JP2001062932A - Fiber-reinforced resin structural body and manufacture of the same - Google Patents
Fiber-reinforced resin structural body and manufacture of the sameInfo
- Publication number
- JP2001062932A JP2001062932A JP23823299A JP23823299A JP2001062932A JP 2001062932 A JP2001062932 A JP 2001062932A JP 23823299 A JP23823299 A JP 23823299A JP 23823299 A JP23823299 A JP 23823299A JP 2001062932 A JP2001062932 A JP 2001062932A
- Authority
- JP
- Japan
- Prior art keywords
- resin
- reinforcing fiber
- fiber base
- layer
- groove
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
Landscapes
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【０００１】[0001]
【発明の属する技術分野】本発明は、芯材層の両側に繊
維強化樹脂層が形成された、いわゆるサンドイッチ構造
を有する板状の繊維強化樹脂（以下、ＦＲＰと略記す
る。）構造体およびその製造方法に関し、特に 船、車
輌、屋根材等のＦＲＰからなる大型の構造体の製造に適
した製造方法に関する。The present invention relates to a plate-like fiber-reinforced resin (hereinafter abbreviated as FRP) structure having a so-called sandwich structure in which fiber-reinforced resin layers are formed on both sides of a core layer. The present invention relates to a manufacturing method, and more particularly to a manufacturing method suitable for manufacturing a large-sized structure made of FRP such as a ship, a vehicle, and a roofing material.
【０００２】[0002]
【従来の技術】従来のＦＲＰ構造体の成形法としては、
ハンドレイアップ成形法や真空バッグ成形法など様々な
成形方法がある。なかでも真空バッグ成形法は、ハンド
レイアップ成形法と同様に型の上に配置した強化繊維基
材に合成樹脂を含浸させた後、全体をバッグフィルムで
覆ってこれを型に密着させ、バッグ内を真空脱泡するこ
とから、ボイドの少ない高品質のＦＲＰ構造体が得られ
るという特徴があり、例えばボートなどの成形に使用さ
れている。2. Description of the Related Art Conventional FRP structures are formed by the following methods.
There are various molding methods such as a hand lay-up molding method and a vacuum bag molding method. Above all, the vacuum bag molding method is similar to the hand lay-up molding method, after impregnating the reinforcing fiber base material placed on the mold with the synthetic resin, covering the whole with a bag film, and bringing it into close contact with the mold. Since the inside is vacuum defoamed, a high-quality FRP structure with few voids can be obtained, and is used for molding boats, for example.
【０００３】しかし、この成形法を芯材層の両面に強化
繊維基材層を配置したサンドイッチ構造からなる板状構
造体の成形に適用すると、芯材層がバッグ内での空気の
自由な移動を遮断することからボイドの抜けが悪く、ま
た、合成樹脂の流れも遮断することから余分な樹脂を絞
ることができず、特に、大型の成形品においては高品質
のＦＲＰ構造体が得られないという問題があった。[0003] However, when this molding method is applied to the molding of a plate-like structure having a sandwich structure in which a reinforcing fiber base material layer is disposed on both sides of a core material layer, the core material layer allows free movement of air in the bag. And the flow of synthetic resin is also blocked, so that excess resin cannot be squeezed. In particular, a high-quality FRP structure cannot be obtained in a large molded product. There was a problem.
【０００４】そこで、この問題を改善する真空バッグ成
形法の一つとして、成形型の上に強化繊維基材を積層し
た後、型全体をバッグフィルムで覆い密着させた後、真
空吸引した状態でバッグ内の強化繊維基材内に樹脂を含
浸させる減圧注入法を用いることができるが、この成形
法をそのまま適用すると、大型の成形品においては樹脂
含浸に非常に時間がかかるため、樹脂の注入箇所や真空
吸引箇所の数を増やさなければいけない問題があった。Therefore, as one of the vacuum bag forming methods for solving this problem, a reinforcing fiber base material is laminated on a forming die, the entire die is covered with a bag film, and the whole is brought into close contact with each other. A vacuum injection method of impregnating the resin into the reinforcing fiber base material in the bag can be used. However, if this molding method is applied as it is, it takes a very long time to impregnate the resin into a large molded product. There was a problem that the number of locations and vacuum suction locations had to be increased.
【０００５】この問題を改善すべく、ＷＯ９６／４０４
８８には、上記減圧注入成形法において、芯材に溝を設
け、この溝から芯材の両面に配置した強化繊維基材に樹
脂を含浸する方法が提案されている。この方法は、樹脂
が芯材の溝を介して強化繊維基材内に浸入することから
短時間での含浸が可能となり、樹脂注入箇所や真空吸引
箇所の数をさほど増やす必要もないというメリットがあ
る。In order to improve this problem, WO96 / 404
No. 88 proposes a method of providing a groove in a core material and impregnating a reinforcing fiber base material disposed on both sides of the core material with a resin from the groove in the above-described vacuum injection molding method. This method has the advantage that it is possible to impregnate the resin in a short time because the resin penetrates into the reinforcing fiber base through the groove of the core material, and it is not necessary to increase the number of resin injection points or vacuum suction points. is there.
【０００６】しかし、例えば、船、車輌、屋根材等の大
型のＦＲＰ成形品においては、当然所定寸法の芯材に配
置した芯材の溝を樹脂が流れるように連続させることが
必要となるが、芯材配置時やバック時のバック圧で溝の
位置がずれるようなことがあれば樹脂流路が遮断される
ことになり、強化繊維基材に樹脂が含浸できない部分が
生じるという問題がある。また、成形時のバック圧によ
りバックフィルムが積層した強化繊維基材とともにこの
溝部内に食い込み、したがって強化繊維が屈曲すること
から強化繊維の持つ優れた機械的特性を有効に発揮でき
なくなる問題がある。さらに、成形毎に芯材層に溝を付
ける必要があり、量産してもコストが低減しにくいとい
う問題もある。However, for example, in a large-sized FRP molded product such as a ship, a vehicle, a roof material, etc., it is necessary to continuously connect the grooves of the core material arranged on the core material of a predetermined size so that the resin flows. If the position of the groove is shifted due to the back pressure at the time of disposing the core material or at the time of backing, the resin flow path is blocked, and there is a problem that a portion where the resin cannot be impregnated into the reinforcing fiber base material occurs. . In addition, there is a problem that the back film at the time of molding cuts into the groove together with the reinforcing fiber base material on which the back film is laminated, so that the excellent mechanical properties of the reinforcing fiber cannot be effectively exhibited because the reinforcing fiber is bent. . Further, it is necessary to form a groove in the core material layer every molding, and there is a problem that it is difficult to reduce the cost even in mass production.
【０００７】[0007]
【発明が解決しようとする課題】本発明は、上述した従
来技術の問題点を解決すること、すなわち、成形すべき
ものが大型のＦＲＰ構造体の成形品であっても、短時間
に合成樹脂含浸が均一、かつ容易にできるとともに、強
化繊維の持つ高強度・高弾性率の特性を十分に発揮で
き、しかも成形作業性にも優れるサンドイッチ構造から
なるＦＲＰ構造体の製造方法を提供することにある。SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems of the prior art, that is, it is possible to impregnate a synthetic resin in a short time even if the object to be molded is a large-sized FRP structure. It is an object of the present invention to provide a method for producing an FRP structure having a sandwich structure, which can uniformly and easily perform, and can sufficiently exhibit the characteristics of high strength and high elastic modulus possessed by reinforcing fibers, and also have excellent molding workability. .
【０００８】[0008]
【課題を解決するための手段】本発明は、上記した問題
点を解決するために鋭意検討を行い、以下の製造方法を
用いることにより、大型のＦＲＰ成形品であっても短時
間に樹脂含浸ができるとともに、強化繊維の持つ高強度
・高弾性率の特性を十分に発揮でき、また、作業性にも
優れるサンドイッチ構造からなるＦＲＰ構造材の製造方
法を見い出すに至った。Means for Solving the Problems The present invention has been studied diligently in order to solve the above-mentioned problems, and by using the following manufacturing method, it is possible to impregnate resin even in a large FRP molded product in a short time. As a result, the present inventors have found a method for producing an FRP structural material having a sandwich structure, which can sufficiently exhibit the properties of high strength and high elastic modulus possessed by reinforcing fibers, and also has excellent workability.
