate of utilization of strength.Promptly, rigidity of base material strengthens if weight per unit area is excessive, then cause following situation: reinforcing fiber base is difficult to along die face three-dimensional shape be carried out needing a large amount of operating times in excipient or the preformedization, and cause the base material confusion this moment, thus degradation under the mechanical characteristic of FRP moulded products.That is,, need have the weight per unit area that meets working condition (moulding model shape, condition of molding etc.) in order to produce efficiently.

In addition, in the condition of molding, particularly temperature or resin injection pressure are higher to the degree of influence of surface quality.When the resin temperature that heats when the temperature or the metal pattern of the resin that is injected itself is higher, the flowability that descends resin viscosity rises, impregnation to base material is good, but when the viscosity climbing raises, mobile sharply variation, moulded products exists resin flows from slowing down midway when big, produce the situation of not impregnation part.Even resin flows into whole zone, even or do not produce not by impregnation in the zone that viscosity raises, also easily produce space or pin hole.On the other hand, if metal pattern temperature inequality, or change in the moulding, grow up to the air pocket that develops into space or pin hole thereby then be in contact with one another between the interior residual atomic minute bubbles of mould.

In addition, moderate pressure is also very important.Promptly have following situation: the resin flow velocity accelerates when too high, makes the braiding structure confusion of base material or the expansion of die cavity inner volume generate bubble; Crossing when low residual bubble can not compress and diminish.

Because reaction resin can produce reacting gas in solidification process, or be included in small gas (bubble) in the resin and grow in time and become big, thereby grown up to space or pin hole, thus the resin impregnation enter solidify as soon as possible as early as possible behind the base material better.

The material behavior of this reaction resin is very high to the degree of influence of moulding yield, for example according to the kind difference of curing agent, it is maximum that the reaction speed of initial reaction stage resin reaches, through after a while, reaction speed reduces, and therefore exists the elongated situation of required time of solidifying.Relative with it, also exist following situation: thus desire to make the temperature rising of shaping mould to shorten hardening time, it is excessive that initial stage viscosity is risen to, resin injects excess stickiness rising when flowing, generation gelation as a result is molded over Halfway Stopping, generates not impregnation part.

As mentioned above, in the FRP moulding (particularly RTM moulding), not moulding is under proper condition then thought aspect quality if having the suitable condition of molding be satisfied with compact dimensions (area) or material behavior, and particularly the surface quality aspect is easy to generate problem.

Following method has also been proposed: with the surface quality that improves moulded products as one of purpose, when the RTM moulding, seize on both sides by the arms with excipient mould up and down in advance, before in shaping mould, setting, give reinforcing fiber base shape to a certain degree in advance, directly reinforcing fiber base is configured in forming surface (as above-mentioned patent documentation 1).

But in the aforesaid forming method in the past, when if the resin that is injected into, solidifies can not fully contain each corner that is dipped into reinforcing fiber base, then become the reason that produces space or pin hole, or reduce the mechanical property of moulded products, thereby cause surface quality to descend.If particularly on the surface, even in inside, space or pin hole appear in pattern plane one side, then replenish resin etc. usually and study for a second time courses one has flunked, but need spended time in this is studied for a second time courses one has flunked, and reduce the whole efficiency of manufacturing process.

As the space of the surface quality that prevents to generate above-mentioned infringement pattern plane or the countermeasure of bubble, unordered felt (random mat) layer is set on the base material of top layer sometimes.Because this unordered mat layer is an outermost layer, so also be the reason that is called as " surfacing mat (surface mat) ", be applicable to that sometimes particularly semi-solid preparation soaks into thing/hot-press solidifying method, RFI (resin molding soaks ResinFilm Infusion) and manual layup method (hand lay-up) etc.But as its structure, compare with the scheme that aftermentioned the present invention relates to, top layer base material and unordered mat layer are the matrix structure that all changes.

Carry out as RTM moulding or vacuum forming etc. with above-mentioned base material formation, be in the base material of drying, to inject resin fluid, make it the forming method of mobile impregnation, must utilize resin flows to discharge bubble, but the place low at Resin Flow also is easy to generate the space, or the residual pin hole that directly becomes of bubble.

Use aforesaid unordered mat layer to be configured in outermost layer as surfacing mat, when carrying out the FRP moulding according to RTM moulding or vacuum forming method, pressing is in the unordered felt of dry substrate state to the metal die face, because the bulkiness of the unordered felt of low weight per unit area is low, so the gap between metal die face and the unordered felt is very little.Therefore, resin is poor to the flowability in this gap, and the result easily generates space or pin hole herein.As mentioned above, especially in RTM forming method or vacuum forming method, even on outermost layer (pattern plane on top layer), the generation that unordered mat layer can not prevent space or pin hole is set.

Patent documentation 1: the spy opens the 2003-305719 communique

Patent documentation 2: the spy opens the 2002-234078 communique

Patent documentation 3: the spy opens flat 8-58008 communique

Patent documentation 4: the spy opens the 2003-11136 communique

Summary of the invention

In view of aforesaid present situation, the 1st problem of the present invention is for providing a kind of RTM forming method and device, even described RTM forming method is for bigger 3-D solid structure, can not produce yet resin circulation less than the zone, be injected into moulding process that impregnation solidifies from resin and also can carry out at a high speed, thereby can realize the shortening molding time with respect in the past RTM forming method or device; Improve speed of production, output, particularly increase the output of each mould; Reduce manufacturing cost.

In addition, the 2nd problem of the present invention be for providing a kind of RTM forming method and device, and described RTM forming method is for being that actual projected area is 1m at the bigger mould of moulding ²Or 1m ²In the RTM moulding of above fiber reinforced resin product, can be at short notice the moulded products of high-quality such as moulding tight efficiently.

And, the 3rd problem of the present invention is for providing a kind of RTM forming method, described RTM forming method is for making the resin of injection spread all over desired gamut easily and well in the operation of injecting resin, thereby produces particularly on the surface or even inner pattern plane one side does not generate the fiber-reinforced resin that space or pin hole, realization surface quality improve.

For solving above-mentioned problem, the RTM forming method that the present invention relates to is characterized by reinforcing fiber base is configured in the die cavity of the shaping mould that is made of a plurality of moulds, inject resin and the RTM forming method of moulding behind the mold closing, it is characterized by, surface direction supposition cut zone at described reinforcing fiber base, and form respectively each cut zone to supposition and import and inject resin to the resin of this cut zone inside and import path, described each cut zone is for injecting resin and can expand in the whole surface in the zone and can be along the base material thickness direction cut zone of impregnation in fact equably.In above-mentioned RTM forming method, at least can from behind the mold closing till begin to inject resin, in official hour, carry out vacuum draw from the resin discharge line.

In addition, RTM shaped device among the present invention is for to be configured to reinforcing fiber base in the die cavity of the shaping mould that is made of a plurality of moulds, inject resin and the RTM shaped device of moulding behind the mold closing, it is characterized by, on the surface direction of described reinforcing fiber base, suppose cut zone, and form respectively each cut zone to supposition and import and inject resin to the resin of this cut zone inside and import path, described each cut zone is for injecting resin and can expand in the whole surface in the zone and can be along the base material thickness direction cut zone of impregnation in fact equably.In this RTM shaped device, have at least can from behind the mold closing till begin to inject resin, the equipment of vacuum draw resin discharge line in official hour.

As mentioned above, in RTM forming method that the present invention relates to and device, for having the larger area reinforcing fiber base, it is presumed to the cut zone of suitable size, formation imports respectively to each cut zone injects the resin importing path of resin to this cut zone inside, import path by this resin and inject resin, the result can make resin rapidly and the whole regional impregnation of impregnation reinforcing fiber base equably.Cut zone cut apart number, can state a plurality of denumerable number of cutting apart shown in the 1st, the 2nd scheme for following, also can be the numerous in fact cut zone number shown in following the 3rd scheme.

The present invention is special above-mentioned the 1st problem that solves, following RTM forming method is provided, promptly between each mould that constitutes described shaping mould, set intermediate member with the resin stream that on thickness direction, connects, by this intermediate member, can be from many places almost simultaneously with resin injection reinforcing fiber base material (method that the 1st scheme relates to).

In addition, the invention provides following RTM shaped device, described RTM shaped device is for being provided with intermediate member between each mould that constitutes described shaping mould, described intermediate member has the resin stream that connects on thickness direction, can be from many places almost simultaneously with resin injection reinforcing fiber base material (device that the 1st scheme relates to) by this resin stream.

In RTM forming method that above-mentioned the 1st scheme relates to and the device, on any mould, form the resin discharge groove that can extend to full week of reinforcing fiber base in fact.In addition, on above-mentioned intermediate member, also form the resin discharge groove that can extend to full week of reinforcing fiber base in fact.

Above-mentioned intermediate member can be for being provided with the structure of resin stream with groove and through hole, wherein, described resin stream is formed on groove on the one side of described intermediate member, and described through hole is the through hole that reinforcing fiber base disposes the face of side for being communicated with, running through described reverse side with this groove.

As above-mentioned intermediate member, can use in metal system or the resin system any.In addition, can hold pressurizing resin under the arm for above-mentioned intermediate member and the mould relative and inject the structure that seals with member (injecting with pipe) as resin with it.Also can be above-mentioned intermediate member and hold pressurizing resin by the reinforcing fiber base mould relative under the arm and discharge the structure that seals (discharging with managing) with member as resin with above-mentioned intermediate member.

Also can use porous plate or resin-made membrane with a plurality of through holes as above-mentioned intermediate member.At this moment, can be on the mould relative, being provided with the structure of resin stream with groove with intermediate member.In addition, also can be between above-mentioned intermediate member and the mould relative, forming the structure in gap with it, wherein, this gap is in 1～10mm scope.

The structure of stacked core in above-mentioned reinforcing fiber base can adopt the representative sandwich of holding core from both sides with fiber reinforced substrate under the arm.

Sealing for the involutory face of mould that improves shaping mould, the sealing of resin injection portion or discharge portion particularly, shorten the RTM shaping cycle duration, can adopt following structure: hold under the arm at the involutory face of mould and press the injection that resin is set, seal with elastomer (sealing elastomer) between this Guan Yumo with pipe and/or discharge pipe.

The structure that above-mentioned sealing improves can be for using the structure of the end of built-in O-ring in the elastomer in sealing, described O-ring is at the die cavity of the involutory facial sealing moulding mould of mould.

In addition, the micro-bubble that is detained for the molten corner of depositing bubble that gas evaporation generates or mould of discharging the resin that produces when resin injects can be discharged the gas in the shaping mould and the structure of residual resin discontinuously for the injection resin limit of pressurize, limit in above-mentioned shaping mould.

In these cases, the resin pressure in the described shaping mould of pressurization injection resin is Pm, when the resin outflow pressure of the inlet of injection resin is Pi, optionally makes Pm=Pi, Pm＜Pi, can control the flow that flows into the resin in the shaping mould.In addition, can be by the resin flow in the bore control inflow shaping mould of regulating the outlet of discharging resin.Also can store the time point of adjusting He its adjusting of above-mentioned outlet bore,, be controlled to the resin flow in the pattern automatically according to this stored information.

In addition, in the time of can injecting resin in the die cavity of shaping mould, pressurizeing, the unit interval flow (Q:cc/min) of resin and the projected area (S:m of die cavity ²) ratio (Q/S:cc/minm ²) structure in 50＜Q/S＜600 scopes.

Under this situation, can be for above-mentioned than (Q/S:cc/minm ²) with product ((the Q/S) * P:ccMPa/minm of the plus-pressure (P:MPa) of resin ²) structure in 20≤(Q/S) * P≤400 scopes.

In addition, can adopt structure, the above-mentioned resin of above-mentioned resin plus-pressure in the scope of 0.2～0.8MPa is the structure of solidifying under 60～160 ℃ of uniform temperatures in the scope 3～30 minutes in heating-up temperature.

RTM forming method that relates in aforesaid the 1st scheme and device are RTM forming method and device based on following basic thought, the described problem of solution.That is, increase the resin inlet, the resin circulating area of each inlet is diminished.Then, resin contain immerse reinforcing fiber base before, be detained after making resin temporarily flow into substrate surface, this resin is exerted pressure, resin is flowed into rapidly and the whole zone of impregnation fully.At this moment, fully flowing of resin can enter the material thickness part.That is to say, make resin fully flow to wide zone in advance, mobile to the thickness direction of base material fully rapidly then, impregnation in surface direction.Therefore can resin be injected base material from the whole zone (not being) of base material from periphery, and impregnation base material extremely apace.Resin is discharged preferably and is carried out from periphery (full week according to circumstances).

For carrying out above-mentioned resin flows behavior, each intermode in above-mentioned RTM forming method and device, for example between a mould (as patrix) and another mould (as counterdie), set the intermediate member (injecting the intermediate plate that multiple-grooved is used) that forms the resin stream as resin, by this intermediate member, resin can be almost simultaneously from the injection reinforcing fiber base material of many places.For example, from being arranged on the many places inlet on the intermediate member, resin almost flows into reinforcing fiber base simultaneously, almost flows into the whole zone of base material equably.

