JP2003127239A - Manufacturing method for reinforced resin molded body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method for a reinforced resin molded body. SOLUTION: The manufacturing method for the reinforced resin molded body has a process wherein data on three-dimensional shaping are outputted; a process wherein a material resin composition of a liquid thermosetting resin is prepared by compounding a filler and a curing agent, and putting them in a uniformly mixed state and wherein a horizontal elevating table whereon the material resin composition is placed is provided in the vicinity of the upper surface in this composition; and a laminating process wherein a part of the molded body is formed by hardening the material resin composition of the thermosetting resin by shining thermic rays onto the elevating table and wherein, the table being lowered, the material resin composition of the thermosetting resin positioned above that part of the molded body is hardened by the thermic rays. This processing is repeated so that the composition is laminated three- dimensionally sequentially.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a reinforced resin molding.

[0002]

2. Description of the Related Art Conventionally, hand lay-up method, spray-up method, SM
C method, BMC method, etc. are known, and the product shape and size,
A suitable method is adopted depending on the production amount. However, these methods require molds and wooden molds, and in the case of a small amount and a large variety of products, time and investment burden are large. The hand lay-up method is low in productivity because it is stacked manually to make a product, and the spray-up method is high in productivity, but is not suitable for those requiring dimensional accuracy. In addition, the SMC method and the BMC method have high dimensional accuracy and can manufacture good products. However, since a highly accurate mold is required, the time and financial investment burden for the mold is handled by handlay. It is larger than the up method and is suitable for mass production, but not suitable for small-quantity, high-mix production.

The present inventors have paid attention to a manufacturing method by a stereolithography method as a technique that does not require a metal mold or a wooden mold.
The stereolithography method, as disclosed in JP-A-62-35966, irradiates a photocurable resin in a resin tank with a light beam,
This is a method of molding a three-dimensional molded article by curing a photocurable resin.

The present invention relates to a method for producing a reinforced resin molded product without using a mold or a wooden mold, in which a reinforced resin molding material made of a thermosetting resin is used instead of the photocurable resin in the stereolithography method. As a result of finding that a thermosetting reinforced resin molding can be obtained by applying energy, the present invention has been achieved.

[0005]

SUMMARY OF THE INVENTION Therefore, the present invention does not use a mold or a wooden mold, has a short manufacturing time, is excellent in productivity and dimensional accuracy, and is suitable for the production of a large number of small lots of reinforced resin. It is intended to provide a method for manufacturing a product.

[0006]

According to a first aspect of the present invention, a raw material resin composition of a liquid thermosetting resin in which a step of outputting data relating to three-dimensional modeling and a filler and a curing agent are blended into a uniform mixed state In the vicinity of the upper surface of the object, a step of providing a horizontal elevating table on which the raw material resin composition is placed, and according to the data for one layer output, heat rays are radiated onto the elevating table for thermosetting. The raw resin composition of the thermosetting resin to form a part of the molded body, lower the elevating table, and heat the raw resin composition of the thermosetting resin located above the part of the molded body by a heat ray. A method of manufacturing a reinforced resin molded body, comprising: a step of repeating curing treatment to sequentially three-dimensionally stack.

According to a second aspect of the present invention, a step of outputting data relating to three-dimensional modeling and a raw material of a liquid thermosetting resin in which a filler is blended and made into a uniform mixed state are provided in the vicinity of an upper surface in a resin composition. According to the step of providing a horizontal elevating table on which the resin composition is placed, and according to the output data for one layer, while applying a curing agent in the horizontal direction on the elevating table, irradiating heat rays. The raw material resin composition of the thermosetting resin is cured to form a part of the molded body, the elevating table is lowered, and the raw material resin composition of the thermosetting resin located above the part of the molded body is formed. The method for producing a reinforced resin molded body is characterized by further comprising: a step of repeatedly curing the composition with a heat ray while supplying a curing agent in a horizontal direction to sequentially three-dimensionally laminate the resin.