【０００９】すなわち、本発明の繊維強化樹脂構造体の
製造方法は、上記課題を解決するため、合成樹脂の進入
溝が設けられた成形型の表面に、第１強化繊維基材層、
芯材層、第２強化繊維基材層をこの順に積層し、さらに
この積層体の上に樹脂拡散媒体を配置した後、これらの
全体をバッグフィルムで覆い、次にバッグフィルムで覆
われた内部を大気圧よりも低い状態にした後、マトリッ
クス樹脂を前記成形型の進入溝と前記樹脂拡散媒体とか
ら前記積層体の強化繊維基材層内に含浸させることによ
り、前記第１および第２強化繊維基材層と前記芯材層と
を一体化させることを特徴とするサンドイッチ構造を有
するものである。That is, in order to solve the above-mentioned problems, the method for producing a fiber-reinforced resin structure of the present invention provides a first reinforcing fiber base layer and a first reinforcing fiber base layer on a surface of a mold provided with a synthetic resin inflow groove.
A core material layer and a second reinforcing fiber base material layer are laminated in this order, and further, a resin diffusion medium is disposed on the laminate, and then the entirety is covered with a bag film, and then the inside covered with the bag film is covered. Is made lower than the atmospheric pressure, and then the matrix resin is impregnated into the reinforcing fiber base material layer of the laminate from the entry groove of the molding die and the resin diffusion medium, whereby the first and second reinforcements are performed. It has a sandwich structure characterized by integrating a fiber base material layer and the core material layer.
【００１０】また、本発明の繊維強化樹脂構造体は、芯
材層の両面に繊維強化樹脂層が形成されたサンドイッチ
構造からなる繊維強化樹脂構造体において、前記繊維強
化樹脂層の少なくとも片面に合成樹脂からなる帯状の突
起部が設けられていることを特徴とする。The fiber-reinforced resin structure of the present invention is a fiber-reinforced resin structure having a sandwich structure in which fiber-reinforced resin layers are formed on both sides of a core material layer, wherein the fiber-reinforced resin structure is formed on at least one surface of the fiber-reinforced resin layer. It is characterized in that a strip-shaped projection made of resin is provided.
【００１１】[0011]
【発明の実施の形態】以下に、本発明のＦＲＰ構造体の
製造方法の望ましい実施の形態を図を用いて工程順に説
明する。DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of a method for manufacturing an FRP structure according to the present invention will be described below in the order of steps with reference to the drawings.
【００１２】図１は、本発明の製造方法の実施に用いる
製造装置の一実施例の断面図である。図において、１
は、表面に合成樹脂流路の溝２が設けられた金属製の成
形型、Ｓは、強化繊維基材層３と芯材層４とからなる本
発明の製造方法による成形対象のサンドイッチ状の構造
体であり、５、６、７、８、９は、構造体Ｓへの含浸性
を高めるためのそれぞれピールプライ、樹脂拡散媒体、
エッジ・ブリーザ、バッグフィルムシール材である。ま
た、１０、１１、１２は、いずれも構造体Ｓへの合成樹
脂供給手段であり、それぞれ吐出口、吸引口、バルブで
ある。FIG. 1 is a sectional view of one embodiment of a manufacturing apparatus used for carrying out the manufacturing method of the present invention. In the figure, 1
Is a metal mold provided with a groove 2 of a synthetic resin flow path on the surface, and S is a sandwich-shaped object to be molded by the production method of the present invention comprising the reinforcing fiber base layer 3 and the core layer 4. 5, 6, 7, 8, 9 are peel ply, resin diffusion medium,
Edge breather, bag film sealing material. Reference numerals 10, 11, and 12 denote synthetic resin supply means for the structure S, which are a discharge port, a suction port, and a valve, respectively.
【００１３】本発明の製造方法は、かかる製造装置を用
いて以下に述べる手順にて行われる。The manufacturing method of the present invention is performed by the following procedure using such a manufacturing apparatus.
【００１４】まず、矩形断面の溝２を設けた成形型１
に、成形型表面に接して芯材４の周囲に強化繊維基材層
３を巻き付けたサンドイッチ状の構造体Ｓを配置する。
配置後の構造体Ｓにおいて、成形型１側に位置する強化
繊維基材層３が本発明で言う第１強化繊維基材層であ
り、反対側に位置する強化繊維基材層３が本発明で言う
第２強化繊維材層である。ここで、成形型１は、金属、
ＦＲＰなど後述するバック圧力でも変形しにくい高剛性
の材料から構成されたものを用いるのが好ましい。ま
た、サンドイッチ状構造体Ｓの形状は、勿論成形すべき
形状によって定まるのであるが、本発明では主として板
状であり、勿論平面形状の他曲面も有する形状を備えて
いる。なお、図においては、芯材層４の周囲に強化繊維
基材層３を２層巻き付けたサンドイッチ状構造体を１つ
配置したケースを示したが、必ずしもこれに限定される
わけではなく、複数個配置してもよい。このようにする
ことにより、特に、大型の成形品においては、部分的に
芯材層の両面に配置した強化繊維基材層が強化繊維基材
で連結させることができることから、サンドイッチ構造
体に曲げなどの負荷が作用した場合に剪断破壊がしにく
くなり、機械的特性を向上させることができる。First, a molding die 1 provided with a groove 2 having a rectangular section.
Then, a sandwich-like structure S in which the reinforcing fiber base layer 3 is wound around the core material 4 in contact with the surface of the molding die is arranged.
In the structure S after the arrangement, the reinforcing fiber base layer 3 located on the mold 1 side is the first reinforcing fiber base layer referred to in the present invention, and the reinforcing fiber base layer 3 located on the opposite side is the present invention. This is the second reinforcing fiber material layer. Here, the mold 1 is made of metal,
It is preferable to use a material such as FRP made of a highly rigid material that is not easily deformed by a back pressure described later. The shape of the sandwich-like structure S is, of course, determined by the shape to be molded. In the present invention, the shape is mainly a plate-like shape and, of course, has a shape having a curved surface in addition to a planar shape. In addition, in the figure, the case where one sandwich-like structure in which two layers of the reinforcing fiber base material layer 3 are wound around the core material layer 4 is shown, but the invention is not necessarily limited thereto. It may be arranged individually. By doing so, particularly in the case of a large-sized molded product, the reinforcing fiber base layers partially disposed on both sides of the core material layer can be connected by the reinforcing fiber base, so that the sandwich structure is bent. When a load such as that described above is applied, shear breakage is less likely to occur, and mechanical properties can be improved.
【００１５】次に、サンドイッチ状構造体Ｓの上に、樹
脂が硬化した後に引き剥がして除去するためのシート、
いわゆるピールプライ５を積層し、さらにその上に樹脂
を強化繊維基材上面全体に拡散させるための樹脂拡散媒
体６を置く。Next, on the sandwich-like structure S, a sheet for peeling and removing after the resin is cured,
A so-called peel ply 5 is laminated, and a resin diffusion medium 6 for diffusing the resin over the entire upper surface of the reinforcing fiber base is placed thereon.
【００１６】なお、本実施例においては上述したよう
に、(１) 成形型１の表面と接して第１強化繊維基材層
３を配置した後、その上に芯材層４、第２強化繊維基材
層３、ピールプライ５、樹脂拡散媒体６をこの順に積層
する製法について記載したが、必ずしもこの順に限定さ
れるものではなく、例えば（２）第１強化繊維基材層
３、芯材層４、第２強化繊維基材層３、樹脂拡散媒体６
の順に積層したり、（３）強化繊維基材層３、芯材層
４、樹脂拡散媒体６、強化繊維基材層３の順であっても
よい。しかし、成形後に樹脂含浸媒体を除去する場合に
おいては、樹脂拡散媒体を除去しやすいようにするた
め、上記(１) の工程順で積層するのが好ましい。In this embodiment, as described above, (1) after arranging the first reinforcing fiber base material layer 3 in contact with the surface of the mold 1, the core material layer 4 and the second reinforcing fiber Although the manufacturing method of laminating the fiber base layer 3, the peel ply 5, and the resin diffusion medium 6 in this order has been described, the present invention is not necessarily limited to this order. For example, (2) the first reinforcing fiber base layer 3, the core material layer 4, second reinforcing fiber base layer 3, resin diffusion medium 6
Or (3) the reinforcing fiber base layer 3, the core material layer 4, the resin diffusion medium 6, and the reinforcing fiber base layer 3 in this order. However, when the resin-impregnated medium is removed after molding, it is preferable to stack the layers in the order of the above (1) in order to facilitate the removal of the resin-diffused medium.