In addition, between reinforcing fiber base and patrix (mould), be provided as the little intermediate plate (porous plate that the resin flows resistance is big or perforated films etc.) of injection aperture area of intermediate member, keep the micro gap (as the slit in above-mentioned 1～10mm scope) between this intermediate plate and the patrix, resin also can flow in this slit.Because flow resistance is little, before flowing into from the hole of intermediate plate, resin is detained after can fully covering broad regions, injects base material by through hole rapidly fully to the reinforcing fiber base direction then.Therefore, in this case, resin also can almost inject simultaneously equably from many places.

Be in particular and solve described the 2nd problem, the invention provides a kind of RTM forming method, described RTM forming method is for injecting resin from the resin filling line that is configured in described die cavity periphery to the resin discharge line, after described reinforcing fiber base includes resin pickup, the RTM forming method that makes it to be heating and curing, wherein, described resin filling line is divided into formation a plurality of (methods that the 2nd scheme relates to).

In addition, the invention provides a kind of RTM shaped device, described RTM shaped device is for injecting resin from the resin filling line that is configured in described die cavity periphery to the resin discharge line, after described reinforcing fiber base includes resin pickup, the RTM shaped device that makes it to be heating and curing, wherein, described resin filling line is divided into formation a plurality of (devices that the 2nd scheme relates to).

In method that the 2nd scheme relates to and the device, above-mentioned resin filling line and resin discharge line preferably fully form on the whole zone of above-mentioned die cavity periphery.In addition, about above-mentioned resin filling line and resin discharge line, the length of preferred resin filling line is more than 2 times or 2 times of described resin discharge line length.

Above-mentioned resin filling line and/or resin discharge line can be made of the groove (groove of recess shape) of processing on shaping mould.When shaping mould was made of upper die and lower die, the preferred all processing of above-mentioned groove was on counterdie.

In addition, above-mentioned resin discharge line also can be to cut apart and forms a plurality of structures.

Form the resin that a plurality of resin filling lines carries out and inject from cutting apart, preferably the resin filling line that comes down to a side of far-end from distance resin discharge line begins to carry out successively.In addition, the resin discharge line also can switch to the resin filling line behind official hour, carries out resin and injects.

In addition, RTM forming method that the 2nd scheme relates to and device can adopt the structure of stacked core on above-mentioned reinforcing fiber base, and be representational for hold the sandwich of core under the arm with fiber-reinforced resin from both sides.

Sealing for the mould involutory surface that improves shaping mould, the sealing of resin injection portion or discharge portion particularly, shorten the RTM shaping cycle duration, can adopt to hold under the arm to press and above-mentioned resin is set injects with pipe and/or discharge with pipe the structure that seals with elastomer (sealing elastomer) between this Guan Yumo at the involutory face of mould.

In the structure that above-mentioned sealing improves, can be for to use the structure of the end of built-in O-ring in the elastomer in sealing, described O-ring is sealed to the die cavity of pattern at the mould involutory surface.

In addition, the micro-bubble that is detained for the molten corner of depositing bubble that gas evaporation generates or mould of discharging the resin that produces when resin injects can be discharged the gas in the shaping mould and the structure of residual resin discontinuously for the injection resin limit of pressurize, limit in above-mentioned shaping mould.

In these cases, the resin pressure in the described shaping mould of pressurization injection resin is Pm, when the resin outflow pressure of the inlet of injection resin is Pi, optionally makes Pm=Pi, Pm＜Pi, can control the resin flow that flows in the shaping mould.In addition, also can flow into the flow of the resin in the shaping mould by the bore control of regulating the outlet of discharging resin.Store the time point of adjusting He its adjusting of above-mentioned outlet bore, can be controlled to the resin flow in the pattern automatically according to this stored information.

Can be for when resin be injected in pressurization in the die cavity of shaping mould, the unit interval flow (Q:cc/min) of resin and die cavity projected area (S:m ²) ratio (Q/S:cc/minm ²) structure in the scope of 50＜Q/S＜600.

In this case, can be for above-mentioned than (Q/S:cc/minm ²) with product ((the Q/S) * P:ccMPa/minm of the plus-pressure (P:MPa) of resin ²) structure in 20≤(Q/S) * P≤400 scopes.

In addition, solidify 3～30 minutes structure under the structure of the plus-pressure that can adopt above-mentioned resin in the scope of 0.2～0.8MPa, the above-mentioned resin uniform temperature in heating-up temperature is 60～160 ℃ scope.

In addition, for described the 3rd problem of special solution, the invention provides a kind of RTM forming method, wherein, at least the one-sided top layer of described reinforcing fiber base is made of the continuous fiber layer, and the just following one deck in this top layer constitutes (method that the 3rd scheme relates to) by unordered mat layer.

Because the orientation of the fiber of unordered mat layer is unordered and weight per unit area is low, makes the resin flows resistance little, therefore can form the more or less freely resin stream of resin flows by this unordered mat layer is set.Then by on one-sided at least top layer be the continuous fiber base material just below the configuration this unordered mat layer, when resin injects, particularly near the top layer, can form good resin flow, wherein, surface direction along the top layer also can form good resin flow, thereby prevent that the bad part of resin impregnation that becomes the space from producing, and improves the surface quality of moulded products.

In the RTM forming method that the 3rd scheme relates to, above-mentioned top layer preferably is made of the continuous fiber layer below 3 layers or 3 layers.Because if the continuous fiber base material is blocked up, resin then may occur is difficult to arrive unordered mat layer by this base material, or mobile resin preferably is difficult to the situation of the continuous fiber base material on impregnation top layer in the unordered mat layer, and therefore preferably making the lamination state of the continuous fiber base material on top layer is below 3 layers or 3 layers.

In addition, total weight per unit area of the continuous fiber layer on formation top layer is preferably 700g/m ²Or 700g/m ²Below, consider preferably to constitute from the viewpoint of picture on surface by fabrics such as plain cloth, twills, satin fabrics.In addition, the bubble that becomes the reason of pin hole is trapped in the braiding reticulate pattern of above-mentioned fabrics easily, but can aforesaidly by the unordered mat layer of configuration under surface substrate bubble be discharged, and prevents that pin hole from producing.Described top layer can be made of for example carbon fibre fabric.But as reinforcing fiber, can use carbon fiber, glass fibre, aromatic polyamide fibre, metallic fiber, boron fibre, alumina fibre, carborundum high strength synthetic fibre etc., preferred especially carbon fiber or glass fibre.Wherein, the reinforcing fiber on above-mentioned top layer preferably is made up of carbon fiber.

Because of the main purpose that disposes unordered mat layer is the little resin stream of resistance when forming resin flows, impregnation, so, preferably be lower than skin-material or reinforcing fiber base 150g/m as total weight per unit area of above-mentioned unordered mat layer ²Or 150g/m ²Below.This unordered mat layer is lower than reinforcing fiber layer by making matrix form resin flow resistance, thereby realization improves this Resin Flow or impregnation impregnation significantly, prevents the effect that space or pin hole generate, improve surface quality.Therefore,, consider that the unordered mat layer of not wishing to constitute reinforcing fiber is too much, total preferably make weight per unit area at 150g/m as mentioned above from mechanical property aspects such as the intensity of keeping FRP or rigidity as long as can reach above-mentioned purpose ²Or 150g/m ²Below.

Unordered mat layer can be used carbon fiber or aromatic polyamide fibre, but more preferably uses comparatively cheap glass fibre.

In addition, in the RTM forming method that the 3rd scheme relates to, preferably adopt the structure of stacked core on above-mentioned reinforcing fiber base, representational for hold the sandwich of core under the arm with fiber reinforced substrate from both sides.

The RTM forming method that relates to according to above-mentioned the 3rd scheme, the operation of injecting resin can make the injection resin spread all over desired gamut easily and positively, can access particularly surperficial or even inner pattern plane one side and can not generate the fiber-reinforced resin that space or pin hole and surface quality improve.The RTM forming method that the 3rd scheme relates to can be used in combination with the RTM forming method that the 2nd scheme relates to, thereby can better bring into play the effect of unordered mat layer.

The RTM forming method and the shaped device that relate in according to the present invention, even situation owing to the wider reinforcing fiber base of usable floor area, suppose suitable cut zone, injecting resin also can spread all over and each cut zone of impregnation well fully, so can not produce resin flow less than the zone implement at high speed be injected into the molding procedure that impregnation is solidified from resin, thereby realize shortening molding time, improve speed of production, increase output, reduce manufacturing cost.In addition, can contain the resin pickup impregnation in whole zone, realize the raising of the surface quality of moulded products with desirable state.

Special RTM forming method and the shaped device that relates to according to above-mentioned the 1st scheme, since by intermediate member make in advance resin flows to back, very wide zone resin can be from many places injection reinforcing fiber base material equably simultaneously almost, even so bigger 3-D solid structure, can not produce yet resin flow less than the zone, can implement moulding apace.As a result, can realize shortening significantly molding time; Increase speed of production and output; Increase the output of each mould; Reduce manufacturing cost.In addition, even large-scale moulded products also can easily prevent the not generation of impregnation part of resin, realize the raising of moulding Products Quality.

In addition, according to RTM forming method and the shaped device that above-mentioned the 2nd scheme relates to, can make the state at short notice efficiently and stably moulding of comparatively large-scale FRP moulded products not generate defectives such as space of RTM difficult forming in the past.That is, a large amount of productions of high circulation become possibility.

The RTM forming method that relates to according to above-mentioned the 3rd scheme, by on one-sided at least top layer be the continuous fiber base material just below the allocation unit area weight be lower than the unordered mat layer of this top layer base material or reinforcing fiber layer base material, resin injects in reinforcing fiber base, during impregnation, it is less and be easy to the resin stream of resin flows to form flow resistance, and, because the unordered injection resin that can make of fiber alignment direction spreads all over each corner well, prevents owing to resin impregnations such as space or pin hole are bad to be the generation of the defective of cause.Particularly, can prevent from efficiently to produce above-mentioned defective, significantly improve the quality of surface quality, the especially patterned surfaces of moulded products on the moulded products surface by under the top layer, locating to dispose unordered mat layer.

Description of drawings

The decomposition side view of employed device in the RTM forming method that [Fig. 1] relates to for the 1st embodiment of the present invention.

[Fig. 2] Fig. 2 A is the plane of patrix of the device of Fig. 1, and Fig. 2 B is its front elevation.

[Fig. 3] Fig. 3 A is the plane of intermediate member of the device of Fig. 1, and Fig. 3 B is the profile along the C-C line of Fig. 3 A.

[Fig. 4] Fig. 4 A is the plane of counterdie of the device of Fig. 1, and Fig. 4 B is the profile along the C-C line of Fig. 4 A.

The profile of employed device in the RTM forming method that [Fig. 5] relates to for the 1st embodiment of the present invention and other embodiments.

[Fig. 6] is the ground plan of patrix of the device of Fig. 5.

[Fig. 7] is the plane of counterdie of the device of Fig. 5.

The side view of one of used shaping mould example in RTM forming method that [Fig. 8] relates to for the 2nd embodiment of the present invention and the device.

[Fig. 9] is the plane of counterdie of the shaping mould of Fig. 8.

[Figure 10] is the longitudinal sectional drawing of the counterdie of Fig. 9.

The whole pie graph of the summary of used formation system in RTM forming method that [Figure 11] relates to for the 2nd embodiment of the present invention and the device.

[Figure 12] is the performance plot of resin used in the embodiment of the invention.

The fragmentary cross-sectional view of the formation of the preformed base material of the fiber-reinforced resin of the RTM forming method institute moulding that [Figure 13] expression the 3rd embodiment according to the present invention relates to.

[Figure 14] expression to the base material shown in 13 inject, situation when containing the resin pickup impregnation fragmentary cross-sectional view.

The fragmentary cross-sectional view of the preformed matrix structure of the fiber-reinforced resin of the RTM forming method institute moulding that [Figure 15] expression relates to according to the 3rd embodiment of the present invention and other embodiments.

[Figure 16] expression to base material shown in Figure 15 inject, the fragmentary cross-sectional view of appearance when containing resin pickup impregnation base material.

[Figure 17] Figure 17 A is the fragmentary cross-sectional view of top layer base material of the preformed base material of Figure 13, and Figure 17 B is its front elevation.

[Figure 18] Figure 18 A～C represents the summary pie graph of spendable forming method in the present invention's the 3rd embodiment.

[Figure 19] Figure 13 represents the fragmentary cross-sectional view of the formation of the fiber-reinforced resin that other embodiments relate to.

Sealing improves the summary decomposition side view of the shaping mould of one of structure example in RTM forming method that [Figure 20] expression the present invention relates to and the device.

[Figure 21] represents the longitudinal sectional drawing of the shaping mould of the structure example that other sealings improve.

[Figure 22] injects the side view of discharging with pipe for the resin that uses in the mould involutory surface of shaping mould.

The resin that [Figure 23] Figure 23 A～F represents to be provided on the mould involutory surface of shaping mould injects the structural texture figure that discharges with the various encapsulation scheme examples of pipe portion.