According to a third aspect of the present invention, in accordance with the step of outputting data relating to three-dimensional modeling, and in accordance with the data for one layer to be output, a filler and a curing agent are blended on a horizontal flat plate and uniformly mixed. The step of supplying the raw material resin composition of the liquid thermosetting resin in a state of being heated, and the raw material resin composition of the thermosetting resin by irradiating the elevating table with a heat ray in accordance with the output data for one layer. To form a part of the molded body, lower the elevating table, and repeat the treatment of curing the raw resin composition of the thermosetting resin located above a part of the molded body with heat rays, A method of manufacturing a reinforced resin molded body, comprising a step of sequentially three-dimensionally stacking.

By molding the reinforced resin molding by the above-described manufacturing method, the manufacturing time can be shortened, the productivity and the dimensional accuracy can be improved as compared with the conventional method, and the manufacturing of a large number of small quantities Can be done easily.

According to a fourth aspect of the invention, the thermosetting resin is an unsaturated polyester resin, an epoxy resin, an alkyd resin, an acrylic resin, a vinyl ester resin, a urethane resin, or a resin obtained by modifying these. It is a manufacturing method of the reinforced resin molding according to any one of claims 1 to 3.

The production method of the present invention is particularly suitable for unsaturated resins such as unsaturated polyester resins, epoxy resins,
Alkyd resin, acrylic resin, vinyl ester resin,
It is suitable for the production of a reinforced resin molded product whose main resin is a resin selected from the group consisting of urethane resins and resins obtained by modifying these.

[0012]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a three-dimensional modeling apparatus to which an embodiment of the present invention is applied, including a resin tank 2, a lifting table 1, a control computer 10, a lifting control device 9, a movement control device 5, a projector 6, a thermal shutter 7, and a heat ray device. It is composed of 8.

In this apparatus, a filler and a curing agent in a resin tank 2 are blended, and a raw resin composition 3 of a liquid thermosetting resin in a uniform mixed state is driven by a vertical movement control device 9 to be horizontally driven. The lifting table 1 in the shape of
The projector 6 is provided with a raw resin composition placed in the vicinity of the upper surface of the inside thereof, and has a projector 6 to irradiate a heat ray toward the liquid surface of the raw resin composition 3. The device 5 controls the movement in the XY directions in the horizontal plane.

Heat rays from an infrared laser device 8 are supplied to the projector 6 via a thermal shutter 7.
The operations of the lifting control device 9, the movement control device 5, and the thermal shutter 7 are controlled by a control computer 10.

The lifting table 1 moves according to the lifting control device 9, and the output of the infrared laser device 8 is adjusted via the thermal shutter 7.

In the above apparatus, the contour data is created by slicing the shape data of the three-dimensional object designed by the CAD system, and the contour data is supplied to the control computer 10 so that the lifting table 1 has a constant pitch ( The heat ray from the projector 6 scans the thermosetting resin 3 on the elevating table 1 in the X-Y direction according to the contour line data while descending in the resin tank 2 by about 0.1 to 0.3 mm). . As a result, the cured resin layer is sequentially deposited on the elevating table 1 in a shape corresponding to the contour line data, and finally the three-dimensional object 4 having a predetermined shape is formed.

Data creation of the CAD system is performed by, for example, manually inputting numerical data, coordinate input by a contact type shape measuring device, coordinate input by a non-contact type shape measuring device, an EWS (engineering workstation) or a personal computer. The three-dimensional data of a three-dimensional molded product to be formed is input to a computer, and three-dimensional CAD data is created by arithmetic processing.

The three-dimensional CAD obtained in this way
Since the data can be used for feedback work such as completing a prototype on a computer, the three-dimensional shape of the three-dimensional molded product to be formed is checked, and the calculation processing is repeated as appropriate to obtain accurate three-dimensional CAD data. Or, a three-dimensional model can be obtained.

As another embodiment, as shown in FIG. 2, a raw material resin composition 3 of a liquid thermosetting resin in which a filler is blended and made into a uniform mixed state is used.
In the vicinity of the upper surface of the inside, the raw material resin composition 3 is placed in a resin tank 2 while being placed on a horizontal elevating table 1.
Similar to the above-described embodiment, the control computer 10 operates the lifting control device 9 and the movement control device 5, and at the same time, the movement control is performed while spraying the curing agent from the nozzle 12 of the curing agent discharge device 11 according to the data of the control computer 10. The raw resin composition 3 is cured by a heat ray from the projector 6 controlled by the device 5, and as a result, a cured resin layer is sequentially deposited on the elevating table 1 in a shape according to the contour line data, and finally. A three-dimensional molded object 4 having a predetermined shape is molded.