【００１７】次に、強化繊維基材３が成形型１と接した
周囲には、エッジ・ブリーザ７として織物や不織布など
多孔性の材料を複数枚積層して張り巡らす。この場合、
成形型の溝２が、真空吸引口１１やエッジ・ブリーザ７
に接しているかもしくは近すぎると、溝部に流れ込んだ
樹脂が第１、第２強化繊維基材層３に含浸するよりも先
に真空吸引口およびエッジ・ブリーザの方に流れてしま
うことになる。この対策として、（Ａ）成形型１の溝部
の平面視の最大外形を成形型と接した第１強化繊維基材
層３の平面視の最大外形と比較した場合、前者の最大外
形が後者の最大外形よりも１０〜５０ｍｍ程度小さくな
るように配置し、真空吸引口やエッジ・ブリーザから最
も近い溝位置までの距離が１０ｍｍ以上離れるようにす
る、（Ｂ）成形型の溝部面積が成形型と接した第１強化
繊維基材層３の面積より小さくできない場合には、成形
型と接した第１強化繊維基材層より周囲がそれぞれ１０
〜５０ｍｍ程度小さくしたのと同じ効果が得られるよう
に溝２を適当な部材で塞ぐか、ないしは、樹脂が浸透し
ない樹脂遮断材を挿入するとよい。同様に、樹脂拡散媒
体６においても真空吸引口やエッジ・ブリーザに接して
いるもしくは近すぎると、樹脂拡散媒体に流れ込んだ樹
脂が第２強化繊維層に含浸するよりも先に真空吸引口お
よびエッジ・ブリーザの方に流れてしまうことから、
（Ａ）真空吸引口１１やエッジ・ブリーザ７から最も近
い樹脂拡散媒体６までの距離が１０ｍｍ以上離れるよう
に樹脂拡散媒体６の平面視の最大外形が樹脂拡散媒体面
の第２強化繊維基材層の平面視の最大外形よりも１０〜
５０ｍｍ程度小さくなるように配置するとよい。Next, a plurality of porous materials such as a woven fabric and a non-woven fabric are laminated and wrapped around the periphery of the reinforcing fiber substrate 3 in contact with the mold 1 as an edge breather 7. in this case,
The groove 2 of the mold is provided with the vacuum suction port 11 and the edge breather 7.
If the resin is in contact with or too close to the groove, the resin flowing into the groove will flow toward the vacuum suction port and the edge breather before impregnating the first and second reinforcing fiber base layers 3. As a countermeasure against this, (A) when comparing the maximum outer shape in plan view of the groove of the mold 1 with the maximum outer shape in plan view of the first reinforcing fiber base layer 3 in contact with the mold, the former maximum outer shape is the latter. (B) The groove area of the mold is set so that the distance from the vacuum suction port or the edge breather to the nearest groove position is 10 mm or more. If the area of the first reinforcing fiber base layer 3 cannot be smaller than the area of the first reinforcing fiber base layer 3 in contact with the molding die, the circumference of each of the first reinforcing fiber base layers 3 should be 10 or more.
It is preferable to close the groove 2 with a suitable member or to insert a resin blocking material through which resin does not penetrate so as to obtain the same effect as the reduction of about 50 mm. Similarly, if the resin diffusion medium 6 is in contact with or too close to the vacuum suction port or the edge breather, the resin that has flowed into the resin diffusion medium and the second reinforcing fiber layer are impregnated with the vacuum suction port and the edge breather.・ Because it flows toward the breather,
(A) The second reinforcing fiber base of the resin diffusion medium 6 has a maximum outer shape in plan view such that the distance from the vacuum suction port 11 or the edge breather 7 to the nearest resin diffusion medium 6 is 10 mm or more. 10 to more than the maximum outer shape of the layer in plan view
It is good to arrange so that it may become small about 50 mm.
【００１８】ついで、全体をバッグフィルム８で覆い、
空気が漏れないようにバッグフィルムと成形型１の周囲
を、ブチルゴム系やシリコーンゴム系のシール材９で型
に接着させ、ついでバッグフィルムの上部に図示しない
樹脂タンクから注入される合成樹脂の吐出口１０とバル
ブ１２を図示の如く成形型１の溝２および樹脂拡散媒体
６に接するように取り付ける。一方、図示しない真空ポ
ンプの空気の吸引口１１は、樹脂の吐出口１０から遠い
エッジ・ブリーザ上に取り付け、吐出口および吸引口の
取り付け部から空気が漏れないようにシール材で接着さ
せる。なお、樹脂タンクには、硬化剤を所定量入れた常
温でシロップ状の常温硬化型あるいは加熱硬化型のマト
リックス樹脂を入れておく。Then, the whole is covered with a bag film 8,
The bag film and the periphery of the mold 1 are adhered to the mold with a butyl rubber-based or silicone rubber-based sealing material 9 so that air does not leak, and then the synthetic resin injected from a resin tank (not shown) is poured over the bag film. The outlet 10 and the valve 12 are attached so as to be in contact with the groove 2 of the mold 1 and the resin diffusion medium 6 as shown in the figure. On the other hand, an air suction port 11 of a vacuum pump (not shown) is mounted on an edge breather far from the resin discharge port 10 and is adhered with a sealing material so that air does not leak from a mounting portion of the discharge port and the suction port. The resin tank is filled with a room temperature-curable or heat-curable matrix resin in the form of a syrup at room temperature containing a predetermined amount of a curing agent.
【００１９】ついで、真空ポンプでバッグフィルムで覆
われたサンドイッチ状構造体Ｓを真空圧力が７００〜７
６０Ｔｏｒｒ程度の真空状態になるように吸引したの
ち、バルブ１２を解放して溝２と樹脂拡散媒体６の両流
路から樹脂を注入する。注入された樹脂は、バッグフィ
ルムで覆われた中が真空状態であることから、ピールプ
ライ６を通過した後、成形型と接する第１強化繊維基材
層においては、流通抵抗の小さい成形型の溝内に拡がっ
た後、強化繊維基材層３の厚み方向および隣り合う溝間
の面方向に進行し、短時間に樹脂含浸が完了する。ま
た、同時に、樹脂拡散媒体６と接する第２強化繊維基材
層３においても、樹脂が流通抵抗の小さい樹脂拡散媒体
全面に拡がった後、ついで第２強化繊維基材層の厚み方
向に含浸が進行することから短時間に樹脂含浸が完了す
る。なお、真空ポンプは少なくとも樹脂の含浸が完了す
るまで運転し、バッグフィルムの中を真空状態に保つこ
とが好ましい。樹脂の含浸完了後は、バルブ１２を閉
じ、室温に放置あるいは適当な温度に全体を加熱するこ
とによりし注入樹脂を硬化させる。樹脂の硬化後、バッ
グフィルムを除去し、成形型からサンドイッチ状構造体
Ｓを脱型することによって短時間に樹脂含浸が可能であ
るなど成形性に優れた大型のＦＲＰ成形品が得られる。Next, the sandwich-like structure S covered with the bag film is vacuum-pumped to a pressure of 700 to 7 mm.
After suctioning to a vacuum state of about 60 Torr, the valve 12 is opened, and the resin is injected from both channels of the groove 2 and the resin diffusion medium 6. Since the injected resin is covered with the bag film and is in a vacuum state, after passing through the peel ply 6, in the first reinforcing fiber base layer in contact with the molding die, the groove of the molding die having a small flow resistance is formed. After spreading inside, it proceeds in the thickness direction of the reinforcing fiber base layer 3 and in the plane direction between adjacent grooves, and the resin impregnation is completed in a short time. At the same time, also in the second reinforcing fiber base layer 3 in contact with the resin diffusion medium 6, after the resin spreads over the entire surface of the resin diffusion medium having a low flow resistance, impregnation is performed in the thickness direction of the second reinforcing fiber base layer. As the process proceeds, the resin impregnation is completed in a short time. Preferably, the vacuum pump is operated at least until the impregnation of the resin is completed, and the inside of the bag film is maintained in a vacuum state. After completion of the impregnation of the resin, the valve 12 is closed and the injected resin is cured by leaving it at room temperature or heating the whole to an appropriate temperature. After the resin is cured, the bag film is removed, and the sandwich-like structure S is removed from the mold, so that a large-sized FRP molded product excellent in moldability, such as resin impregnation in a short time, can be obtained.