Symbol description

1,20 shaping moulds

2,21 patrixes

3,24 intermediate members

4,22 counterdies

5 resins inject the stream groove

6,24a through hole

8,26 resins inject member

9,23 reinforcing fiber bases

11,27 resins are discharged member

25 slits (gap)

The 41RTM shaping mould

42 patrixes

43 counterdies

44 preformed base materials (reinforcing fiber base)

45 mould encapsulants

46,47,48 resin ascending pipes

46a, 47a, 48a sealing rubber components

46b, 47b, 48b resin inject valve

46c, 47c, 48c resin inject runner

46d, 47d, 48d resin inject membrane gate (filmgate)

49 resin discharge pipes

49a sealing rubber components

49b resin discharge valve

The 49c resin is discharged runner

The 49d resin is discharged membrane gate

50 die cavitys

51 pin-and-holes

52 latchings

The 54RTM formation system

55 metal pattern lowering or hoisting gears

56 metal pattern hydraulic device for elevating/lowering

57 resin injection devices

58 vavuum pumps

59 resin traps (trap)

60 thermoregulators

61a host container

61b curing agent container

62 pressue devices

63 mixing arrangements

64 arms

65 resins inject stream

66 oil cylinder

67 discharge stream

68 oil pressure pumps

71,76,100 fiber-reinforced resins

72,72a, 72b top layer base material

73, the unordered mat layer of 73a, 73b

74,74a, 74b constitute the reinforcing fiber base of strengthening layer

75a, 75b, 75c, 75d resin flows circuit

75,77a, 77b resin

78,79,82 bubbles

83 patrixes

84 counterdies

85 resin inlets

86 pump orifices

87 preformed base materials

88 resins inject uses runner

89 suction runners

90 seal grooves

91 plastic holding devices

92,95 valves

93 resins inject path

94 vavuum pumps

96 suction path

97 moulded products

101 cores

111,131,151 patrixes

112,132,152 counterdies

113,133 die cavitys

114,138 resins inject and use runner

115,139 resins are discharged and are used runner

116,134 resins inject with pipe

117,135 resins are discharged with pipe

118,119,136,137,153 sealing elastomers

121,154O-ring

122 reinforcing fiber bases

123 reinforcing fiber preforms

124 cores

125 reinforcing fiber bases

126,127 cast gates

The specific embodiment

Below, with reference to the desirable embodiment of description of drawings the present invention.At first,, can use carbon fiber, glass fibre, aromatic polyamide fibre, metallic fiber, boron fibre, alumina fibre, carborundum high strength synthetic fibre etc., preferred especially carbon fiber as the reinforcing fiber base among the present invention.The form of reinforcing fiber base is not particularly limited, and can adopt unidirectional sheets or fabric, usually to form reinforcing fiber base, the preformed form use of excipient in advance as required with its stacked several layers.

As the resin that uses in RTM forming method that the present invention relates to and the device, preferred RIM (Resin Injection Molding) monomer etc., described monomer can form the heat-curing resin or the thermoplastic resin of low, the easy impregnation reinforcing fiber of viscosity.As heat reactive resin, impregnation for example can be enumerated polyimide resins such as epoxy resin, unsaturated polyester resin, polyvinyl ester, phenolic resins, guanamine resin or bismaleimide-triazine resin, furane resins, polyurethane resin, poly-phthalic acid diallyl phthalate resin, be also had Melantine or urea resin or amino resins.

Can also enumerate polyamide such as Fypro 6, Fypro 66, Fypro 11; Or the copolymer of these polyamide; Or polyester such as poly terephthalic acid vinyl acetate, poly terephthalic acid butene esters; Or the copolyesters of these polyester; Also have Merlon, polyamide-imide resin, polyphenylene sulfide, poly-(two) phenylate, polysulfones, polyether sulfone, polyether-ether-ketone, polyimide, polyolefin etc., also have representational thermoplastic rubbers such as lactoprene, polyamide elastomer etc. in addition.

In addition, also can use fusion to be selected from multiple resin in above-mentioned heat-curing resin, thermoplastic resin, the rubber.

Wherein, the viewpoint consideration of thermal contraction as preferred resin, can be enumerated epoxy resin when suppressing that automobile brought the moulding of influence with the pattern of outer panel member.

Usually, as composite epoxy resin, host can be used bisphenol A type epoxy resin, phenylol phenol aldehyde type epoxy resin, epoxy propylamine type epoxy resin.On the other hand,, consider that the curing agent class of combination dichlorophenyl dimethyl urea in the dicyan diamides is good on the balance of operability, physical property etc. as curing agent, and preferred the use.But, be not particularly limited, also can use diamino diphenyl sulfone, aromatic diamine, acid anhydrides polyamide etc.Consider that from the viewpoint that keeps the outside plate appropriate rigidity ratio preferred weight ratio of resin and described reinforcing fiber is in 20: 80～70: 30 scope in addition.Wherein,, suppress the viewpoint consideration that crackle generates, more preferably cooperated denaturation loop resene, Fypro resin, the dcpd resin of epoxy resin or thermoplastic resin or rubber constituent etc. from reducing the heat-shrinkable of FRP structure.

In addition, the present invention also can be applicable to the moulding of the fiber-reinforced resin structure of the stepped construction with fiber-reinforced resin and core.For example can enumerate, dispose the sandwich of fiber-reinforced resin in the core both sides.As core, can use elastomer or expanded material, honeycomb material, wherein expanded material or honeycomb material are preferred because of lighting.Material as expanded material is not particularly limited, and can use the expanded material of macromolecular materials such as polyurethanes for example or acrylic resin, polystyrene, poly-imines, vinyl chloride, phenol etc.Material as honeycomb material is not particularly limited, and for example can use aluminium alloy, paper, aromatic polyamide paper etc.

Fig. 1～Fig. 4 represents the RTM forming method and the device of the 1st embodiment of the present invention.Among Fig. 1, shaping mould 1 is made of a plurality of moulds, in the present embodiment, comprises that the centre is contained as the resin system of intermediate member (as polyethylene) intermediate plate 3 as the patrix 2 of the steel of a mould and counterdie 4 as the identical material of another mould.This patrix 2 and intermediate plate 3 form the injection groove that resin injects stream and leads to base material.Be processed with on intermediate plate 3 with resin and inject the resin stream groove 5 that member 8 is communicated with, the end of each groove 5 is processed with (perforation) and injects groove through hole 6.Resin injects member 8 and is made of metal rider or resin pipe, is sealed with the encapsulant 10a that constitutes through elastomers such as rubber on metal pattern that constitutes patrix 2 and intermediate plate 3.The periphery of patrix 2 and intermediate plate 3 is with 7 sealings of O-ring, and O-ring 7 combines with encapsulant 10a.In four jiaos of patrix 2, be provided with the guide groove 13 that is used to connect intermediate plate 3 or counterdie 4.

Reinforcing fiber base 9 is arranged on the die cavity position of counterdie 4, is processed with resin at the outer circumferential side of base material 9 and discharges with groove 12 (runner).Residual resin can be discharged with pipe 11 from the resin of the part of insertion groove 12 and be discharged outside the moulds.Sealing with O-ring 14 be arranged on this groove 12 around, be used to manage 11 and metal pattern 4 between the encapsulant 10b of formations such as elastomer of sealing combine.

Fig. 2 represents patrix 2, and Fig. 2 A is its plane, and Fig. 2 B is a front elevation.Form resin and inject stream 15 in patrix 2, the first half that resin injects member 8 can stretch into this inlet.

Fig. 3 represents intermediate plate 3, and Fig. 3 A is its plane, and Fig. 3 B is the profile along the C-C line of Fig. 3 A.This routine intermediate plate 3 is of a size of width 1800mm, length 2000mm, thickness 12mm.In intermediate plate 3, be processed with the resin stream that is radial extension with groove 5, described resin stream injects member 8 with groove 5 and resin by metal catheter or pitch tube and is communicated with, in the middle of its groove 5 or the end bore a hole the injection groove of diameter 5mm through hole 6 arranged.In this example, groove is of a size of width 5mm, degree of depth 4mm, the flow path length that the is radial extension 540mm that respectively does for oneself.Periphery seals with O-ring 7, and combines with above-mentioned elastomer 10a.

Fig. 4 represents counterdie 4, and Fig. 4 A is its plane, and Fig. 4 B is the profile along the C-C line of Fig. 4 A.(for example, 6 layers of east beautiful (strain) system toraycaT300 flat fabric CO6644B (weight per unit area of lay fiber reinforced substrate 9 in the central mould cavity part of forming surface; 300g/m ²)).Resin after the outer circumferential side of this base material is processed with the resin impregnation is discharged with groove 12 (runner: be of a size of width 12mm, degree of depth 5mm).Residual resin can be discharged outside the moulds from the resin discharge pipe 11 of external diameter 12mm, the internal diameter 10mm of the part of insertion groove 12.

In the moulding of upper and lower mould 2,4 that adopts above-mentioned formation and intermediate plate 3, owing on intermediate plate 3, form a plurality of resin streams, therefore inject the resin that member 8 injects from resin, at first the surface direction along intermediate plate 3 flows rapidly, spreads all over wide zone.Then, because a plurality of through holes 6 by suitably being provided with, from many places in fact almost side by side fully the injection reinforcing fiber base material 9, so resin can be well and the wide regional impregnation of impregnation reinforcing fiber base 9 promptly.That is, because the flow resistance of through hole 6 than resin stream height, is injected the surface that resin temporarily is trapped in intermediate plate 3, the through hole 6 by many places in fact almost side by side contains and is dipped in the reinforcing fiber base 9 then.Use epoxy resin in the reality, in the result of 90 ℃ of compacted unders of metal pattern temperature for preventing resin not in the generation of impregnation part, make that resin injects, the impregnation time foreshorten to significantly in the past below 1/10 or 1/10, reach rapid shaping.

Fig. 5～Fig. 7 represents RTM forming method and the device that above-mentioned the 1st embodiment and other embodiments relate to.Shown in Figure 5, between the patrix 21 of shaping mould 20 and counterdie 22, be equipped with the intermediate member 24 (being porous plate under the present embodiment) that constitutes by porous plate or the thin mould of perforation.In patrix 21, be processed with the resin stream and can spread all over whole zone with groove 36a, 36b (Fig. 6).Form gap 25 between porous plate 24 and the patrix 21, only form the gap 25 of (about 0.5～1mm) in the present embodiment.In addition, if the position of porous plate or perforated films mesopore matches with the position that processes the groove in patrix, then can carry out the resin flows impregnation more efficiently.From (for example: sheet rubber) resin of sealing injects the resin that member 26 flows into, and almost all flows in the above-mentioned gap 25, is full of the space in this gap 25 with containment member 28.Have small through hole 24a (diameter is about 0.5～3.5mm) in the whole zone on the porous plate 24 with the interval of 3～8mm.Therefore, the resin flow resistance also is far longer than the resistance that flows into above-mentioned gap 25.Be equipped with reinforcing fiber base 23 in the die cavity 31, behind the closed patrix 21, utilize discharge member 27 to carry out vacuum draw through containment member 29 sealings.The resin of pressurized filling in above-mentioned gap 25, from the hole 24a of porous plate 24 rapidly fully pressurization inject and cover to whole zone.Residual resin after the impregnation, inflow is arranged in the membrane gate/runner of die cavity 31 peripheries, is discharged to the outside from discharge pipe 27.If the resin impregnation is then closed discharge pipe 27 to whole zone, keep resin pressure to be heating and curing simultaneously.Lift patrix 21 during the demoulding, moulded products is taken out from counterdie with porous plate 24, separate with porous plate 24 again.When separating porous plate 24 or under the situation of the processing time consuming after the adhered resin projection on the moulded products, can be in advance between porous plate 24 and reinforcing fiber base 23 the configuration demoulding with fabric (fabric of polypropylene or polyethylene system: also claim peelable protective layer (Peel ply)).In addition, difference according to circumstances also can not dispose porous plate 24, only disposes demoulding fabric.

Fig. 6 represents patrix 21, is processed with the resin stream groove 36a, the 36b that are used for distribution of resin on the whole zone of moulded products face.As an example, be processed with main stream (width 8mm * degree of depth 5mm) in central authorities, be processed with auxiliary stream (width 3mm * degree of depth 3mm) almost until end in its both sides with the interval of 10mm.In addition, in metal pattern, be processed with the groove 32,33 that is used to dispose the containment member 28,29 between resin ascending pipe 26 or resin discharge pipe 27 and the metal pattern.

Fig. 7 represents counterdie 22, is processed with into mould die cavity 31 on almost whole of mould.Discharge side at resin and also be processed with membrane gate and the runner 30 that links to each other with die cavity 31.On the position that coincide with patrix 21, in metal pattern, be processed with the groove 34,35 that is used to dispose the containment member 28,29 between resin ascending pipe 26 or resin discharge pipe 27 and the metal pattern and sealing with O-annular groove 37.

Use in the upper and lower mould 21,22 and the moulding as the porous plate 24 of intermediate member of as above structure, resin flows into rapidly in the gap 25 along the surface direction of porous plate 24, and is full of wide zone.Then, by being arranged on a plurality of through hole 24a in the porous plate 24 from many places in fact almost side by side the injection reinforcing fiber base material 23, so resin can be well and the wide regional impregnation of impregnation reinforcing fiber base 23 promptly.Therefore in the present embodiment, also can prevent the generation in the zone that resin can not spread all over, can reduce resin simultaneously significantly and inject the impregnation time, realize rapid shaping.

Embodiment 1

In above-mentioned each embodiment, metal pattern is of a size of 1500mm * 1200mm * degree of depth 3mm in forming surface (die cavity face), as reinforcing fiber base, uses the toraycaT700 fabric BT70-30 (300g/m of stacked 8 layers of east beautiful (strain) system ²) sandwich, as resin, use high speed solidified type epoxy resin (host: " Epikoto " 828 (oiling Shell Epoxy society system epoxy resin); Curing agent: east beautiful (strain) fusion (blend) TR-C35H (imdazole derivatives)) during moulding, even than relatively large moulded products, also can be well and moulding apace.Need to prove that when the resin injection pressure was 0.7MPa, the time of the complete impregnation base material of resin all was below 5 minutes or 5 minutes, can foreshorten to below 1/5～1/10 or 1/5～1/10 of previous methods.