Further, as another embodiment, as shown in FIG. 3, a raw material resin composition 3 of a liquid thermosetting resin in which a filler and a curing agent are mixed in a tank 14 to be in a uniform mixed state. And the nozzle 15 from the tank 14 on the flat plate 13 according to the data of the control computer 10.
After injecting the raw material resin composition 3 by, after curing the raw material resin composition 3 by the heat ray from the projector 6 controlled by the movement control device 5, after confirming that the resin on the flat plate is cured, The flat plate 13 is lowered by one layer by the elevating and lowering control device 9, and thereafter, the respective raw materials are sprayed from the nozzles and the lowering of the flat plate 13 is repeated to sequentially stack three-dimensionally to manufacture a molded body.

The component constituting the reinforced resin molding material in the present invention is not particularly limited, and liquid thermosetting resin as a main component, a curing agent and the like other than the filler are used, and polymerization is carried out if necessary. Initiators, polymerization accelerators, colorants and the like are used.

The thermosetting resin as the main component is not particularly limited as long as it is generally used, and examples thereof include unsaturated polyester resin, epoxy resin, alkyd resin, acrylic resin, vinyl ester resin, urethane resin, And resins obtained by modifying these.

The unsaturated polyester resin is obtained by mixing an unsaturated polyester obtained by reacting an acid such as an unsaturated dibasic acid and an alcohol with a polymerizable monomer such as styrene, and optionally adding a polymerization inhibitor or the like. Obtained by adding.

As the acid, unsaturated dibasic acids such as maleic acid, fumaric acid, itaconic acid and citraconic acid and anhydrides of these acids are used. Some of these unsaturated dibasic acids are phthalic acid and isophthalic acid. , Terephthalic acid, 3,6-endomethylenetetrahydrophthalic anhydride, adipic acid, sebacic acid, etc., or anhydrides of these acids may be used.

As the alcohol, ethylene glycol, propylene glycol, 1,3-methylene glycol, neopentyl glycol, diethylene glycol,
Dipropylene glycol, hexylene glycol or the like is used, and a monohydric alcohol such as cyclohexyl alcohol or benzyl alcohol, or a polyhydric alcohol such as glycerin or trimethylolpropane may be used as a part thereof.

The epoxy resin is a resin having an epoxy group which is hardened by an amine, an acid or the like, and a resin obtained by reacting an epoxy compound with a bisphenol or a polyhydric alcohol and an unsaturated group are epoxied by a peracid. Examples of the resin include those obtained. Specifically, tetraglycidyl diaminodiphenylmethane, triglycidyl-p-, as an epoxy resin containing an amine as a precursor.
Various isomers of aminophenol, triglycidyl-m-aminophenol, triglycidylaminocresol,
As an epoxy resin using a phenol as a precursor, a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, a bisphenol S type epoxy resin, a phenol
Examples of the lunovolac type epoxy resin, the cresol- novolac type epoxy resin, the resorcinol type epoxy resin, and the epoxy resin having a compound having a carbon-carbon double bond as a precursor include alicyclic epoxy resins.

The alkyd resin is a resin obtained by condensing a polyhydric alcohol and a polybasic acid. The polyhydric alcohol is glycerin, pentaerythritol, neopentyl glycol, ethylene glycol, diethylene glycol or the like, and the polybasic acid is phthalic anhydride. Examples thereof include acids and maleic anhydride.

The acrylic resin is obtained by copolymerizing several kinds of acrylic monomers of acrylic acid or methacrylic acid derivatives, and examples thereof include ethyl acrylate, ethyl methacrylate, ethyl acrylate, hydroxyethyl acrylate and butyl methacrylate.