【００２０】ここで、本発明の製造方法においては、第
１および第２強化繊維基材層３への樹脂含浸は、それぞ
れ成形型１に設けた溝２および樹脂含浸媒体６を経て行
うために、所定寸法の芯材を複数個敷き詰めて芯材層４
を構成する場合であっても、樹脂の流路である溝２ない
し樹脂含浸媒体６は連続して常時存在する。このため、
従来技術のように芯材の位置が多少ずれたとしても確実
に強化繊維基材に樹脂含浸ができるとともに、芯材の配
置作業を短時間で行うことができるという効果がある。
さらに、成形毎に芯材に溝加工をする必要がないため作
業性もよい。Here, in the manufacturing method of the present invention, the first and second reinforcing fiber base layers 3 are impregnated with the resin through the grooves 2 and the resin impregnating medium 6 provided in the mold 1, respectively. A plurality of core materials of a predetermined size
However, the groove 2 or the resin-impregnated medium 6, which is the resin flow path, is always present continuously. For this reason,
Even if the position of the core material is slightly displaced as in the prior art, there is an effect that the reinforcing fiber base material can be surely impregnated with the resin and the work of disposing the core material can be performed in a short time.
Further, since there is no need to form a groove in the core material for each molding, workability is good.
【００２１】その上、サンドイッチ構造からなるＦＲＰ
構造体Ｓの芯材部分自体には溝を設けないことから成形
時のバック圧によりバックフィルムが積層した強化繊維
基材層とともに溝内に入り込み強化繊維が屈曲するよう
なこともなく、強化繊維の持つ優れた機械的特性を有効
に発揮することができる。In addition, an FRP having a sandwich structure
Since no groove is provided in the core portion itself of the structure S, the reinforcing fiber does not enter the groove together with the reinforcing fiber base layer on which the back film is laminated due to the back pressure during molding, and the reinforcing fiber does not bend. The excellent mechanical properties possessed by can be exhibited effectively.
【００２２】上記に記載した製造方法は、大きくは減圧
注入成形法の範疇に入るが、樹脂注入と同時に樹脂を第
１および第２強化繊維基材層の面方向に拡散させる点
で、従来の減圧注入成形法とは異なる。The manufacturing method described above falls broadly in the category of reduced pressure injection molding method. However, in the point that the resin is diffused in the surface direction of the first and second reinforcing fiber base layers simultaneously with the injection of the resin, the conventional manufacturing method is used. It is different from the vacuum injection molding method.
【００２３】本発明のサンドイッチ状構造体Ｓの成形方
法は、その一方の面が成形型に連続した溝に接してお
り、また、他方の面が樹脂拡散媒体と接していることか
ら、溝や樹脂拡散媒体により強化繊維基材層の面方向に
樹脂を均一に拡散させた後、これとは直交する方向の第
１および第２強化繊維基材層の内部にまで樹脂が含浸す
ることから、大型の成形品においても安定して短時間に
樹脂の含浸が可能となる。また、成形後において成形型
と接する面は、合成樹脂のみからなる帯状の突起を有す
ることになるが、この突起はサンドイッチ構造体に刃物
などの擦過や衝撃が作用した際には適度な防護層とな
り、サンドイッチ構造体に刃物や衝突により傷がつくの
を防ぐことができる。According to the method of molding the sandwich-like structure S of the present invention, one surface is in contact with the groove continuous with the molding die, and the other surface is in contact with the resin diffusion medium. After uniformly diffusing the resin in the surface direction of the reinforcing fiber base layer with the resin diffusion medium, the resin impregnates the interior of the first and second reinforcing fiber base layers in a direction orthogonal to this direction, It is possible to stably impregnate the resin even in a large molded product in a short time. In addition, the surface that comes into contact with the molding die after molding has band-shaped projections made of only synthetic resin, and these projections have an appropriate protective layer when abrasion or impact of a blade or the like acts on the sandwich structure. Thus, it is possible to prevent the sandwich structure from being damaged by a blade or a collision.
【００２４】また、本発明に係る製造方法は、成形型１
と第１強化繊維基材層３の間にピールプライ５を配置し
たことを特徴とするものである。ピールプライを配する
ことにより、真空バッグにより第２強化繊維基材層方向
に加圧されるとピールプライがつっぱった状態で固定さ
れることから、ピールプライを配さない場合に比べ、強
化繊維が成形型の溝部に入り込むのを防ぐことができ、
強化繊維基材の屈曲が発生しにくい。Further, the manufacturing method according to the present invention provides
The peel ply 5 is disposed between the first reinforcing fiber base layer 3 and the first reinforcing fiber base layer 3. By disposing the peel ply, when the vacuum bag presses in the direction of the second reinforcing fiber base layer, the peel ply is fixed in a tight state, so that the reinforcing fiber is formed in a molding die as compared with the case where the peel ply is not disposed. Can be prevented from entering the groove of the
Bending of the reinforcing fiber base is unlikely to occur.
【００２５】また、図示は省略したが本発明に係る他の
製造方法は、成形型１と第１強化繊維基材層３の間にピ
ールプライ６を配置し、樹脂を含浸させた後、ＦＲＰ表
面に転写された溝部の合成樹脂および／またはピールプ
ライを除去することを特徴とするものである。ここで、
ピールプライ６は、樹脂が硬化した後にＦＲＰ成形品表
面に固着するが、このピールプライを引き剥がして除去
することにより、溝２に相当する樹脂からなる帯状の突
起をなくすることができ、表面が平滑なＦＲＰ構造体を
得ることができる。Although not shown in the drawings, another manufacturing method according to the present invention is to dispose a peel ply 6 between the mold 1 and the first reinforcing fiber base layer 3 and impregnate the resin with the peel ply 6. And removing the synthetic resin and / or the peel ply in the groove transferred to the groove. here,
The peel ply 6 is fixed to the surface of the FRP molded product after the resin is cured, but by removing the peel ply by peeling it off, it is possible to eliminate the belt-like projections made of the resin corresponding to the grooves 2 and to make the surface smooth. A FRP structure can be obtained.
【００２６】次に、本発明に使用する成形型の溝２の配
置の一例を示す一部断面の斜視図を図２に示す。成形型
１において溝２は、型面全面ではなく周囲には溝の存在
しない部分を有する。この溝の存在しない部分は、真空
バック時に空気が漏れないようにシール材で型に密着さ
せるシール材の取り付け位置となる。なお、成形型面に
おける溝の存在する部分の面積は、積層体が成形型に接
する面積より大きくてもかまわないが、使用する樹脂量
をできるだけ少なくするために、積層体と同じ面積であ
るかないしは周囲が５０ｍｍ程度まで小さい方が好まし
い。Next, a perspective view of a partial cross section showing an example of the arrangement of the grooves 2 of the molding die used in the present invention is shown in FIG. In the molding die 1, the groove 2 has a portion where the groove does not exist on the periphery but not on the entire die surface. The portion where the groove does not exist is a mounting position of the sealing material which is brought into close contact with the mold with the sealing material so that air does not leak during vacuum back. In addition, the area of the portion where the groove is present on the mold surface may be larger than the area where the laminate is in contact with the mold, but in order to minimize the amount of resin used, the area is not the same as the laminate. It is preferable that the circumference is as small as about 50 mm.
【００２７】また、成形型表面における溝２の配列形状
は、特に限定されないが、第１強化繊維基材層への合成
樹脂の含浸を安定させるために、連続した溝が並行に配
列し交錯した、すなわち、成形型表面から見た溝の配置
形状が、菱形や長方形、正方形の格子状ないし、交錯し
ないまでも隣の溝と並行に配向した直線状が好ましい。
さらに、樹脂注入口と溝が接すると溝部に短時間に樹脂
を拡散できることから好ましい。The arrangement shape of the grooves 2 on the surface of the molding die is not particularly limited. However, in order to stabilize the impregnation of the first reinforcing fiber base material layer with the synthetic resin, continuous grooves are arranged and crossed in parallel. That is, it is preferable that the arrangement shape of the grooves as viewed from the surface of the molding die is a rhombus, a rectangle, or a square lattice, or a straight line oriented parallel to the adjacent grooves even if they do not intersect.
Further, it is preferable that the groove is in contact with the resin injection port because the resin can be diffused into the groove in a short time.