Represent RTM forming method and the device that the 2nd embodiment of the present invention relates to as Fig. 8～Figure 12.Figure 11 represents to use the summary pie graph of one of formation system 54 of the RTM shaped device that the present invention relates to example.RTM molding metal mold 41 is made up of patrix 42 and counterdie 43, and patrix 42 is installed on the metal pattern lowering or hoisting gear 55, and described metal pattern lowering or hoisting gear 55 carries out lifting by the metal pattern hydraulic device for elevating/lowering 56 that contains oil pressure pump 68, oil cylinder 66.Be provided with direct reinforcing fiber base or preformed base material 44 (reinforcing fiber base) in the counterdie 43, this preformed base material 44 is given article shape in advance in order to pack shaping mould into easily, closes patrix 42.Can enumerate FRP, cast steel, structure carbon steel, aluminium alloy, kirsite, nickel electroforming, copper electroforming as the material of shaping mould.Consider that from rigidity, hear resistance, operability aspect preferable configuration is used for volume production with carbon steel.

On molding metal mold 41, dispose a discharge pipe 49 that is connected on a plurality of resin ascending pipes 46,47,48 that link to each other with resin injection runner.Each resin ascending pipe 46,47,48 and discharge pipe 49 inject valve 46b, 47b, 48b and discharge pipe valve 49b by each and are connected resin injection stream 65, discharge on the stream 67.Resin injects stream 65 and is connected on the resin injection device 57.In host container 61a, the curing agent container 61b of resin injection device 57, pack into respectively host, curing agent, wherein, each container have can heat, the device of vacuum exhaust.When resin injects, inject stream 65 from each container flow to resin by pressue device 62 resins.This pressue device 62 can use syringe pump 62a, 62b as an example, guarantees quantitative property by pushing this syringe pump simultaneously, is preferred for by the mixing cured resin of 2 liquid.The host of extrusion, curing agent flow into resin and inject stream 65 after hydrid component 63 mixes.For preventing that resin from flowing in the vavuum pump 58, discharges stream 67 and link to each other with resin trap 59.

In addition, the quantity of resin ascending pipe or position, according to the shape of shaping mould or size or in a mould difference of the moulded products quantity of moulding simultaneously change, but for preventing to increase with the junction of stream 65 with resin ascending pipe 46,47,48 from the injection of resin injection device 57, make implant operation become assorted, preferred ascending pipe is the least possible.But, for the bigger moulded products of high-speed molding,, compare with carry out the resin injection with single ascending pipe by using a plurality of resin ascending pipes whiles or carrying out resin successively and inject, can carry out resin flows, impregnation efficiently with the speed of several times.

Fig. 9 has the plane, the particularly plane of counterdie 43 of RTM shaping mould of the flat board of curvature for four jiaos of high-speed moldings.As shown in Figure 8, patrix 42 and counterdie 43 are with following state mold closing: insert by the latching 52 that makes patrix 42 sides in the pin-and-hole 51 of counterdies 43 sides and overlap the position, between with 45 sealings of mould encapsulant.Figure 10 represents the profile of shaping mould shown in Figure 9.With reference to Fig. 9 explanation, RTM forming method in the past as this dull and stereotyped forming method, be forming method as described below: from being communicated with the ascending pipe 46 pressurization injection resins that resin injects runner 46c and resin injection membrane gate 46d, flow to and discharge membrane gate 49d and discharge runner 49c, the impregnation reinforcing fiber base, wherein, resin filling line on one side of the periphery of described resin injection runner 46c and resin injection membrane gate 46d formation shaping mold cavity 50, the resin discharge line that has on one side of the periphery of the shaping mold cavity 50 that the discharge pipe impregnation 49 set with discharging runner 49c formation and opposite of described discharge membrane gate 49d formation is communicated with.Promptly, the single resin filling line that constitutes from one side (injecting runner 46c and resin by the resin that links to each other with resin ascending pipe 46 injects membrane gate 46d and form) by the periphery of shaping mold cavity 50, the single resin discharge line that constitutes to one side (discharging membrane gate 49d and resin by the resin that links to each other with resin discharge pipe 49 discharges runner 49c and form) by the periphery of shaping mold cavity 50, from the resin filling line resin of pressurization is flowed into the fiber reinforced substrate in the shaping mold cavity, and make it impregnation.

In this method, forming smaller moulded products promptly under the situation of the short moulded products of the distance from the resin filling line to discharge line, but moulding within a short period of time and volume production, but, at large-scale moulded products promptly under the situation of distance, because of resin flows is successively decreased with higher order functionality, so the resin flows time is also elongated from the resin filling line to the resin discharge line, difference according to circumstances exists the situation that the resin gel time remains unfulfilled impregnation that reaches.In this case, can take to use low viscous resin, improve the method that the pressure of resin injects at a high speed, but this operation can make reinforcing fiber become chaotic under the effect of resin flow pressure, and because of the size of moulded products or shape difference to containing of whole zone of moulded products being soaked with certain limitation.

As mentioned above, according in the past RTM forming method when the moulding goods because of large-scale when being difficult to rapid shaping and volume production, can be by not only being provided with and in many places the resin filling line being set and solving as shown in Figure 9 on one side of the periphery of shaping mold cavity 50.Promptly, except that resin filling line 46 in the past, by resin discharge line 49 sides are appended resin ascending pipe 47,48, inject resin filling line that membrane gate 46d forms from inject runner 46c and resin by resin, inject runner 47c and resin by resin and inject resin filling line that membrane gate 47d forms, inject runner 48c and resin by resin and inject the resin filling line while that membrane gate 48d forms or carry out the resin injection successively, can eliminate the resin flows of successively decreasing with higher order functionality.In a word, resin filling line and resin discharge line can be arranged on the Zone Full of the periphery of moulded products (that is, reinforcing fiber base is all).Special effective method be this periphery half or over half the resin filling line is set, if better situation is more than 2 times or 2 times of resin discharge line for the resin filling line is set, then can the moulding at high speed of high effect.In addition, the 46a among Fig. 9,47a, 48a, 49a represent the sealing rubber component respectively.

Whether fill up from the resin injection of resin ascending pipe 47,48 must be according to the model or the shape decision of moulded products from the resin injection or the injection length of resin ascending pipe 46.In addition, in this case, enter lateral section owing to trying to be the first from base material central authorities easily from the resin of the resin ascending pipe of filling up 47,48, so must carry out following modification: make the length of resin discharge line be shorter than 1 limit as much as possible, or the position of change resin discharge pipe 49 etc.

In addition, moulded products be similar to as Fig. 8, flat board shown in Figure 9 be about relatively under the shape or the big for example situation more than 2 times or 2 times of L/D (length-width-ratio) of symmetry, except that resin discharge line 49, with resin ascending pipe 46 be the resin filling line of starting point from initial just as the resin discharge line, make from being that the method that the injection resin flow of the resin filling line of starting point is divided into the efficient impregnation of left and right sides two parts also is effective with resin ascending pipe 47,48.

When the almost Zone Full of resin injection reinforcing fiber base material, or inject the way, it is also effective that the resin discharge line is changed the method that becomes the resin filling line.That is, in the resin flow moment, wait for that in any case resin flows out, enter the resin discharge line, resin also can't arrive under the situation of resin discharge line, can prevent the not generation of impregnation part of resin by injecting resin from this resin discharge line on the contrary.

For example, the resin detecting sensor of configuration detection resin flows in mould in advance, beginning gelation before resin arrives the resin discharge line and under the situations such as delay, inject resin from the resin discharge line can prevent the not generation of impregnation part of resin effectively.

The material that resin injects stream 65 or resin ascending pipe 46,47,48 must consider guarantee sufficient flow and with the adaptability (heat resisting temperature or solvent resistance, compression resistance etc.) of resin.It is the material of 5～30mm that this injection stream or ascending pipe use bore, must be for tolerating its resistance to pressure of resin injection pressure at 1.0MPa or more than the 1.0MPa, and must be for tolerating its hear resistance of resin solidification temperature more than 100 ℃ or 100 ℃.Therefore, be " Teflon " (registration mark) tubulation about 2mm preferably as thickness.But, except that " Teflon " (registration mark), also can be the metal tube of comparatively cheap polyethylene pipe or Fypro pipe, steel, aluminium or copper etc.

Need to prove, the quantity of resin discharge pipe 9 or position, change to some extent according to the difference of the moulded products quantity of moulding simultaneously in the shape of shaping mould or size, the film, but consider that resin flows is stable and the resin flows control operation is simple, the preferred resin outlet is the least possible.

Also to inject stream 65 identical with resin for the material that resin discharge pipe or resin are discharged stream, must consider guarantee sufficient flow and with the adaptability (heat resisting temperature or solvent resistance, compression resistance etc.) of resin.Discharge the metal tube that stream 67 can be enumerated steel, aluminium etc. as resin, or the plastic pipe of polyethylene, " Teflon " (registration mark) etc., consider that from the operability aspect more preferably diameter is that 5～10mm, thickness are " Teflon " (registration mark) system plastic tube of 1～2mm.

Resin when being arranged on resin and injecting injects injection valve 46b～48b or the resin discharge valve 49b that stream 46～48, resin are discharged stream 49, can be waited with locking pliers (ViseGrip) by directory operator and clamp stream and make Zone Full switching or change bore.In addition, can adjuster be set at the handle portion of locking pliers and make it automation, or use electromagnetic valve or air control (air operation) valve etc. to replace the valve opening and closing device of locking pliers.Then, also can carry out accuracy and more open and close on the highland by connecting this valve opening and closing device and the memory storage of importing valve opening and closing information in advance.And resin discharge valve 49b only two values of switching just, also can change stream bore (aperture of ball valve is regulated).

According to the pressure method that utilizes syringe pump etc., the resin pressurization also can obtain quantitative property.The injection of resin is pressed and is preferably used in the scope of 0.1～1.0MPa.Resin injects to press and is meant the getable maximum pressure of use pressue device 62 pressurizations herein.

Finally, the complete impregnation of resin enters in the interior reinforcing fiber base of mould, when discharging stream 67, resin discharge pipe 49 or resin close discharge valve 49b when arriving, then behind temporary transient maintenance cavity pressure under the injection pressure that resin pressue device 62 is applied, also close resin and inject valve 46b～48b, finish resin and inject.Shaping mould makes resin solidification by circulating thermoregulator 60 heating of thermophore.Can make water, steam or mineral wet goods as thermophore.

Carry out the RTM moulding by aforesaid former (formation system) 54, in order to obtain producing defectives such as space, have good presentation quality, to have the high-quality FRP moulded products of regulation mechanical characteristic, the severing of reinforcing fiber base, stacked, preformedization, when lay etc. is suitably prepared in advance in mould, from resin inject, to contain the condition of molding that is dipped into curing also extremely important.Particularly, must suitably set and considered creating conditions of productivity (efficient activity of production).

Therefore, pointed out when considering the reaction resin characteristic fully, " resin injection pressure ", " forming temperature " or " resin flow velocity ", " temperature characterisitic of resin " etc. must be set at the appropriate value that adapts with compact dimensions.Particularly pointing out, need good fluidity because this patent is considered production efficiency, on the other hand, is object with the reaction resin material that solidifies immediately after the gelation at short notice, so must the flow at high speed impregnation.

But,, then cause base material chaotic or generate space or pit on the surface as mentioned above easily if the rising resin pressure, accelerate flow velocity and inject.Owing to simple accelerate the problem that injection rate can cause described presentation quality aspect, the resin flow velocity that therefore must set and be adapted by the impregnation material, the i.e. flow that adapts with this base material area.

In addition, RTM forming method and device that the present embodiment relates to, it not merely is general RTM forming method, it also is when air is discharged by vacuum draw in the mould or most of back injection resin of discharging, close the RTM forming method that pump orifice pressurizes and inject to solidify then, also comprise, shaping mould is sealed film chamber portion in one side with packaging material such as films, behind the vacuum draw die cavity, utilize vacuum to press pressurization, in die cavity, inject the method for vacuum-assisted rtm of resin forming, wherein, described general method is: shaping mould is made of two moulds up and down, adds the pressurizing resin limit and flows into the air of limit in mould from the resin inlet and discharge through the resin outlet, arranged the moment of air and closed outlet, the limit adds resin limit curing in the pressing mold.

Embodiment 2

In the RTM formation system 54 that the present embodiment shown in Figure 11 relates to,, the example of large flat (length 1500mm * width 700mm * highly (thickness) 3mm) moulding is described as one of condition of molding moulding according to the present invention example.The overall diagram of the RTM molding metal mold 1 that uses in this example such as Fig. 8, shown in Figure 9, the relation of the temperature of used resin and viscosity and the resin solidification degree-time response under forming temperature are shown in Figure 12 A and Figure 12 B in the moulding.In the counterdie 43 of the shaping mould 41 that contains resin ascending pipe 46～48, discharge pipe 49 (long 2000mm, wide 1000mm, the high 350mm identical) in the set shaping mold cavity portion 50 with patrix 42, counterdie 43, stacked 8 layers (0/90 ° of directed base material, 4 layer; 45 ° of directed base materials, 4 layers) east beautiful (strain) system carbon fiber " torayca " fabric (CO6343B:T300B-3K, order: 192g/m ²) after, dispose in advance that figuration is the preformed base material 44 of writing board shape, with metal pattern lowering or hoisting gear 55 closed patrixes 42, airtight fully.Patrix 42 is applied in 200 tons pressure by metal pattern lowering or hoisting gear 55.In addition, patrix 42 and counterdie 43 utilize thermoregulator 60 (Figure 12) much at one and keep stably being warmed up to 100 ℃ simultaneously.