The vinyl ester resin is a polyepoxide in the presence of an addition catalyst, in which α and β are approximately equimolar to the epoxy group.
-A reaction product obtained by adding an unsaturated monobasic acid is mixed with a polymerizable monomer such as styrene, and a polymerization inhibitor or the like is added if necessary.

The urethane resin refers to a polymer compound having a urethane bond and can be obtained by polymerizing addition of an aliphatic diamine or glycol with a diisocyanate.

Examples of the filler include inorganic fibers such as aluminum hydroxide, calcium carbonate, glass fiber, carbon fiber and asbestos, organic fibers such as cotton, hemp, rayon, polyester and polyacryl, boron fiber, whiskers and ceramic fiber. , Special glass fiber, metal fiber, etc. are used.
These may be used alone or in appropriate combination of two or more. These fillers are preferably subjected to a coupling treatment. Further, the content of the filler can be appropriately selected according to the target strength, but it is preferably used in the range of 10% by weight to 90% by weight with respect to the total amount with the curable resin raw material. The length and orientation of the filler fibers are not particularly limited.

As the curing agent, benzoyl peroxide, methyl ethyl ketone peroxide, acetyl peroxide, percarbonate, diacyl peroxide,
Examples thereof include alkyl peresters, diethylenetriamine, triethylenetetramine, diethylaminopropylamine and the like.

In the present invention, it is preferable to use heat rays generated from a near infrared laser, an infrared laser, a far infrared laser or the like as the heat energy for curing the resin, and an infrared laser device is particularly preferably used. When an infrared laser device is used as the active energy heat ray, it is possible to raise the energy level and shorten the modeling time, and by utilizing the good condensing property of the laser beam, it is possible to obtain a molded product with high modeling accuracy. You can get it.

[0034]

The present invention will be described in more detail below with reference to examples, but the present invention is not limited thereto. <Example 1> 50 mol% of maleic anhydride, 50 mol% of phthalic anhydride and 110 mol% of propylene glycol were reacted at 200 ° C in a nitrogen gas stream according to a conventional method to obtain 60 parts by weight of the resulting unsaturated polyester. Hydroquinone 0.0
Dissolved in 40 parts by weight of styrene monomer containing 2 parts by weight,
A liquid thermosetting resin was used. To this resin, 1.0 part by weight of benzoyl peroxide (manufactured by NOF CORPORATION, Nyper BO) was added, and after stirring for about 1 minute, chopped strands (manufactured by Nippon Sheet Glass, Microglass) were 9 to 13 μm in diameter and 1 in length. Used as ~ 15 mm, glass content is about 30% by weight
And a stirring rate of 30 to 60 rpm, and a raw material resin composition 3 of a liquid thermosetting resin in a uniform mixed state was prepared. This raw material resin composition 3 was poured into the resin tank 2 and was placed 0.1 mm from the liquid surface of the raw material resin composition 3.
The elevating table 1 was placed in the. Two-dimensional contour line data obtained by horizontally cutting a three-dimensional CAD drawing is created from the shape data of the three-dimensional object, and the contour line data is supplied to the control computer 10 and the control computer 10
According to the instructions from the thermal shutter 7, the movement control device 5
And the lifting control device 9 operates. Output 380 from infrared laser device 8 via thermal shutter 7
The CO ₂ laser beam of W (wavelength: 10.6 μm) is moved by the projector 6 whose movement is controlled by the movement control device in the horizontal direction according to the contour line data.
The raw material resin composition 3 on the lifting table 1 was cured by scanning at 0 m / min. After the completion of the curing, the elevating table 1 was moved down in the resin tank 2 by 0.1 mm, and this process was repeated to finally form the three-dimensional object shown in FIG.

<Example 2> A raw material resin composition 3 of a liquid thermosetting resin in a uniform mixed state was prepared in the same manner as in Example 1 except that benzoyl peroxide was not contained, and the control computer 10 was used. The benzoyl peroxide is sprayed from the nozzle 12 of the curing agent discharge device 11 in accordance with a normal spraying method at a spraying rate of about 0.1 g / min, and a 20 cm square area is 0.1 mm in 0.5 minutes at a time.
By repeating this process in the same manner as in Example 1 except that thickness / spraying is repeated, the three-dimensional molded article shown in FIG. 4 is finally molded.