【００２８】前記帯状の隣り合う溝と溝との間隔は、溝
の断面形状にもよるが、１０〜２００ｍｍの範囲が好ま
しい。１０ｍｍ未満であると、第１強化繊維基材層に合
成樹脂が含浸する時間は短時間ですむものの溝の数が多
くなりすぎ、合成樹脂からなる突起部分が多くなること
からＦＲＰ重量が重くなってしまう。また、２００ｍｍ
を越えると隣り合う溝部の距離が離れすぎることによ
り、樹脂の含浸時間が遅くなることや樹脂が未含浸とな
る箇所が発生しやすくなる。さらに好ましくは、適度に
防護層となる樹脂突起を形成することができ、かつ、短
時間に樹脂含浸できることから１０〜１００ｍｍの範囲
がよい。さらに、本発明に使用した溝２の断面拡大図を
図３に示したが、溝の断面形状は、成形時に樹脂注入口
から樹脂を流し込む際に樹脂が流れやすく、かつ、成形
後に成形型からＦＲＰ構造体が脱型しやすければ、特に
溝の断面形状は限定されるものではないが、好ましく
は、強化繊維基材もしくはピールプライと接している成
形型の面が、溝の底部および中間部より同じ幅もしくは
広幅の断面形状であるＶ字形、Ｕ字形、四角形および多
角形であるとよい。前記溝２の幅は、溝の深さにもよる
が、０．５〜５ｍｍの範囲が好ましい。０．５ｍｍ未満
であると溝の深さを大きくしても樹脂の流通抵抗が大き
くなり、樹脂が流れにくくなる。また、５ｍｍを越える
と樹脂は流れやすくなるものの、真空バッグ時に強化繊
維基材層が溝に入り込みやすくなり、強化繊維基材の屈
曲および膨れを生じやすくなる。このため、０．５〜５
ｍｍの範囲が好ましい。さらに好ましくは、樹脂が流れ
やすく、強化繊維基材の溝への入り込みが少ないことか
ら０．５〜２ｍｍの範囲がよい。The interval between the adjacent strips in the band shape is preferably in the range of 10 to 200 mm, though it depends on the cross-sectional shape of the groove. When it is less than 10 mm, the time for impregnating the first reinforcing fiber base material layer with the synthetic resin is short, but the number of grooves is too large and the number of protrusions made of the synthetic resin is large, so the FRP weight becomes heavy. Would. Also, 200mm
When the distance exceeds, the distance between adjacent groove portions is too large, so that the impregnation time of the resin is delayed and a portion where the resin is not impregnated easily occurs. More preferably, the thickness is in the range of 10 to 100 mm, since resin protrusions serving as a protective layer can be appropriately formed and the resin can be impregnated in a short time. Further, FIG. 3 shows an enlarged cross-sectional view of the groove 2 used in the present invention, and the cross-sectional shape of the groove is such that the resin easily flows when the resin is poured from the resin injection port during molding, and the groove is formed from the molding die after molding. If the FRP structure is easy to remove from the mold, the cross-sectional shape of the groove is not particularly limited. However, preferably, the surface of the mold in contact with the reinforcing fiber base or the peel ply is closer than the bottom and the middle of the groove. V-shaped, U-shaped, square, and polygonal sections having the same width or a wide cross section may be used. The width of the groove 2 is preferably in the range of 0.5 to 5 mm, depending on the depth of the groove. If it is less than 0.5 mm, even if the depth of the groove is increased, the flow resistance of the resin increases, and the resin hardly flows. When the thickness exceeds 5 mm, the resin easily flows, but the reinforcing fiber base layer easily enters the groove during the vacuum bag, and the bending and swelling of the reinforcing fiber base tend to occur. Therefore, 0.5 to 5
The range of mm is preferred. More preferably, the range is 0.5 to 2 mm because the resin easily flows and the penetration of the reinforcing fiber base into the groove is small.
【００２９】前記溝２の深さは、溝の幅にもよるが、
０．５〜２０ｍｍの範囲が好ましい。０．５ｍｍ未満で
あると溝の幅を大きくしても、樹脂の流通抵抗が大きく
なり樹脂が流れにくくなる。また、２０ｍｍを越えると
成形後ＦＲＰ構造体を成形型から脱型する際に、ＦＲＰ
に転写された樹脂部分が折れやすく、樹脂の突起からな
る防護層を安定して形成することができない。また、う
まく脱型できたとしても突起の長さが長すぎるため重量
が重くなる。さらに好ましくは、脱型しやすく、ＦＲＰ
重量もさほど大きくならないことから０．５〜１０ｍｍ
の範囲がよい。The depth of the groove 2 depends on the width of the groove.
A range of 0.5 to 20 mm is preferred. If it is less than 0.5 mm, even if the width of the groove is increased, the flow resistance of the resin is increased and the resin is less likely to flow. If it exceeds 20 mm, the FRP structure may be removed from the mold after molding.
The resin portion transferred to the resin is easily broken, and a protective layer composed of resin protrusions cannot be formed stably. In addition, even if the mold is successfully removed, the weight is heavy because the length of the projection is too long. More preferably, it is easy to remove the mold, and FRP
0.5 to 10 mm because the weight is not so large
Range is good.
【００３０】本発明に用いる第１および第２強化繊維基
材層３を構成する強化繊維は、炭素繊維、ガラス繊維、
アラミド繊維やポリアミド繊維からなる織物やチョップ
ド・ストランド・マット、コンティニュアンス・ストラ
ンド・マットであってもよい。また、これら強化繊維糸
を平行に配列したシートを０°（繊維基材の長さ方
向）、９０°（繊維基材の幅方向）や±４５°（繊維基
材の斜め方向）に積層され、これをガラス繊維、ポリエ
ステル繊維やポリアミド繊維などのステッチ糸で縫合し
た多軸ステッチ布帛であってもよい。The reinforcing fibers constituting the first and second reinforcing fiber base layers 3 used in the present invention are carbon fibers, glass fibers,
It may be a fabric made of aramid fiber or polyamide fiber, a chopped strand mat, or a continuity strand mat. In addition, sheets in which these reinforcing fiber yarns are arranged in parallel are laminated at 0 ° (the length direction of the fiber base), 90 ° (the width direction of the fiber base) or ± 45 ° (the oblique direction of the fiber base). Alternatively, a multi-axis stitched fabric which is sewn with a stitch thread such as glass fiber, polyester fiber, or polyamide fiber may be used.
【００３１】本発明に用いるマトリックス樹脂として
は、エポキシ樹脂、不飽和ポリエステル樹脂、ビニルエ
ステル樹脂、フェノール樹脂、変性エポキシ樹脂などの
熱硬化性樹脂や、ナイロン樹脂、ポリエステル樹脂、Ａ
ＢＳ樹脂、ポリエチレン樹脂、ポリプロピレン樹脂、ポ
リ塩化ビニル樹脂、ポリエーテルケトン樹脂、ポリエー
テルケトン樹脂、ポリフェニレンサルファイド樹脂など
の熱可塑性樹脂である。As the matrix resin used in the present invention, thermosetting resins such as epoxy resin, unsaturated polyester resin, vinyl ester resin, phenol resin and modified epoxy resin, nylon resin, polyester resin, A
Thermoplastic resins such as BS resin, polyethylene resin, polypropylene resin, polyvinyl chloride resin, polyether ketone resin, polyether ketone resin, and polyphenylene sulfide resin.
【００３２】本発明に用いる芯材層４を構成する芯材
は、有機系あるいは無機系の発泡体であると、得られる
成形体が軽量となるので好ましいが、発泡していない樹
脂板や無機系の板、または金属板や木材であってもよ
い。有機系あるいは無機系の発泡体としては、ポリウレ
タン、ポリスチレン、ポリエチレン、ポリプロピレン、
ＰＶＣ（塩化ビニル）、シリコーン、イソシアヌレー
ト、フェノール、アクリル樹脂のフォームや軽量気泡コ
ンクリート、珪酸カルシウムフォームや炭酸カルシウム
フォームなどが挙げられる。It is preferable that the core material constituting the core material layer 4 used in the present invention is an organic or inorganic foam because the resulting molded article is light in weight. It may be a system plate, or a metal plate or wood. Organic or inorganic foams include polyurethane, polystyrene, polyethylene, polypropylene,
Examples include foams of PVC (vinyl chloride), silicone, isocyanurate, phenol, and acrylic resin, lightweight cellular concrete, calcium silicate foam and calcium carbonate foam.
【００３３】なお、芯材の圧縮強さは、０．１ＭＰａ以
上が好ましい。圧縮強さが０．１ＭＰａ未満であると、
成形時に真空バッグする際減圧され、芯材の潰れが発生
してしまうので好ましくない。The compressive strength of the core material is preferably 0.1 MPa or more. When the compressive strength is less than 0.1 MPa,
It is not preferable because the pressure is reduced when the vacuum bag is applied during molding, and the core material is crushed.