As shown in figure 10, be arranged on resin filling line (for example position of resin ascending pipe 46) in the counterdie 43 and inject stream 65 by branched pipe 64 and resin and link to each other, in the way structure by the resin ascending pipe 46 by injecting valve 46b, make that the resin that injects by this resin ascending pipe pressurization is that the temporary transient resin that stores of wire injects runner 46c, the resin injection membrane gate 46d of injection resin in die cavity that injects that runner 46c is communicated with this resin is (with the gap of patrix; 0.5mm) constitute.Its elsewhere of resin filling line also is provided with the resin ascending pipe 47,48 that forms pair of right and left with identical structure as shown in Figure 9.In addition, resin discharge line and resin are discharged stream 67 and are communicated with, in the way structure by the resin discharge pipe 49 by resin discharge valve 49b, with this resin discharge pipe link to each other and make that the resin of discharge is that the temporary transient resin that stores of wire is discharged runner 49c, the resin discharge membrane gate 49d that makes discharges such as resin and gas in the die cavity that injects that runner 49c is communicated with this resin is (with the gap of patrix; 0.5mm) constitute, be arranged on 1 limit.

As a result, resin filling line and resin discharge line almost can be enclosed in the full week of die cavity fully.In addition, the resin filling line is nearly 5 times length of resin discharge line.

Resin shown in Figure 11 injects stream 65 and resin ascending pipe 46～48 and uses diameter to be 12mm, thickness " Teflon " (registration mark) tubulation as 1.5mm jointly.On the other hand, discharging stream 67 and discharge pipe 49 uses diameter to be 16mm, thickness " Teflon " (registration mark) tubulation as 2mm jointly.Resin flows in the vavuum pump 58 in the stream 67 in order to prevent to discharge, and is provided with resin trap 59 midway.

In addition, for carrying out between resin ascending pipe 46～48 or discharge pipe 49 and the counterdie 43 sealing, sealing is set with rubber component 46a～49a respectively, sets mould encapsulant (O-ring) 45 for guaranteeing the periphery that is sealed in the chamber face between upper and lower mould in the periphery of chamber face.

In the above-mentioned shaped device, discharge the air of (in the die cavity) in the mould from resin outlet 49 with vavuum pump 58, confirm cavity pressure at 0.01MPa or after below the 0.01MPa with pressure vacuum ga(u)ge (record slightly), begin to inject the epoxy resin of resin injection device 57 pressurizations through having pressue device 62.Need to prove that pressue device 62 uses syringe pump 62a, 62b, the resin adverse current was to the structure of vessel side when formation can prevent the resin injection.Used resin is for having mixed the liquid-state epoxy resin that host " Epikoto " 828 (oiling Shell Epoxy society system epoxy resin), curing agent east beautiful (strain) fusion (blend) TR-C35H (imdazole derivatives) obtain.The metal pattern temperature is the viscosity-time response of moulding temperature this epoxy resin when being 100 ℃, is specified as viscosity with composition epoxy resin and changes value as the used cure index of the tracking index of resin solidification curve shown in Figure 12 A.As seen from the figure, this resin solidification index rises 90% in about 6 minutes, but reaches the state of the demoulding.

In the resin injection device 57, host 61a, curing agent 61b limit are stirred 60 ℃ of heating down in the limit in advance, make it to drop to the viscosity of regulation, and carry out exhaust with vavuum pump 58.

Resin injects the initial stage, air in the mixed with resin device that is stirred or resin inject stream and enter in the mould with the air in the pipe, think that it is not flowed in the branch road that the resin that will be mixed with air in the mould do not show dumps from figure, after confirming that then no air is sneaked in the resin, injection adds pressurizing resin in mould.In addition, the outflow condition enactment of pressue device syringe pump 62a, 62b is at the 500cc/ stroke.After dumping the resin of initial entrained gas, the injection pressure meter (diagram slightly) that utilizes resin to inject stream 65 outfits is determined to inject resin pressure (0.6MPa), opens injection valve 46b, injects resin in mould.When injecting beginning, the discharge valve 49b of discharge pipe 49 is open state.

Begin to inject resin was opened resin ascending pipe 47 after 1 minute and 30 seconds valve 47b from resin ascending pipe 46, begin to inject resins from resin ascending pipe 47.Then, the valve 48b of open resin ascending pipe 48 after 1 minute begins to inject resin from resin ascending pipe 48 again.

, promote resin to reach the operation of removing the built-in micro bubble of this base material efficiently therebetween, can use locking pliers that discharge valve 49b is opened and closed 4 times to the reinforcing fiber base impregnation as being used for.

Begin to inject resin from resin ascending pipe 46, resin can flow out from discharge pipe 49 after 3 minutes and 30 seconds.Then, after making resin flow out about 30 seconds under this state, close the valve 49b of discharge pipe 49.Begin to be about 4 minutes from the resin injection.

Inject fully at resin under the above-mentioned state of impregnation end, after keep-uping pressure 30 seconds with resin pressure 0.6MPa, keep heating 12 minutes, from metal pattern, take out moulded products.

Estimate the outward appearance of the Zone Full of moulded products, tight or pin hole are the high-quality products that is rich in pattern.

Comparative example 1

As a comparative example 1, under above-mentioned shaped device and condition, do not inject any resin (blocking runner 47c, 48c and membrane gate 47d, 48d) from resin ascending pipe 47,48, during only from 46 injection mouldings of resin ascending pipe, resin injects impregnation needs about 11 minutes, and generation has 400cm approximately near discharging the position ²Not impregnation position.

Embodiment 3

In addition, the foregoing description 2 is veneer structures of reinforcing fiber resin base material, as other embodiment, even core rod (thick 10mm is contained in inside, apparent specific gravity 0.1) carbon reinforcing fiber sandwich (difference stacked 3 layers of above-mentioned carbon fiber " torayca " fabric on the top and bottom of described core rod) also can obtain the good much at one moulded products of surface quality.Additional disclosure, is the time of above-mentioned same weak point at about 4.5 minutes of impregnation time.

Then, the RTM forming method that the 3rd embodiment of the present invention relates to is described.At first, with reference to the manufacturing of Figure 18 explanation according to the reinforcing fiber base of this RTM forming method.As shown in figure 18, in the patrix 83 of two moulds resin inlet 85 and pump orifice 86 are set.Contain resin in the counterdie 84 and inject, form seal groove 90 around the die cavity with runner 88 and suction runner 89.Heat the temperature of above-mentioned upper and lower mould 83,84 simultaneously to regulation.Behind the preforming material 87 of configuration as reinforcing fiber base on the cavity surface of counterdie 84, fall patrix 83, form die cavity with counterdie 84.By regulation among the present invention as the structure of this preforming material, as Figure 13 or the unordered mat layer of configuration under the continuous fiber base material on top layer in advance shown in Figure 15.

Under this state, shown in Figure 18 B, the resin that utilizes valve 92 sealings to be communicated with plastic holding device 91 injects pathway 93, utilizes the valve 95 open suction pathways 96 that are communicated with vavuum pump 94, then, pump orifice 86, the suction runner 89 vacuum draw die cavitys by communicating with suction pathway 96.The valve 95 of suction pathway is with open state, and open resin injects the valve 92 of pathway 93, injects pathway 93 by resin when utilizing the matrix form resin in the pump pressurization plastic holding device 91 and injects inlet 85, injects with runner 88 pressurizations from resin and injects die cavity.Resin flows is to the Zone Full of die cavity, the Zone Full of resin reinforcing material 87 is gone in impregnation, remaining resin is after particularly residual bubble flows into suction pathways 96 by pump orifice 86 in the reinforcing fiber base in die cavity, close the valve 95 of suction pathway 96, temporarily in the die cavity of sealing, apply resin and press (static pressure), make it abundant impregnation.Then, close the valve 92 that resin injects pathway 93, in official hour, keep heated condition to make resin solidification.

Then, shown in Figure 18 C, rising patrix 83 deviates to stay the moulded products 97 in the counterdie 84.Need to prove the manufacture method of the fiber-reinforced resin that the present invention relates to, vacuum forming method, preforming material/autoclave solidification method, RFI (Resin FilmInfusion), the semi-solid preparation impregnation thing/baking oven that also can be applicable to other method etc. that is heating and curing.

According to above-mentioned manufacture method, the fiber-reinforced resin that the present invention relates to by manufacturing as follows.

Embodiment 4

As shown in figure 13, when making reinforcing fiber base resin 71,1 layer of eastern beautiful (strain) system toraycaT300 fabric CO6343B (weight per unit area of using as pattern of configuration in top layer 72 (continuous fiber base material); 200g/m ²) after, the unordered mat layer 73 (weight per unit areas that configuration is made of glass fibre as the one deck under it; 70g/m ²).Below described unordered mat layer 73, configuration is as reinforcing fiber base 74 (east beautiful (strain) the system toraycaT700 fabric BT70-30 of 3 layers of formation of enhancement layer; Weight per unit area; 300g/m ²), constitute preformed base material 87.Use this preformed base material 87, form CFRP (carbon fiber-reinforced resin) according to the RTM forming method shown in Figure 18 A～Figure 18 C.At this moment, the temperature of metal pattern (being made of patrix 83 and counterdie 84) is 95 ℃, and the epoxy resin 75 that utilizes the plastic holding device 91 with vacuum exhaust function temperature to be remained on 60 ℃ is pressed at resin and is the injection moulding of pressurizeing under the 0.6MPa.Need to prove that plastic holding device 91 is made of with container host used for epoxy resin container and curing agent.

A enlarged drawing Figure 14 partly according to Figure 18 B illustrates resin flows situation in the above-mentioned RTM moulding.Epoxy resin 75 from plastic holding device 91 outflows, being filled into the resin that is arranged on counterdie by inlet 85 injects with runner 88, from this runner 88, flow out then,, flow in the die cavity through by die cavity and 88 gaps that form of runner (before and after the 1mm) membrane gate.At this moment, resin flows into the Zone Full of the thickness direction of base material 87, compares with the position that carbon fibre fabric constitutes, because the zone of the unordered mat layer 73 of glass fibre is thicker than base material, flow resistance is low, so initiatively moving to the laminar flow of unordered mat layer 73.Owing to directly being given as security on patrix 83 with the carbon fibre fabric 72 that base material disposes as pattern, and almost there is not the gap between this fabric 72 and the patrix 83, so the wherein most resin of the resin that is injected into flows out from unordered mat layer 73, direction to patrix 83 flows, and flows to the gap between described fabric 72 and the patrix 83.Even the vacuum draw die cavity, the resin flow that residual bubble 78 also can longshore current line 75a to 75b in the gap between the reticulate pattern of this fabric 72 or this fabric 72 and the patrix 83 flows, and is discharged to outside the film of chamber.Particularly point out, shown in Figure 17 A, B, undischarged residual bubble is detained easily in the warp 72c of formation fabric 72 and the intertwined point of parallel 72b.This bubble is discharged outside the die cavity with above-mentioned resin flow, can prevent the generation of space or pin hole.

Embodiment 5

The foregoing description 4 is that pattern plane is the situation of single face, also forms fiber-reinforced resin shown in Figure 15 76.That is, even under the situation that requires multiaspect (top and bottom among Figure 15) for pattern plane and great surface quality, also can be same as described abovely under the reinforcing fiber base (72a, 72b) on the surface that becomes pattern plane configuration be 30g/m by weight per unit area ²The unordered mat layer (73a, 73b) that constitutes of fiberglass batts, inject resin with condition same as described above.Shown in Figure 16 as the A of presentation graphs 18B part, resin flow that utilization is flowed to 75b from streamline 75a or the resin flow that flows to 75d from streamline 75c, stream flows into top layer usefulness base material 72a and patrix 83, the top layer usefulness base material 72b of opposite face and the gap separately between the counterdie 84 efficiently from the resin of unordered mat layer 73a or 73b, the space is disappeared, thereby bubble 78,79 limits that the limit discharge is detained are full of the whole zone of impregnation impregnation.Therefore, with respect to tow sides, bubble prevents the generation of space or pin hole outside above-mentioned resin flow is discharged the film chamber.

Embodiment 6

Sandwich shown in forming as shown in figure 19: central authorities have polyurethane resin molding core 101; Be laminated with multilayer east beautiful (strain) system toraycaT300 fabric CO6644B (weight per unit area on its two sides; 300g/m ²) as enhancement layer 74a, 74b; Further dispose unordered felt 73a, the 73b (weight per unit area of glass fibre thereon respectively; 50g/m ²); In forming outermost each top layer, dispose (1 strand of east beautiful (strain) system toraycaT300 fabric CO6343B respectively; 3K system, weight per unit area; 200g/m ²).According to the RTM forming method shown in Figure 18 A～Figure 18 C this sandwich shaping fiber is strengthened resin 100.The temperature of metal pattern (patrix 83, counterdie 84) is set at 85 ℃.Among the figure 77a, 77b represent to inject, the epoxy resin of impregnation, curing.As a result, can form have sandwich, particularly have a FRP tectosome of excellent surface (two sides) quality.