Example 3 A tank 14 was filled with a liquid thermosetting resin prepared in the same manner as in Example 1, and benzoyl peroxide and chopped strands were added and stirred in the same manner as in Example 1 to obtain a uniform mixture. A raw material resin composition 3 of a liquid thermosetting resin in a mixed state was prepared. From the tank 14 to the nozzle 15 according to the control computer 10,
In accordance with the usual spraying method, the raw material resin composition 3
The amount of jetting per 20 cm square was 8 g / min, and the jetting was performed on the flat plate 13. After the injection, in the same manner as in Example 1, the heating wire was supplied from the projector 6 to cure the raw material resin composition 3 on the flat plate 13. After curing, the flat plate 13 is 0.1
By descending the inside of the resin tank 2 by mm, and repeating this process, the three-dimensional molded object shown in FIG. 4 was finally molded.

[0037]

According to the method for manufacturing a reinforced resin molded product of the present invention, a reinforced resin molded product having a short manufacturing time, excellent productivity and dimensional accuracy can be manufactured without using a mold or a wooden mold. Therefore, it is possible to easily handle the production of a wide variety of products in small quantities.

[Brief description of drawings]

FIG. 1 is a diagram showing a schematic configuration of an apparatus which is an example for carrying out a manufacturing method of the present invention.

FIG. 2 is a diagram showing an outline of a configuration of an apparatus which is another example for carrying out the manufacturing method of the present invention.

FIG. 3 is a diagram schematically showing a configuration of an apparatus that is another example for carrying out the manufacturing method of the present invention.

FIG. 4 is a diagram showing an example of a three-dimensional object molded by the manufacturing method of the present invention.

[Explanation of symbols]

1 Lifting table 2 resin tank 3 Raw material resin composition of thermosetting resin 4 molded body 6 projector 12 nozzles 13 Flat plate 14 tanks 15 nozzles

Claims (4)

[Claims] 1. A raw material resin composition is provided in the vicinity of an upper surface of a raw material resin composition of a liquid thermosetting resin in which a step of outputting data regarding three-dimensional modeling and a filler and a curing agent are mixed to make a uniform mixed state. A step of providing a horizontal elevating table on which an object is placed, and according to the data for one layer output, heat rays are radiated onto the elevating table to cure the raw resin composition of the thermosetting resin. A process of forming a part of the molded body, lowering the elevating table, and curing the raw material resin composition of the thermosetting resin located above the part of the molded body with heat rays is repeated, and three-dimensionally sequentially. And a laminating step of laminating. 2. A raw material resin composition is placed in the vicinity of an upper surface of a raw material resin composition of a liquid thermosetting resin in which a step of outputting data on three-dimensional modeling and a filler is mixed and made into a uniform mixed state. According to the step of providing a horizontal elevating table to be placed, and according to the output data for one layer, while supplying a curing agent in the horizontal direction on the elevating table, heat rays are irradiated to heat the thermosetting resin. The raw material resin composition is cured to form a part of the molded body, the elevating table is lowered, and the raw material resin composition of the thermosetting resin located above the part of the molded body is horizontally cured. A method of manufacturing a reinforced resin molded body, comprising: a step of repeating curing by heat rays while supplying the agent, and sequentially stacking three-dimensionally. 3. A step of outputting data relating to three-dimensional modeling, and a filling material and a curing agent are mixed on a horizontal flat plate in accordance with the outputted data for one layer to obtain a uniform mixed liquid state. According to the step of supplying the raw material resin composition of the thermosetting resin, and the heating table is irradiated with heat rays according to the data for one layer to be output to cure and form the raw material resin composition of the thermosetting resin. A process of forming a part of the body, lowering the elevating table, and curing the raw material resin composition of the thermosetting resin located above the part of the molded body by heat rays is repeated to sequentially stack three-dimensionally. And a step of laminating the same. 4. The thermosetting resin is unsaturated polyester resin, epoxy resin, alkyd resin, acrylic resin,
The method for producing a reinforced resin molding according to any one of claims 1 to 3, which is a vinyl ester resin, a urethane resin, or a resin obtained by modifying these.