【００３４】本発明の成形に用いるピールプライ５は、
合成樹脂を通過させることができることが必要であり、
例えばナイロン繊維織物、ポリエステル繊維織物やガラ
ス繊維織物などである。なお、ナイロン繊維織物やポリ
エステル繊維織物は安価であるため好ましく用いられる
が、これら織物を製造する際に用いられている油剤やサ
イジング剤がＦＲＰの樹脂に混入するのを防ぐため、精
錬を行い、また、成形で用いる樹脂の硬化発熱などの熱
による収縮を防ぐため、熱セットされた織物を使用する
ことが好ましい。The peel ply 5 used in the molding of the present invention comprises:
It must be able to pass through synthetic resin,
For example, nylon fiber woven fabric, polyester fiber woven fabric, glass fiber woven fabric, etc. In addition, nylon fiber woven fabrics and polyester fiber woven fabrics are preferably used because they are inexpensive, but in order to prevent oils and sizing agents used in producing these woven fabrics from being mixed into the FRP resin, refining is performed. Further, in order to prevent shrinkage of the resin used for molding due to heat such as curing heat, it is preferable to use a heat-set fabric.
【００３５】本発明に用いる樹脂拡散媒体６の一実施例
を図４に示したが、樹脂拡散媒体はバッグ内の真空圧力
を繊維基材に伝え、かつ注入される樹脂を樹脂拡散媒体
の隙間を通して、媒体側の繊維基材上面に樹脂を行き渡
らせるものである。すなわち、バッグフィルムとピール
プライ間に配置する樹脂拡散媒体に樹脂が注入される
と、図４において、注入された樹脂はバッグフィルムに
接するＡ群のバー１３の隙間を流れて、バー１３の方向
とＢ群のバー１４の隙間を流れるから全面に樹脂が均一
に拡散することになる。また、バー１３にかかる力をバ
ー１４に伝えることができる。バーの太さは特に限定さ
れるものではないが、０．２〜２ｍｍが好ましい。ま
た、隙間の幅は０．２〜２ｍｍが好ましい。樹脂拡散媒
体の具体的なものとしては、ポリプロピレン、ポリエチ
レン、ポリ塩化ビニルや金属などからなるメッシュ状の
シートで、たとえば、メッシュ状樹脂フィルム、織物、
網状物や編物などであり、必要に応じてこれらを数枚重
ねて使用することができる。FIG. 4 shows an embodiment of the resin diffusion medium 6 used in the present invention. The resin diffusion medium transmits the vacuum pressure in the bag to the fiber base material and allows the injected resin to have a gap between the resin diffusion media. To spread the resin on the upper surface of the fiber substrate on the medium side. That is, when the resin is injected into the resin diffusion medium disposed between the bag film and the peel ply, the injected resin flows through the gap of the bar 13 in the group A in contact with the bag film in FIG. Since the resin flows through the gap between the bars 14 of the group B, the resin is uniformly diffused over the entire surface. Further, the force applied to the bar 13 can be transmitted to the bar 14. The thickness of the bar is not particularly limited, but is preferably 0.2 to 2 mm. Further, the width of the gap is preferably 0.2 to 2 mm. Specific examples of the resin diffusion medium include a mesh-like sheet made of polypropylene, polyethylene, polyvinyl chloride, metal, or the like, for example, a mesh-like resin film, a woven fabric,
It is a net-like or knitted fabric, and several of these can be used as needed.
【００３６】本発明に用いるバッグフィルム８は、気密
性であることが必要で例えばナイロンフィルム、ポリエ
ステルフィルム、ポリエチレンフィルム、ＰＶＣ（塩化
ビニル）フィルム、ポリプロピレンフィルムやポリイミ
ドフィルムなどである。The bag film 8 used in the present invention is required to be airtight and is, for example, a nylon film, a polyester film, a polyethylene film, a PVC (vinyl chloride) film, a polypropylene film or a polyimide film.
【００３７】また、本発明に用いるエッジ・ブリーザ７
は、空気および樹脂を通過させることができることが必
要であり、例えばナイロン繊維織物、ポリエステル繊維
織物、ガラス繊維織物やナイロン繊維、ポリエステル繊
維からなる不織布を使用することができる。The edge breather 7 used in the present invention
Is required to be able to allow air and resin to pass therethrough, and for example, a nylon fiber woven fabric, a polyester fiber woven fabric, a glass fiber woven fabric, or a nonwoven fabric made of nylon fibers and polyester fibers can be used.
【００３８】図５は、以上に述べた本発明の製造方法に
よって得られたＦＲＰ構造体の一例の斜視図である。芯
材層４の両面に繊維強化樹脂３が配されたサンドイッチ
構造からなる繊維強化樹脂構造体において、繊維強化樹
脂層３の少なくとも片面に樹脂からなる帯状の突起部を
有している。前記溝付きの成形型を用いて成形した後に
脱型することで、成形型と接する面は、樹脂のみからな
る帯状の突起を突起を有することになるが、この突起は
サンドイッチ構造体に刃物などの擦過や衝撃が作用した
際には保護層となり、サンドイッチ構造体に刃物擦過や
衝撃による傷が付きにくくなることから、ＦＲＰサンド
イッチ構造体の持つ優れた機械的特性が急激に低下する
ようなことはない。FIG. 5 is a perspective view of an example of the FRP structure obtained by the above-described manufacturing method of the present invention. In a fiber reinforced resin structure having a sandwich structure in which the fiber reinforced resin 3 is disposed on both surfaces of the core material layer 4, at least one surface of the fiber reinforced resin layer 3 has a strip-shaped protrusion made of resin. By removing the mold after molding using the grooved mold, the surface in contact with the mold will have a band-shaped protrusion made of only resin, but this protrusion is a blade or the like in the sandwich structure. The protective layer becomes a protective layer when rubbing or impact is applied, and the excellent mechanical properties of the FRP sandwich structure are rapidly reduced because the sandwich structure is less likely to be scratched by blade rubbing or shock. There is no.
【００３９】[0039]
【実施例】以下、実施例により、本発明をさらに詳細に
説明する。The present invention will be described in more detail with reference to the following examples.
【００４０】まず、以下に示す条件で幅が２００ｃｍ、
長さが４００ｃｍ、厚みが５１ｍｍのサンドイッチ構造
の積層体である図１のサンドイッチ状構造体Ｓを製作し
た。First, the width is 200 cm under the following conditions.
The sandwich-like structure S of FIG. 1 which is a laminate having a sandwich structure with a length of 400 cm and a thickness of 51 mm was manufactured.
【００４１】強化繊維基材としては、炭素繊維が二方向
に配向した３００ｇ／ｍ2の炭素繊維クロス、８００ｇ
／ｍ2のガラスロービングクロス、４５０ｇ／ｍ2のガラ
スチョップドストランドマットを用いた。また、マトリ
ックス樹脂として、水溶性レゾールタイプのフェノール
樹脂を用いた。さらに、芯材として幅が１００ｃｍで長
さが１００ｃｍであり、厚みが５０ｍｍで密度が６０ｋ
ｇ／ｍ3のフェノール樹脂発泡体を用いた。As the reinforcing fiber base material, 300 g / m 2 carbon fiber cloth in which carbon fibers are oriented in two directions, 800 g
/ M 2 glass roving cloth and 450 g / m 2 glass chopped strand mat. In addition, a water-soluble resol type phenol resin was used as the matrix resin. Further, the core material has a width of 100 cm and a length of 100 cm, a thickness of 50 mm and a density of 60 k.
g / m 3 phenolic resin foam was used.
【００４２】また、成形型１としては、溝断面が幅１ｍ
ｍ、深さ２ｍｍの長方形であり、並行して隣り合う溝２
と溝２との間隔が２５ｍｍであり、型面において溝によ
って囲まれた部分が菱形の格子状であり、成形型表面に
おける溝部の面積が、樹脂が未含浸であるサンドイッチ
構造体の成形型と接する面積よりもそれぞれ周囲２５ｍ
ｍ小さくしたものを用いた。The molding die 1 has a groove cross section of 1 m in width.
m, 2 mm deep rectangular, adjacent grooves 2 in parallel
The distance between the groove and the groove 2 is 25 mm, the area surrounded by the groove on the mold surface is a rhombic lattice, and the area of the groove on the surface of the mold is the same as that of the sandwich structure in which the resin is not impregnated. 25m around each area than contact area
m was used.