Comparative example 2

As the contrast of the foregoing description, take out among the embodiment 4 by be configured in top layer 72 under the unordered mat layer 73 that constitutes of glass fibre, the fibre structure of other top layer and reinforcing fiber layer all is a same structure.In addition, the FRP forming method is also to carry out the RTM moulding with embodiment 4 identical conditions of molding.

The moulding result is: owing to there is not a little unordered mat layer of resin flows resistance, so though compare resin with embodiment 4 and begin to inject the back and consumed 1.38 times up to residual resin from the time that pump orifice 86 flows out more, also obtained moulded products.But the pin hole 82 that does not occur among the embodiment 4 many places in the intertwined point of the reticulate pattern shown in Figure 17 B or warp and parallel occur, and are judged as inferior goods with picture on surface.

In aforesaid RTM forming method that the present invention relates to and the device,, can adopt formation as follows for improving the sealing of resin injection portion and/or resin discharge portion.Need to prove,, followingly simple forming model is described with reference to Figure 20～Figure 23 though the present invention is supposing that described cut zone is a prerequisite.Hermetically-sealed construction with reference to this Figure 20～Figure 23 explanation can be applicable to RTM forming method and the device that the present invention relates to, RTM forming method and device that the particularly described the 1st and the 2nd scheme relates to.

Promptly, this structure presses the injection that resin is set with managing and/or discharge with pipe for holding under the arm at the mould involutory surface, with the structure of elastomeric seal, is preferably between this Guan Yumo, in the structure of sealing with the end of built-in O-ring in the elastomer, described O-ring is sealed to the die cavity of pattern at the mould involutory surface.Because seizing resin on both sides by the arms injects with managing and/or discharging and fix with pipe, so for example do not use resin to inject with through hole or sleeve (sleeve) etc. in the shaping mould middle punch, also can easily install, clean, the result can shorten molding cycle, reaches moulding more efficiently.In addition, this pipe uses cheap resin pipe etc., and therefore directly waste treatment after the moulding can cut down cleaning greatly, and causes that cost reduces because workload is cut down.And then, owing to by using sealing to use elastomer, can guarantee vacuum and the vacuum that keeps in the moulding in the die cavity more, also can prevent seepage of resin simultaneously, so can access the high-quality goods of tight free of pinholes.

Figure 20 is the side view of upper and lower mould 111,112, and Figure 21 is the amplification profile of its counterdie, and Figure 22 represents to be installed in resin between the upper and lower mould of Figure 20 and injects and discharge with pipe 30.As shown in figure 20, the reinforcing fiber base 122 that is endowed article shape in advance is configured in this shaping mold cavity 113 of the counterdie 112 that is equipped with O-ring 121, described O-ring 121 is provided in the periphery of the shaping mold cavity that forms above 113 of counterdie 112.Then, when metal pipe 142 is inserted the end of the pipe that contacts with groove 141 shown in Figure 22, the periphery that sets the end in groove is wound with the resin injection member 140 of band, wherein, described groove be with resin inject with runner 114 and resin discharge the resin that is communicated with runner 115 inject with pipe 116 and resin discharge with rubber system (as the NBR system) sealing that is provided with in the middle of the groove 120 of the semi-section shape of pipe 117 and this groove 120 with elastomer 118,119 reach with as described in the sealing that is communicated with of groove 120 groove of elastomer 118 settings.Then, closed patrix 111, pressurization makes patrix 111 press to counterdie 112, holds under the arm to press and states resin injection member 140.Under this state,, make the whole intensification of shaping mould by feeding warm water in the pipe arrangement (not shown) that in shaping mould, is provided with.

Then, discharge with pipe 117 by the resin that links to each other with the vacuum collecting device (not shown) that is communicated with vavuum pump, make die cavity 113 evacuation after, inject with pipe 116 to these die cavity 113 pressurization injection resins by resin.After resin inject to finish, close resin and inject with pipe 116 and resin and discharge with pipe 117, in official hour, utilize shaping mould to make the resin solidification of heating after, be opened into pattern, the demoulding obtains the FRP goods.

In addition, other the structure example that can improve sealing as shown in figure 21, the reinforcing fiber preform 123 of the sandwich of the core 124 that will form by the foaming body that be processed as article shape in the lining of the periphery of reinforcing fiber base 125, be configured in by being provided with sealing elastomer 136,137 patrix 131, in the shaping mold cavity 133 that counterdie 132 constitutes, wherein, described sealing elastomer 136,137 encircle (not shown) with the O-that is arranged on die cavity 133 peripheries is communicated with, make and be communicated with resin and inject and discharge resin with runner 139 with runner 138 and resin and inject to discharge with managing 135 and contact described sealing elastomer 136 with pipe 134 and resin, 137 and seal the cramping upper and lower mould.

Above-mentioned resin injects with pipe 134 and resin discharge and uses for example metal tubulation with pipe 135.By under this state, feeding warm water in the pipe arrangement (not shown) in being arranged on shaping mould, shaping mould is heated up.Afterwards, with shown in Figure 20 routine identical, by be connected resin on the vacuum collecting device that is communicated with vavuum pump discharge with pipe 135 make become vacuum in the die cavity 133 after, inject with pipe 134 to these die cavity 133 pressurization injection resins by resin.The resin of pressurization is full of resin and injects with behind the runner 138, flows into the die cavity 133 that is provided with described reinforcing fiber preform 123 by injecting with membrane gate 126 resins, contains in the reinforcing fiber that is dipped into this reinforcing fiber preform 123.During this period, after residual resin is full of resin discharge runner 139 by discharge membrane gate 127, by discharging with in the pipe 135 inflow vavuum pumps.After resin injects and finishes, close the resin injection and discharge with managing 135, under this state, after heating makes resin solidification in official hour, be opened into pattern, obtain the FRP sandwich structural body of the high rigidity of hat with pipe 134 and resin.

Figure 22 represents that resin used in the described example injects the structure example of using pipe 117 with pipe 116 or resin discharge.Described structure is metal tubulation 142 to be inserted into resinous resin inject the inside of discharging the front end of using pipe with pipe or resin, and the outside is the structure that twines band 143.Closed patrix 111 and counterdie 112, holding pressurizing resin under the arm with upper and lower mould injects with pipe (being designated as symbol 31) or resin and discharges when managing, metal tubulation 142 be not processed on elastomer 118,119 in upper die and lower die and sealing the groove (also little R) 10,10 of semicircle shape than the radius of curvature of aforementioned each pipe ' destroy, keep resin to inject and use pipe 116 or resin discharge, the mobile smoothly of interior vacuum draw of die cavity and resin carried out effectively with the circular cross-sectional shape of pipe 117.

In addition, closed patrix 111 and counterdie 112 are also held pressurizing resin under the arm with upper and lower mould and are injected when discharging with pipe with pipe or resin, can improve sealing and use elastomeric sealing effectiveness by making band 143 contact sealing elastomers, stably improve the vacuum retentivity in the die cavity.When elastomer is used in the configuration sealing of the two sides place of upper die and lower die, also can omit band 143.

Resin injects with pipe and resin discharges the plastic pipe that can use Fypro, polyethylene, polypropylene, " Teflon " fluororesin such as (registration marks) etc. with pipe, also can use the metal tubulation of iron, aluminium, brass, copper, stainless steel etc.

In addition, be inserted in the resin injection and can use iron, aluminium, brass, copper, stainless steel with the metal tubulation 142 in the end of pipe with pipe or resin discharge.Also can use the plastic pipe of ABS, polyethylene, polypropylene, Fypro, vinyl chloride, propylene etc. in addition.The all preferred 0.5mm of the wall thickness of any pipe or more than the 0.5mm.

And then the band of being implemented outside resin injects the end of discharging with pipe or resin with pipe 143 can use the band of the formations such as fluororesin, Fypro, polyethylene, acrylic resin of " Teflon " (registration mark) etc.When on the upper and lower mould two sides, using sealing to use elastomer, also can omit.

Figure 23 A～F represents with profile that various kinds of resin is injected and discharges with pipe and sealing routine with elastomeric relation with pipe and resin.O-ring 154 is used elastomer 153 with sealing, and can use the fluororesin of silicon, NBR, " Teflon " (registration mark) etc., also can use the material of solid or hollow.In addition, the foaming body that also can use above-mentioned resin to constitute.

Be arranged on sealing on any or two in patrix 151 and the counterdie 152 with elastomer 153, protrude in the mould surface that is set up a little, closed patrix 151, give as security sealing on its mould surface when compressing with elastomer 153, inject with pipe 150 (or the resin discharge is with managing) with elastomer 153 and patrix 151 and resin by sealing and to produce reaction force each other, guarantee sealing.

In addition, by ensconcing sealing in the end with O-ring 154 with in the elastomer 153, during closure patrix 151, the sealing of compression makes sealing press together with elastomer 153 and O-ring 154 with the reaction force that produces in elastomer 153 and the O-ring 154, can keep the continuity of sealing (O-ring) and the vacuum in the die cavity.

Below, illustrate that by Figure 23 A～F resin injects the encapsulating method of using pipe with pipe or resin discharge.

Structure shown in Figure 23 A, be carved with sealing with the patrix 151 of elastomer shape and/or counterdie 152 on the configuration sealing with the sealing on elastomer 153 and the O-ring 154 with elastomer 153, described sealing forms groove and groove curve form with elastomer 153 curvature is identical or littler with pipe 150 than the resin injection with above-mentioned resin injection pipe 150 (or resin is discharged with managing), cut off resin injects with pipe or resin and discharges with the portion that sets of managing 150 at the center of O-ring 154, sealing is provided in elastomer 153 is carved with sealing, seize resin with above-mentioned STA representation on both sides by the arms with patrix 151 and counterdie 152 and inject with pipe or resin and discharge 150 the state of managing of using with on the patrix 151 and/or counterdie 152 of elastomer shape.Encircling 154 ends by built-in O-on sealing with elastomer 153 this moment guarantees the vacuum retentivity in the die cavity and prevents seepage of resin.

Structure shown in Figure 23 B, in being carved with the counterdie 152 of sealing, set sealing elastomer 153 with elastomer 153 shapes, sealing elastomer 153 on patrix 151 and the O-ring 154, described sealing forms groove with elastomer 153, the curvature of described groove curve form and above-mentioned resin inject identical or less than this pipe with pipe 150, cut off resin injects with pipe or resin and discharges with the portion that sets of managing 150 at the center of O-ring 154, sealing is provided in elastomer 153 is carved with sealing, under above-mentioned state, seize resin on both sides by the arms and inject with pipe or resin and discharge with managing 150 with upper die and lower die with on the patrix 151 and/or counterdie 152 of elastomer shape.Encircling 154 ends by built-in O-on sealing with elastomer 153 this moment keeps the vacuum in the die cavity and prevents seepage of resin.

Structure shown in Figure 23 C, inject on the O-ring 154 of discharging with pipe and resin and cut off the closed circuit that O-encircles being equipped with resin on patrix 151 or the counterdie 152 with the part of pipe 150, it is identical or less than the groove of aforementioned tube 150 that described patrix 151 or counterdie 152 forms curvature and aforementioned tube 150, thereby make the cut-out portion contact of O-ring 154 use pipe to guarantee the vacuum retentivity that die cavity is interior and prevent seepage of resin.

Structure shown in Figure 23 D, it is identical or than its little patrix 151 and O-ring 154 and non-individual body sealing usefulness elastomer 153 that the curvature that forms groove and groove and aforementioned tube 150 are set, seize resin on both sides by the arms with upper die and lower die and inject, guarantee the vacuum retentivity in the die cavity and prevent seepage of resin with pipe or resin discharge pipe 150.

Structure shown in Figure 23 E, stride across and be used for setting processing in that to form groove and groove curvature and aforementioned tube 150 identical or inject with pipe or resin than the resin of its little patrix 151 and counterdie 152 and to discharge with the groove of managing 150, discharge with the little curvature configuration non-individual body O-ring 154 of pipe 150 to inject to discharge to inject with pipe or resin with the identical curvature of pipe 150 or than resin with pipe or resin with resin, the configuration resin injects with pipe or resin and discharges with pipe 150 on this O-ring 154, seize on both sides by the arms with upper die and lower die, guarantee the vacuum retentivity in the die cavity and prevent seepage of resin.

Being configured to shown in Figure 23 F do not have the state of the patrix of Figure 23 A or Figure 23 B, is from the plane of the visible sealing in mould involutory surface top with the relation of elastomer 153 and O-ring 154.

As mentioned above, resin is injected the structure that can adopt various sealings to strengthen with tube portion with pipe or resin discharge.

In addition, in described RTM forming method that the present invention relates to and device, for eliminating remains in minute bubbles in the material gap, or the resin molten bubble that generates when depositing gas evaporation that injects the resin that produces because of decompression, or the micro bubble that is detained in the corner of mould, can adopt structure shown below.Being the limit pressurizes in shaping mould and injects the resin limit and discharge the gas in the shaping mould and the structure of residual resin discontinuously.According to above-mentioned steps, can make resin with suitable fluctuating flow, promote the discharge of bubble in the resin.In this constitutes, resin pressure Pm in the shaping mould, the resin of inlet flows out pressure P i, optionally makes Pm=Pi, Pm＜Pi, also can control the flow that flows into the resin in the shaping mould, and can be by regulating the bore control resin flow of the outlet of discharging resin.In addition, also can store the adjusting of bore of outlet and the time point of this adjusting,, be controlled to the resin flow in the pattern automatically according to this stored information.