【００４３】そして、成形型表面に離型剤を塗布し、つ
いで発泡体からなる板状の芯材層４を幅方向に２枚長さ
方向に４枚の計８枚並べ、周囲に強化繊維基材層３とし
て、芯材と接する面からガラスロービングクロス、炭素
繊維クロス、ガラスロービングクロス、炭素繊維クロ
ス、ガラスチョップドストランドマットの順で巻き付け
た樹脂が未含浸のサンドイッチ状構造体を配置し、その
上にナイロン繊維織物からなるピールプライ５を配置し
た。Then, a mold release agent is applied to the surface of the mold, and two plate-shaped core layers 4 made of foam are arranged in the width direction and four in the length direction, for a total of eight sheets. As the base layer 3, a glass-roving cloth, a carbon fiber cloth, a glass-roving cloth, a carbon fiber cloth, a resin wound in the order of a glass chopped strand mat from the surface in contact with the core material, and a resin-impregnated sandwich-like structure are arranged. A peel ply 5 made of a nylon fiber fabric was placed thereon.
【００４４】さらにその上に樹脂拡散媒体６としてポリ
エチレンからなる厚みが１．０ｍｍ、メッシュの開口寸
法が２．６×２．６ｍｍ、メッシュの開口率（全体面
積；１００に対するメッシュの開口部面積の比率）が６
２％のメッシュシートを強化繊維基材の上面全体よりそ
れぞれ周囲２５ｍｍ小さくしたものを配置した。ここ
で、ガラスロービングクロス、炭素繊維クロス、ガラス
チョップドストランドマット、ピールプライ、樹脂拡散
媒体は製品幅が１００ｃｍであったため幅方向にラップ
させながら４枚並べて使用した。Further, a resin diffusion medium 6 made of polyethylene having a thickness of 1.0 mm, an opening size of the mesh of 2.6 × 2.6 mm, and an opening ratio of the mesh (total area; Ratio) is 6
A 2% mesh sheet was placed around the entire upper surface of the reinforcing fiber base material 25 mm smaller than the entire upper surface thereof. Here, the glass roving cloth, carbon fiber cloth, glass chopped strand mat, peel ply, and resin diffusion medium were used side by side while being wrapped in the width direction because the product width was 100 cm.
【００４５】さらに積層した樹脂が未含浸であるサンド
イッチ構造体の周囲に、ガラス繊維織物からなるエッジ
・ブリーザ７を張り巡らした。Further, an edge breather 7 made of a glass fiber fabric was stretched around the sandwich structure in which the laminated resin was not impregnated.
【００４６】そして、積層体全体を全体をポリプロピレ
ンフィルムからなるバッグフィルム８で覆い、空気が漏
れないようにバッグフィルムの周囲をシール材で接着さ
せた。さらに、バッグフィルム上部に樹脂タンクから注
入される樹脂の吐出口を成形型の溝および樹脂拡散媒体
と接するように取り付け、また、真空ポンプの吸引口を
樹脂の吐出口から一番遠いエッジ・ブリーザ上に取り付
けた。そして、吐出口および吸引口の取り付け部から空
気が漏れないようにシール材９で密着させた。つぎに、
真空ポンプでバックフィルムに覆われた内部を７５６Ｔ
ｏｒｒの真空状態にしたのち、樹脂吐出口１０のバルブ
１２を解放して樹脂粘度が４ポイズの常温硬化型フェノ
ール樹脂を注入し、成形型表面に設けた溝部および樹脂
拡散媒体から強化繊維基材に樹脂を含浸させた。そし
て、樹脂が充分硬化するまで真空ポンプを運転した。樹
脂硬化後にバッグフィルムを除去し、成形型から脱型し
てサンドイッチ構造からなるＦＲＰ構造体Ａを得た。 （比較例）比較例として、芯材に溝を設ける方法でＦＲ
Ｐ構造体Ｂを得た。すなわち、芯材の強化繊維基材層３
と接する面に、溝２の断面が３×３ｍｍ、溝と溝との間
隔は２５ｍｍで正方形の格子状に溝が配置した芯材を用
い、この溝から強化繊維基材層に樹脂を含浸させる他は
実施例と同じようにしてサンドイッチ構造からなるＦＲ
Ｐ構造体Ｂを得た。The entire laminate was covered with a bag film 8 made of a polypropylene film, and the periphery of the bag film was adhered with a sealing material so that air did not leak. Furthermore, a discharge port for the resin injected from the resin tank is attached to the upper part of the bag film so as to be in contact with the groove of the molding die and the resin diffusion medium, and a suction port of the vacuum pump is an edge breather furthest from the resin discharge port. Mounted on top. Then, they were adhered with the sealing material 9 so that air did not leak from the attachment portions of the discharge port and the suction port. Next,
756T inside covered with back film by vacuum pump
After the vacuum state of orr was reached, the valve 12 of the resin discharge port 10 was opened to inject a room-temperature-curable phenol resin having a resin viscosity of 4 poise, and the reinforcing fiber base material was formed from the grooves provided on the surface of the mold and the resin diffusion medium. Was impregnated with a resin. Then, the vacuum pump was operated until the resin was sufficiently cured. After the resin was cured, the bag film was removed and the mold was released from the mold to obtain an FRP structure A having a sandwich structure. (Comparative Example) As a comparative example, a method of providing a groove in a core material by FR
P structure B was obtained. That is, the reinforcing fiber base layer 3 of the core material
Is used, a core material in which the cross section of the groove 2 is 3 × 3 mm, the distance between the grooves is 25 mm, and the grooves are arranged in a square lattice, and the reinforcing fiber base material layer is impregnated with the resin from the grooves. Otherwise, the FR having a sandwich structure is the same as in the embodiment.
P structure B was obtained.
【００４７】そして、これらのサンドイッチ構造体の機
械的特性を調査すべく、圧子間隔が１８０ｃｍ、支点間
距離が３６０ｃｍで４点曲げ試験を行った。Then, in order to investigate the mechanical properties of these sandwich structures, a four-point bending test was performed with an indenter spacing of 180 cm and a fulcrum distance of 360 cm.
【００４８】これら樹脂含浸時間、強化繊維基材への樹
脂含浸状態などの成形性と４点曲げ試験結果をまとめた
のが次の表１である。The following Table 1 summarizes the moldability such as the resin impregnation time and the resin impregnation state of the reinforcing fiber base material and the results of the four-point bending test.
【００４９】[0049]
【表１】 表１に示すように、実施例のものは成形型に設けた溝お
よび積層体上面に配置した樹脂拡散媒体の両流路から繊
維基材層に樹脂を含浸させるため、短時間に樹脂を繊維
基材層に均一に含浸させることができ、また、樹脂の流
路である溝および樹脂含浸媒体は連続して常時存在する
ため、確実に強化繊維基材に樹脂含浸ができる。さら
に、芯材に樹脂の流路となる溝を設ける必要や溝の位置
をあわせる必要もないことから、芯材の配置作業を短時
間で行うことができることや成形毎に芯材に溝加工をす
る必要がないため作業性もよい。さらに強化繊維基材に
樹脂が完全に含浸できることから、曲げ試験においても
破壊荷重が１０．３ｋＮと強化繊維の持つ高強度、高弾
性特性を十分に発揮することができた。[Table 1] As shown in Table 1, in the case of the example, the resin was impregnated into the fiber base material layer from both the grooves provided in the molding die and the flow path of the resin diffusion medium disposed on the upper surface of the laminate. Since the base material layer can be uniformly impregnated, and the groove as the resin flow path and the resin impregnating medium are always present continuously, the reinforcing fiber base material can be surely impregnated with the resin. Furthermore, since there is no need to provide a groove in the core material that serves as a flow path for the resin or to adjust the position of the groove, the work of arranging the core material can be performed in a short time. Workability is good because there is no need to do it. Furthermore, since the reinforcing fiber base material can be completely impregnated with the resin, the breaking load was 10.3 kN even in the bending test, and the high strength and high elastic properties of the reinforcing fiber could be sufficiently exhibited.
【００５０】一方、比較例のものにおいては、成型時の
バック圧により芯材に設けた溝の位置がずれてしまった
ため、一部樹脂の未含浸箇所が発生するとともに樹脂の
含浸速度も遅かった。さらに、曲げ試験においても一部
樹脂が未含浸部分が存在するとともに、バックフィルム
面におけるのＦＲＰ構造体の強化繊維がバック圧で芯材
の溝に入り込み、強化繊維が屈曲したことで、破壊荷重
が４．２２ｋＮと低く、強化繊維の持つ高強度、高弾性
特性を有効に発揮することができなかった。On the other hand, in the case of the comparative example, the position of the groove provided in the core material was shifted by the back pressure at the time of molding, so that some unimpregnated portions of the resin were generated and the impregnation speed of the resin was slow. . Further, in the bending test, there is a part where the resin is not impregnated, and the reinforcing fiber of the FRP structure on the back film surface enters the groove of the core material by the back pressure, and the reinforcing fiber is bent, thereby causing a breaking load. Was as low as 4.22 kN, and the high strength and high elastic properties of the reinforcing fiber could not be effectively exhibited.