If specific description more, in shaping mould, set mold closing behind the reinforcing fiber base in advance according in the past method, with close the state that injects valve with vavuum pump from the drain passageway that is communicated with open discharge valve to carrying out vacuum draw in the mould, make the interior resin of mould press Pm at preferred 0.01MPa or the decompression state below the 0.01MPa, with the open valve that injects of the state of closing discharge valve, resin injects in the mould until complete filling and moulding from injecting the path pressurization then.But, in the method, because discharge valve was in closed condition when resin injected, so can't discharge bubble residual between the lamination of bubble residual in the reticulate pattern as the textile material of reinforcing fiber base or reinforcing fiber base, and mould in inject resin the molten bubble that gas forms in the process evaporation of hot briquetting operation etc. of depositing, minute bubbles remain in the moulded products behind the straight forming, cause the serious deterioration of Products Quality.Special when these bubbles are emerging in the surface as space or pin hole, in the goods of attention pattern, be considered as inferior goods.For solution causes the problem of these quality of item deteriorations or inferior goods, even the process of injecting at resin also must be suitably discharged in the mould and remained in the gas (bubble) that Mo Nei and evaporation produce.

So, in said method, when can add pressurizing resin, for example be arranged on the discharge valve in the drain passageway or change bore by switching from the inlet injection, be interrupted and discharge bubble and the residual resin that is detained in the mould efficiently.For example, opening injection valve injection resin and closing fully under the situation of discharge valve, make to inject and press resin pressure Pm in the Pi=mould, owing to flow into the pressure height of the resin in the shaping mould, so the easy impregnation reinforcing fiber of resin impregnation, on the contrary, the bubble of delay is mixed in the resin pressing to be compressed under much at one the pressure with resin.Under this state, open discharge valve, make resin pressure Pm in resin injection pressure Pi＞mould, can discharge bubble and the residual resin that is detained in the mould from outlet simultaneously.

Herein, the opening and closing speed of discharge valve is preferably below 1 second or 1 second, and cavity pressure Pm is along with opening and closing speed one gas reduction, and residual gas sharply expands.Then, pressure differential and gas volume change and produce resin flow, because this resin flow makes and is trapped between reinforcing fiber base or the medium gas in corner of mould can't be detained, discharge from outlet.Underspeeding of cavity pressure Pm is fast more, and the variation of gas volume is also fast more, and by giving the gas resin flow of resin impact on every side, residual gas breaks away from from delay all the more easily.The temporary transient gas that breaks away from is discharged with flowing to the resin flow of discharging the road.Then, close discharge valve and supply with resin from injecting valve.

As mentioned above, by opening and closing discharge valve (being not limited to standard-sized sheet, complete shut-down) repeatedly by phased manner, slowly discharge the bubble (gas) that is detained in the mould, under final state of discharging fully, close discharge valve fully, after temporary transient maintenance applies the state that injects the resin pressure, close the injection valve fully, the resin that riddles in the mould is heating and curing.Under this state, to the resin pressurization, even injection pressure Pi is an atmospheric pressure, cavity pressure is that negative pressure also can obtain identical effect.

As mentioned above moment make cavity pressure from the method for Pi or negative pressure variation as switching the vavuum pump that be connected on the resin trap and press empty pump to realize by moment.In addition, be arranged on the aperture of the discharge valve on the drain passageway by adjusting, resin is pressed the pace of change of Pm in the control mould, can discharge bubble more efficiently.

In addition, about above-mentioned discharge valve, the cycle that storage in advance opens and closes, for example import computer (making its storage) in advance, be that the basis operates with this information, need not increase workload and can solve in the past moulding problem.

By in advance resin injection condition or the optimal discharge valve of being satisfied with the resin flows situation being opened and closed the condition entry computer, can realize being adapted to the suitableeest resin flows of environment (atmospheric temperature etc.) variation etc.

According to said method, can access that previous methods is difficult to obtain, do not contain or contain the few space relevant or the FRP moulded products of pit with picture on surface.According to this method, usually can stably satisfy desired engineering properties, and stably obtain the surface quality of high-quality, compare also with method in the past and can carry out the higher production of yield rate.

And then, in described RTM forming method that the present invention relates to and device,, can adopt method as follows for forming the high moulded products of picture on surface at short notice efficiently.Promptly, vertical mould and horizontal mould are arranged in the RTM shaping mould, vertically there is following problems in mould (ejection formation is with more in the mould): because under the influence of gravity, resin flow is easy to certainization, the bubble rising is discharged easily in the mould, be not easy to produce the space of formation shaping mould surface quality problems or the advantage of pit so have, on the contrary, in shaping mould, dispose fiber-reinforced resin, promptly be difficult to configuration base material orderly on the die cavity face of shaping mould and be fixed on the die face, and need expend a large amount of time, so productivity is low.On the other hand, laterally mould is that shaping mould is made of upper and lower mould, though have described be easy to configuration fiber-reinforced resin and short advantage consuming time in mould, but there is following problems on the contrary: according to general resin method for implanting, promptly under the pressure of 0.2～1.0MPa, pressurize, when not controlling flow velocity injection resin especially, resin flows in the mould with the flow velocity that adapts with pressure, resin is packed in the mould in the short period of time, but reinforcing fiber base is because of resin rheology confusion, generate the fast and uneven resin flow of flow velocity, generate a large amount of gap or pit on the moulded products surface.Particularly, in order to shorten molding time or to make large-area moulded products moulding at short notice, when being that (therefore under high speed) is when injecting resin at the resin outflow pressure under 0.5MPa or the high pressure more than the 0.5MPa, the braiding structure of base material (particularly flat fabric) is chaotic easily, or because of resin in mould, to flow at a high speed, make trickle uneven thickness of appearance in the material or structural change and to cause flow resistance to be disperseed chaotic in flow region, can not keep uniform resin flow, therefore, produce " trying to be the first of resin flow " partly etc., generate big space.In addition, in fact resin flows in the base material part, but flow velocity is fast, and for example the gas that runs at the fabric reticulate pattern does not have the time of discharging and is detained, and can produce defective on the surface as pit.In the condition of molding in the past or forming process of the above-mentioned decline that causes the presentation quality relevant, adopts injection at a high speed for molding time is shortened, but can not guarantee great surface quality with pattern.The model of moulded products is big more, because of injecting resin at a high speed, so also be easy to generate the defective on the above-mentioned presentation quality more.

Because the resin flow state has very big influence to producing space or the pit relevant with above-mentioned pattern, so the density of reinforcing fiber base, be that weight per unit area also becomes important factor.In a word, as the weight per unit area of every layer of reinforcing fiber, owing to can influence the resin flows resistance or make bubble be easy to discharge, so must set the suitable weight per unit area that adapts with the resin flows condition.Not only consider, and consider, must establish the local weight per unit area of setting from viewpoints such as preformed operability or rate of utilization of strength from independent surface quality aspect.That is, if the excessive material stiffness of weight per unit area raises, then reinforcing fiber base is difficult to along die face three-dimensional shape be carried out expending a large amount of time in figuration or the preformedization, thereby causes the mechanical characteristic of base material confusion and FRP moulded products low.That is,, need the weight per unit area that adapts with working condition (compact dimensions, condition of molding etc.) for producing efficiently.

In addition, in condition of molding, particularly temperature or resin injection pressure also have a significant impact surface quality.If the resin temperature height that injects, then viscosity descends, the mobile rising, and resin is to the impregnation enhancing of base material, but viscosity climbing mobile sharply variation when uprising, resin flows produced the part of not impregnation from deceleration midway when moulded products was big.Even resin flow to universe reluctantly, even or in the zone of viscosity increased, do not have the part of not impregnation, also be easy to generate space or pit.On the other hand,, remain between the micro-bubble in the mould and be in contact with one another, become the air pocket that can develop into space or pit if the shaping mould temperature is uneven or change in forming process.In addition, pressure also must be suitably.Too high then the expansion in the die cavity inner volume generates bubble, and excessively low then residual bubble can not compress and diminish.

In addition, grow up change in time greatly, also may have grown into space or pit, so the resin impregnation is solidified better after entering material as early as possible as soon as possible owing in solidification process, can from reaction resin, produce the small gas (bubble) that contains in reacting gas or the resin.The material behavior of this reaction resin is very high to the degree of influence of ratio of briquetting, for example has following situation: according to curing agent kind difference, increase in resin reaction initial reaction speed, reduce through reaction speed in time, it is elongated therefore to solidify required time.With respect to this situation, also have this following situation: if rising shaping mould temperature, shorten hardening time, viscosity rises to excessive in the early stage earlier, resin injects excess stickiness rising when flowing, generation gelation as a result is molded over Halfway Stopping, generates not impregnation part.

As mentioned above, in the FRP moulding (particularly RTM forming method), if have the condition of molding or the material behavior that adapt with compact dimensions (area), but do not have moulding under suitable condition can think that then quality particularly is easy to generate problem in the aspect of surface quality.

Therefore, in RTM forming method that the present invention relates to and the device, the high moulded products of picture on surface that does not almost have space or pit in particular for moulding efficiently at short notice, when resin is injected in pressurization in the die cavity of shaping mould, can adopt resin unit interval flow (Q:cc/min) and die cavity projected area (S:m ²) ratio (Q/S:cc/minm ²) method in 50＜Q/S＜600 scopes.

In the method, above-mentioned than (Q/S:cc/minm ²) with product ((the Q/S) * P:ccMPa/minm of the plus-pressure (P:MPa) of resin ²) preferably in 20≤(Q/S) * P≤400 scopes.In addition, preferably in the scope of 0.2～0.8MPa, resin is under 60～160 ℃ of uniform temperatures in the scope in heating-up temperature preferably to the plus-pressure of resin, solidifies 3～30 minutes.

According to above-mentioned RTM condition of molding, can make the moulded products that is difficult to obtain, on the pattern plane surface, can not produce defectives such as space or pit in the RTM condition of molding in the past, and moulding efficiently and stably at short notice, the high moulded products of the high a large amount of production surface quality of circulation.

RTM condition of molding and the device that the present invention relates to, can be applicable to all RTM moulding that require high-speed molding, particularly, can make effectively than the efficient at short notice moulding of the moulded products of relatively large and shape more complicated, and has the high-quality surface quality, particularly the high-quality pattern plane.

More specifically, the present invention is applicable to that product size is 1m ²Or 1m ²More than than relatively large general industry FRP, particularly automobile with outer panel member or structural material, be applicable to as the demanding outer panel member of pattern the RTM moulding of the FRP member of use.In addition, the automobile outer panel member is all sheet materials such as door-plate in car or the truck or shadow shield, roof panels, truck cap, baffle, spoiler, side skirt, front skirtboard, dashboard, door interior plate.Particularly, be applicable to and require pattern and than relatively large sheet material.As other FRP sheet material, be applicable to the various plate classes of aviation machine member, rail truck door, side skirt, interior dress door etc., the shell class of building machineries such as crane, dashboard in the building, dividing plate, door-plate, shield etc., the appearance panel of the surfboard of using in moving in addition, the sweep that single leg slides coaster, bicycle assembly parts etc.

Claims (85)

1, a kind of RTM forming method, described RTM forming method is characterized by reinforcing fiber base is configured in the die cavity of the shaping mould that is made of a plurality of moulds, inject resin and the RTM forming method of moulding behind the mold closing, it is characterized by, on the surface direction of described reinforcing fiber base, suppose cut zone, and form respectively each cut zone to supposition and import and inject resin to the resin of this cut zone inside and import path, described each cut zone is for injecting resin and can expand in the whole surface in the zone and can be along the cut zone of impregnation in fact equably on the base material thickness direction.

2, RTM forming method as claimed in claim 1, wherein, at least from behind the mold closing till begin to inject resin, in official hour, carry out vacuum draw from the resin discharge line.

3, RTM forming method as claimed in claim 1, wherein, between each mould that constitutes described shaping mould, set intermediate member with the resin stream that on thickness direction, connects, by this intermediate member, resin can almost inject described reinforcing fiber base simultaneously from many places.

4, RTM forming method as claimed in claim 3 wherein, forms the resin discharge groove that can extend to full week of reinforcing fiber base in fact on any mould.

5, RTM forming method as claimed in claim 3 wherein, forms the resin discharge groove that can extend to full week of reinforcing fiber base in fact on described intermediate member.

6, RTM forming method as claimed in claim 3, wherein, on described intermediate member, be provided with resin stream groove and through hole, described resin stream is arranged on groove on the one side of described intermediate member, described through hole for is communicated with this groove, to run through described reverse side be the through hole that reinforcing fiber base disposes the face of side.

7, RTM forming method as claimed in claim 3, wherein, described intermediate member is metallic article or resin.

8, RTM forming method as claimed in claim 3, wherein, described intermediate member is held the pressurizing resin injection under the arm with the mould relative with it and is sealed with member.

9, RTM forming method as claimed in claim 3, wherein, described intermediate member with hold pressurizing resin by the reinforcing fiber base mould relative under the arm and discharge and to seal with member with described intermediate member.

10, RTM forming method as claimed in claim 3, wherein, described intermediate member is made of porous plate with a plurality of through holes or resin-made membrane.

11, RTM forming method as claimed in claim 10 wherein, is provided with resin stream groove on the mould relative with described intermediate member.

12, RTM forming method as claimed in claim 10 wherein, forms the gap between described intermediate member and the mould relative with it, and this gap is set in the scope of 1～10mm.

13,, wherein, on described reinforcing fiber base, be laminated with core as RTM forming method as claimed in claim 3.

14, RTM forming method as claimed in claim 3 wherein, is held under the arm at the mould involutory surface and to be pressed the injection that described resin is set with pipe and/or discharge with pipe, uses elastomeric seal between this Guan Yumo.

15, RTM forming method as claimed in claim 14, wherein, in the end of sealing with built-in O-ring in the elastomer, described O-ring is at the die cavity of the involutory facial sealing moulding mould of mould.

16, RTM forming method as claimed in claim 3, wherein, pressurize in described shaping mould and inject the resin limit and discharge gas and residual resin in the shaping mould discontinuously in the limit.

17, RTM forming method as claimed in claim 16, wherein, the resin pressure of resin in described shaping mould that injects when pressurization is Pm, when the resin outflow pressure of the inlet of injection resin is Pi, optionally make Pm=Pi, Pm＜Pi, control flows into the flow of the resin in the shaping mould.

18, RTM forming method as claimed in claim 16 wherein, flows into the flow of the resin in the described shaping mould by the bore control of regulating the outlet of discharging resin.

19, RTM forming method as claimed in claim 18 wherein, is stored the time point of adjusting He its adjusting of described outlet bore, according to this stored information, is controlled to the resin flow in the pattern automatically.

20, RTM forming method as claimed in claim 3, wherein, when resin is injected in pressurization in the die cavity of described shaping mould, the unit interval flow (Q:cc/min) of resin and die cavity projected area (S:m ²) ratio (Q/S:cc/minm ²) in the scope of 50＜Q/S＜600.

21, RTM forming method as claimed in claim 20, wherein, described than (Q/S:cc/minm ²) with product ((the Q/S) * P:ccMPa/minm of the plus-pressure (P:MPa) of resin ²) in the scope of 20≤(Q/S) * P≤400.

22, RTM forming method as claimed in claim 20, wherein, the plus-pressure of described resin is in the scope of 0.2～0.8MPa.

23, RTM forming method as claimed in claim 20 wherein, is to make described resin solidification 3～30 minutes under 60～160 ℃ of uniform temperatures in the scope in heating-up temperature.

24, RTM forming method as claimed in claim 1, be to inject resin to the resin discharge line from the resin filling line that is configured in described die cavity periphery, after described reinforcing fiber base includes resin pickup, the RTM forming method that makes it to be heating and curing, wherein, it is a plurality of that described resin filling line is cut apart formation.

25, RTM forming method as claimed in claim 24 wherein, forms described resin filling line and resin discharge line in fact on the whole zone of described die cavity periphery.

26, RTM forming method as claimed in claim 24, wherein, the length of described resin filling line is more than 2 times or 2 times of described resin discharge line length.

27, RTM forming method as claimed in claim 24, wherein, described resin filling line and/or resin discharge line are made up of the groove of processing in shaping mould.

28, RTM forming method as claimed in claim 27, wherein, described shaping mould is made up of upper die and lower die, and described groove is all processed on counterdie.

29, RTM forming method as claimed in claim 24, wherein, it is a plurality of that described resin discharge line is cut apart formation.

30, RTM forming method as claimed in claim 24 wherein, is divided into the resin that a plurality of resin filling lines begins and injects from described, begins to carry out successively from the resin filling line that comes down to a side of far-end from the resin discharge line.

31, RTM forming method as claimed in claim 24, wherein, described resin discharge line switches to the resin filling line and carries out the resin injection behind official hour.

32, RTM forming method as claimed in claim 24, wherein, stacked core on described reinforcing fiber base.

33, RTM forming method as claimed in claim 24 wherein, is held under the arm to press at the mould involutory surface and described resin is set is injected with pipe and/or discharge with pipe, uses elastomeric seal between this Guan Yumo.

34, RTM forming method as claimed in claim 33, wherein, in the end of described sealing with built-in O-ring in the elastomer, described O-ring is sealed to the die cavity of pattern at the mould involutory surface.

35, RTM forming method as claimed in claim 24, wherein, pressurize in described shaping mould and inject the resin limit and discharge gas and residual resin in the shaping mould discontinuously in the limit.

36, RTM forming method as claimed in claim 35, wherein, the resin pressure of resin in described shaping mould that injects when pressurization is Pm, when the resin outflow pressure of the inlet of injection resin is Pi, optionally make Pm=Pi, Pm＜Pi, control flows into the flow of the resin in the shaping mould.

37, RTM forming method as claimed in claim 35 wherein, flows into the flow of the resin in the described shaping mould by the bore control of regulating the outlet of discharging resin.

38, RTM forming method as claimed in claim 37 wherein, is stored the time point of adjusting He its adjusting of described outlet bore, according to this stored information, is controlled to the resin flow in the pattern automatically.

39, RTM forming method as claimed in claim 24, wherein, when resin is injected in pressurization in the die cavity of described shaping mould, the unit interval flow (Q:cc/min) of resin and die cavity projected area (S:m ²) ratio (Q/S:cc/minm ²) in the scope of 50＜Q/S＜600.

40, RTM forming method as claimed in claim 39, wherein, described than (Q/S:cc/minm ²) with product ((the Q/S) * P:ccMPa/minm of the plus-pressure (P:MPa) of resin ²) in the scope of 20≤(Q/S) * P≤400.

41, RTM forming method as claimed in claim 39, wherein, the plus-pressure of described resin is in the scope of 0.2～0.8MPa.

42, RTM forming method as claimed in claim 39 wherein, is to make described resin solidification 3～30 minutes under 60～160 ℃ of uniform temperatures in the scope in heating-up temperature.

43, RTM forming method as claimed in claim 1, wherein, the one-sided at least top layer of described reinforcing fiber base is made of the continuous fiber layer, and the just following one deck on this top layer is made of unordered mat layer.

44, RTM forming method as claimed in claim 43, wherein, described top layer is made of the continuous fiber layer below 3 layers or 3 layers.

45, RTM forming method as claimed in claim 43, wherein, the total weight per unit area that forms the continuous fiber layer on described top layer is 700g/m ²Or 700g/m ²Below.

46, RTM forming method as claimed in claim 43, wherein, the reinforcing fiber on described top layer is made of carbon fibre fabric.

47, RTM forming method as claimed in claim 43, wherein, total weight per unit area of described unordered mat layer is 150g/m ²Or 150g/m ²Below.

48, RTM forming method as claimed in claim 43, wherein, described unordered mat layer is made of glass fibre.

49, RTM forming method as claimed in claim 43 wherein, is laminated with core on described reinforcing fiber base.

50, a kind of RTM shaped device, in the die cavity of described RTM shaped device for the shaping mould that reinforcing fiber base is configured to a plurality of moulds and constitutes, inject resin and the RTM shaped device of moulding behind the mold closing, it is characterized by, on the surface direction of described reinforcing fiber base, be presumed to cut zone, and form respectively each cut zone to supposition and import and inject resin to the resin of this cut zone inside and import path, described each cut zone is for injecting resin and can expand in the whole surface in the zone and can be along the cut zone of impregnation in fact equably on the base material thickness direction.

51, RTM shaped device as claimed in claim 50, have at least from behind the mold closing till begin to inject resin, in official hour from the equipment of resin discharge line vacuum draw.

52, RTM shaped device as claimed in claim 50, wherein, between each mould that constitutes described shaping mould, set intermediate member with the resin stream that on thickness direction, connects, by this resin stream, resin can be almost simultaneously from many places injection reinforcing fiber base material.

53, RTM shaped device as claimed in claim 52 wherein, forms the resin discharge groove that extends to full week of reinforcing fiber base in fact on any mould.

54, RTM shaped device as claimed in claim 52 wherein, forms the resin discharge groove that extends to full week of reinforcing fiber base in fact on described intermediate member.

55, RTM shaped device as claimed in claim 52, wherein, on described intermediate member, be provided with resin stream groove and through hole, described resin stream is arranged on groove on the one side of described intermediate member, described through hole for is communicated with this groove, to run through described reverse side be the through hole that reinforcing fiber base disposes the face of side.

56, RTM shaped device as claimed in claim 52, wherein, described intermediate member is metallic article or resin.

57, RTM shaped device as claimed in claim 52, wherein, described intermediate member is held the pressurizing resin injection under the arm with the mould relative with it and is sealed with member.

58, RTM shaped device as claimed in claim 52, wherein, described intermediate member with hold pressurizing resin by the reinforcing fiber base mould relative under the arm and discharge and to seal with member with described intermediate member.

59, RTM shaped device as claimed in claim 52, wherein, described intermediate member is made of porous plate with a plurality of through holes or resin-made membrane.

60, RTM shaped device as claimed in claim 59 wherein, is provided with resin stream groove on the mould relative with described intermediate member.

61, RTM shaped device as claimed in claim 59 wherein, forms the gap between described intermediate member and the mould relative with it, and this gap is set in the scope of 1～10mm.

62, RTM shaped device as claimed in claim 52 wherein, is laminated with core on described reinforcing fiber base.

63, RTM shaped device as claimed in claim 52 wherein, is held under the arm at the mould involutory surface and to be pressed the injection that described resin is set with pipe and/or discharge with pipe, uses elastomeric seal between this Guan Yumo.

64, as the described RTM shaped device of claim 63, wherein, in the end of described sealing with built-in O-ring in the elastomer, described O-ring is sealed to the die cavity of pattern at the mould involutory surface.

65, RTM shaped device as claimed in claim 52 has the limit and pressurizes in described shaping mould and inject the resin limit and discharge the gas in the shaping mould and the equipment of residual resin discontinuously.

66, as the described RTM shaped device of claim 65, have following equipment: the resin pressure of resin in described shaping mould that injects when pressurization is Pm, when the resin outflow pressure of the inlet of injection resin is Pi, described equipment can optionally make Pm=Pi, Pm＜Pi, and control flows into the flow of the resin in the shaping mould.

67,, has the equipment that flows into the flow of the resin in the described shaping mould by the bore control of regulating the resin outlet as the described RTM shaped device of claim 65.

68, as the described RTM shaped device of claim 67, have the adjusting of the described outlet bore of storage and the time point of its adjusting, according to this stored information, be controlled to the equipment of the resin flow in the pattern automatically.

69, as the described RTM shaped device of claim 67, wherein, the conditioning equipment of described outlet bore is made of the switching device of valve.

70, RTM shaped device as claimed in claim 50, be to inject resin to the resin discharge line from the resin filling line that is configured in described die cavity periphery, after described reinforcing fiber base includes resin pickup, the RTM shaped device that makes it to be heating and curing, wherein, it is a plurality of that described resin filling line is cut apart formation.

71,, wherein, on the whole zone of described die cavity periphery, fully form described resin filling line and resin discharge line as the described RTM shaped device of claim 70.

72, as the described RTM shaped device of claim 70, wherein, the length of described resin filling line is more than 2 times or 2 times of described resin discharge line length.

73, as the described RTM shaped device of claim 70, wherein, described resin filling line and/or resin discharge line are made of the groove of processing in shaping mould.

74, as the described RTM shaped device of claim 73, wherein, described shaping mould is made of upper die and lower die, and described groove is all processed in counterdie.

75, as the described RTM shaped device of claim 70, wherein, described resin discharge line is divided into a plurality of.

76, as the described RTM shaped device of claim 70, wherein, be divided into the resin that a plurality of resin filling lines begins and inject from described, begin to carry out successively from the resin filling line that comes down to a side of far-end from the resin discharge line.

77, as the described RTM shaped device of claim 70, wherein, described resin discharge line also switches to the resin filling line and carries out the resin injection behind official hour.

78, as the described RTM shaped device of claim 70, wherein, stacked core on described reinforcing fiber base.

79, as the described RTM shaped device of claim 70, wherein, hold under the arm to press at the mould involutory surface and described resin is set injects with pipe and/or discharge with pipe, use elastomeric seal between this Guan Yumo.

80, as the described RTM shaped device of claim 79, wherein, in the end of described sealing with built-in O-ring in the elastomer, described O-ring is sealed to the die cavity of pattern at the mould involutory surface.

81,, have the limit and in described shaping mould, pressurize and inject the resin limit and discharge the gas in the shaping mould and the equipment of residual resin discontinuously as the described RTM shaped device of claim 70.

82, as the described RTM shaped device of claim 81, have following equipment: the resin pressure of resin in described shaping mould that injects when pressurization is Pm, when the resin outflow pressure of the inlet of injection resin is Pi, described equipment can optionally make Pm=Pi, Pm＜Pi, and control flows into the flow of the resin in the shaping mould.

83,, has the equipment that flows into the flow of the resin in the described shaping mould by the bore control of regulating the resin outlet as the described RTM shaped device of claim 81.

84, as the described RTM shaped device of claim 83, have the adjusting of the described outlet bore of storage and the time point of its adjusting, according to this stored information, be controlled to the equipment of the resin flow in the pattern automatically.

85, as the described RTM shaped device of claim 83, wherein, the equipment of regulating described outlet bore is made of the valve switch device.

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