【００５１】[0051]
【発明の効果】以上説明したように、本発明のＦＲＰ構
造体の製造方法によれば、サンドイッチ状の構造体を真
空バッグ成形で製作する際に、芯材の両面に配した強化
繊維基材層の一方の層には強化繊維基材層と接した成形
型に設けた溝から、他方の層には強化繊維基材層と接し
させて配置した樹脂拡散媒体から同時に樹脂を含浸させ
るために、成形対象が大型のＦＲＰ構造体であっても短
時間に強化繊維基材層内部にまで樹脂を十分に、かつ均
一に含浸させることが可能であり、また、成形時のバッ
ク圧によりバックフィルムが積層した強化繊維基材とと
もに成形型の溝内部にまで入り込み、強化繊維を屈曲さ
せるようなこともない。したがって、強化繊維の持つ優
れた機械的特性を有効に発揮することができる大型のＦ
ＲＰ構造体を作業性よく容易に製造することができる。As described above, according to the method of manufacturing an FRP structure of the present invention, when a sandwich-like structure is manufactured by vacuum bag molding, a reinforcing fiber base material arranged on both surfaces of a core material is used. In order to impregnate the resin simultaneously from the resin diffusion medium arranged in contact with the reinforcing fiber base layer on the other layer from the groove provided in the mold in contact with the reinforcing fiber base layer on one of the layers Even if the object to be molded is a large FRP structure, the resin can be sufficiently and uniformly impregnated into the inside of the reinforcing fiber base layer in a short time, and the back film is formed by the back pressure at the time of molding. Does not penetrate into the groove of the mold together with the laminated reinforcing fiber base material, and the reinforcing fibers are not bent. Therefore, a large F that can effectively exhibit the excellent mechanical properties of the reinforcing fiber can be obtained.
The RP structure can be easily manufactured with good workability.
【図１】本発明に係るＦＲＰ構造体の製造方法の実施に
用いる製造装置の一実施例の断面図である。FIG. 1 is a cross-sectional view of one embodiment of a manufacturing apparatus used for carrying out a method of manufacturing an FRP structure according to the present invention.
【図２】本発明の製造方法に用いられる成形型の溝の一
実施例の斜視図である。FIG. 2 is a perspective view of one embodiment of a groove of a molding die used in the manufacturing method of the present invention.
【図３】図２の成形型の溝の拡大斜視図である。FIG. 3 is an enlarged perspective view of a groove of the mold shown in FIG. 2;
【図４】本発明の製造方法に用いられる樹脂拡散媒体の
斜視図である。FIG. 4 is a perspective view of a resin diffusion medium used in the manufacturing method of the present invention.
【図５】本発明の製造方法により得られたＦＲＰ構造体
の斜視図である。FIG. 5 is a perspective view of an FRP structure obtained by the manufacturing method of the present invention.
１：成形型 ２：溝 ３：第１、第２強化繊維基材層 ４：芯材層 ５：ピールプライ ６：樹脂拡散媒体 ７：エッジ・ブリーザ ８：バッグフィルム ９：シール材 １０：吐出口 １１：吸引口 １２：バルブ １３：Ａ群のバー １４：Ｂ群のバー 1: molding die 2: groove 3: first and second reinforcing fiber base material layers 4: core material layer 5: peel ply 6: resin diffusion medium 7: edge breather 8: bag film 9: sealing material 10: discharge port 11 : Suction port 12: Valve 13: Bar of group A 14: Bar of group B
───────────────────────────────────────────────────── フロントページの続き Ｆターム(参考） 4F205 AA36 AA37 AB25 AD02 AD04 AD16 AD17 AD18 AG03 AG28 AH18 AH28 AH47 AJ03 HA09 HA14 HA23 HA32 HA33 HA34 HA35 HA36 HA37 HA47 HB01 HC05 HC06 HC14 HC16 HC17 HF01 HF05 HF23 HF30 HK02 HK04 HK05 HK16 HK31 HM06 HM18 HT02 HT13 HT27 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F205 AA36 AA37 AB25 AD02 AD04 AD16 AD17 AD18 AG03 AG28 AH18 AH28 AH47 AJ03 HA09 HA14 HA23 HA32 HA33 HA34 HA35 HA36 HA37 HA47 HB01 HC05 HC06 HC14 HC16 HC17 HF01 HF05 HF23 HK30 HK02 HK16 HK31 HM06 HM18 HT02 HT13 HT27
Claims (6)
表面に、第１強化繊維基材層、芯材層、第２強化繊維基
材層をこの順に積層し、さらにこの積層体の上に樹脂拡
散媒体を配置した後、これらの全体をバッグフィルムで
覆い、次にバッグフィルムで覆われた内部を大気圧より
も低い状態にした後、マトリックス樹脂を前記成形型の
進入溝と前記樹脂拡散媒体とから前記積層体の強化繊維
基材層内に含浸させることにより、前記第１および第２
強化繊維基材層と前記芯材層とを一体化させることを特
徴とするサンドイッチ構造を有する繊維強化樹脂構造体
の製造方法。1. A first reinforcing fiber base layer, a core material layer, and a second reinforcing fiber base layer are laminated in this order on a surface of a molding die provided with a synthetic resin inflow groove, and After arranging the resin diffusion medium thereon, these are entirely covered with a bag film, and then the interior covered with the bag film is brought into a state lower than the atmospheric pressure. By impregnating the reinforcing fiber base layer of the laminate with a resin diffusion medium, the first and second fibers are impregnated.
A method for producing a fiber-reinforced resin structure having a sandwich structure, wherein a reinforcing fiber base layer and the core layer are integrated.
体との間に、ピールプライを介在させることを特徴とす
る請求項１記載の繊維強化樹脂構造体の製造方法。2. The method for producing a fiber reinforced resin structure according to claim 1, wherein a peel ply is interposed between the second reinforcing fiber base material layer and the resin diffusion medium.
強化繊維基材層との間に介在させること特徴とする請求
項１記載の繊維強化樹脂構造体の製造方法。3. The method according to claim 2, wherein the resin diffusion medium is provided between the core material layer and the second material layer.
The method for producing a fiber-reinforced resin structure according to claim 1, wherein the method is interposed between the fiber-reinforced resin layer and the reinforcing fiber base layer.
繊維基材層との間に介在させることを特徴とする請求項
１ないし３のいずれかに記載の繊維強化樹脂構造体の製
造方法。4. The method for producing a fiber reinforced resin structure according to claim 1, wherein a peel ply is interposed between the mold and the first reinforcing fiber base layer.
樹脂を含浸させ硬化させた後に、前記繊維強化樹脂層の
表面に転写された溝部の合成樹脂および／またはピール
プライを除去することを特徴とする請求項４記載の繊維
強化樹脂構造体の製造方法。5. After the first and second reinforcing fiber base layers are impregnated with a synthetic resin and cured, the synthetic resin and / or peel ply in the groove transferred to the surface of the fiber reinforced resin layer are removed. The method for producing a fiber-reinforced resin structure according to claim 4, wherein:
たサンドイッチ構造からなる繊維強化樹脂構造体におい
て、前記繊維強化樹脂層の少なくとも片面に合成樹脂か
らなる帯状の突起部が設けられていることを特徴とする
繊維強化樹脂構造体。6. A fiber-reinforced resin structure having a sandwich structure in which fiber-reinforced resin layers are formed on both surfaces of a core material layer, wherein at least one surface of the fiber-reinforced resin layer is provided with a strip-shaped projection made of synthetic resin. A fiber reinforced resin structure characterized by the following.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP23823299A JP4106826B2 (en) | 1999-08-25 | 1999-08-25 | Fiber-reinforced resin structure and method for producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP23823299A JP4106826B2 (en) | 1999-08-25 | 1999-08-25 | Fiber-reinforced resin structure and method for producing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2001062932A true JP2001062932A (en) | 2001-03-13 |
| JP4106826B2 JP4106826B2 (en) | 2008-06-25 |
Family
ID=17027122
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP23823299A Expired - Fee Related JP4106826B2 (en) | 1999-08-25 | 1999-08-25 | Fiber-reinforced resin structure and method for producing the same |
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| Country | Link |
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