JP2004188965A - Manufacturing process and device for fiber reinforced resin structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To inhibit occurrence of an impregnation defect and shorten a manufacturing cycle by increasing resin injection speed. <P>SOLUTION: In a process for manufacturing a fiber reinforced resin structure, a cavity 3 is formed by a primary mold 2 and a secondary mold 1, a fluid resin is injected into the cavity 3, and a fiber layer 9 placed in the cavity 3 is impregnated with the fluid resin. Resin passage structures 6 and 16 to supply the fluid resin are arranged on both sides of the fiber layer 9. Further, pass media 8 and 18 for increasing the fluidity of the fluid resin are arrange in the whole or partial area of the layer 9 between the resin passage structures 6, 16 and the layer 9, and the fluid resin supplied from the resin passage structures 6 and 16 is made to permeate into the layer 9 through the pass media 8 and 18. <P>COPYRIGHT: (C)2004,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a fiber-reinforced resin structure applicable to a large-sized structure such as an aircraft body and a windmill wing, and an apparatus for manufacturing the same.

Applications of fiber reinforced resin (FRP) are expanding in various fields. Carbon fiber rods are usefully used for fishing rods and golf putters. Multilayered fiber reinforced resins are usefully used in hull structures such as boats and yachts.
Because of such lightweight and high-strength characteristics, it is desired to use fiber-reinforced resin for large structures such as aircraft bodies and windmill blades.

In order to guarantee the strength of this type of structured object or to stabilize its physical properties, it is important that bubbles and cavities do not enter the fiber reinforced resin during the manufacturing process. In a construction method in which a fluid resin is poured into a fiber layer laid in a molding die and the fiber layer is impregnated with the fluid resin, a cavity may be formed in the resin layer. A vacuum forming method is known as a technique for preventing this cavity from being generated in a layer (for example, see Patent Document 1).
According to Patent Document 1, the inside of the mold cavity closed by the vacuum film and the inner surface of the mold is evacuated on one side, and the fluid resin is injected from the other side. Describes a technique for producing a fiber-reinforced resin structure having no bubbles and no voids.

According to this technique, it is necessary to improve the vacuum forming technique so that the fluid resin is spatially uniformly distributed and distributed in the fiber layer. As such an improved technique, for example, Japanese Patent Application Laid-Open Nos. H11-163, and H10-27138 are known.
The common point of these known technologies is that a structure having a grid-like hole in a cavity formed between a mold 101 and a vacuum film 102, particularly a nylon net 103, as shown in FIG. 13, as shown in FIG. 13, a flowable resin 105 is injected from many holes opened in the resin injection hose 104, and vacuum evacuation 107 is performed from the end 106 of the cavity, thereby forming a lattice-shaped nylon net 103. This is to impregnate the resin into the fiber mat 108 of the base layer through the mesh. The nylon net 103 is used to provide two-dimensional diffusion uniformity of the fluid resin.

According to this technology, the weight is reduced by hollowing, but when manufacturing FRP products with a semi-cylindrical shape with a high structural strength and a half of a flat ellipsoidal hollow shape, the flow speed is uniform. As shown in FIG. 13, the flowable resin does not flow evenly, and the non-impregnated portion 108 where the resin is not impregnated into the fiber layer is likely to be generated, and impregnation defects are easily generated.

Thus, it is required to suppress the occurrence of impregnation defects by simultaneously improving the fluidity and the diffusivity of the injected resin. As a result, it is desired to shorten the manufacturing cycle by increasing the resin injection speed.

Therefore, a device for manufacturing a fiber-reinforced resin structure capable of suppressing the occurrence of impregnation defects by facilitating adjustment of the resin injection speed and shortening the manufacturing cycle by increasing the resin injection speed, and The manufacturing method was previously filed (Japanese Patent Application No. 2002-167785).
JP-A-60-83826 U.S. Pat. No. 4,902,215 U.S. Pat. No. 5,904,972

  According to this manufacturing method, it is required to suppress the occurrence of impregnation defects by further improving the fluidity and diffusibility of the injected resin, and particularly to manufacture a thick plate structure having a plate thickness exceeding 10 mm. At the time, there was a problem.

The present invention suppresses the generation of impregnation defects, shortens the manufacturing cycle by increasing the resin injection speed, and has a remarkable effect when manufacturing a thick plate structure in which the plate thickness exceeds 10 mm. It is an object of the present invention to provide a method for producing a fiber-reinforced resin structure capable of producing a resin, and an apparatus for producing the same.

In order to solve the above problems, the present invention forms a cavity with a first mold and a film-shaped second mold, injects a fluid resin into the cavity, and arranges a fiber disposed in the cavity. In a manufacturing method for producing a fiber-reinforced resin structure by impregnating a layer with a flowable resin, a resin passage structure having a resin passage for supplying the flowable resin is disposed on both surfaces of the fiber layer, and the resin A pass media for amplifying the fluidity of the flowable resin is disposed between the passage structure and the fiber layer over the entire area or a part of the fiber layer, and the flowable resin supplied from these resin passage structures is disposed above the path medium. An object of the present invention is to produce a fiber reinforced resin structure by impregnating the fiber layer through a pass media.
Further, according to the present invention, a cavity is formed by a first mold and a film-shaped second mold, and a fluid resin is injected into the cavity by evacuating the cavity, and the cavity is formed in the cavity. In a manufacturing method for manufacturing a fiber reinforced resin structure by impregnating a fluid resin into an arranged fiber layer, a first resin passage structure having a resin passage formed in the first mold is placed, and The fiber layer is arranged in the passage structure, and a guide passage for guiding the fluid resin in a one-dimensional direction on the fiber layer, and a flow of the fluid resin in the guide passage intersects a flow of the guide passage. Forming a second resin passage structure including a diffusion passage for diffusing in a two-dimensional direction, between the first resin passage structure and the fiber layer, and between the second resin passage structure and the fiber layer; Amplifies the flowability of the flowable resin between A path media is disposed on the entire surface or on both sides of the fiber layer, or is partially impregnated with the flowable resin supplied from the first and second resin passage structures into the fiber layer through the path medium. Manufacturing a structure.
Furthermore, in the present invention, in addition to the upper and lower surfaces of the fiber layer, at least a pair of side surfaces of the fiber layer, the resin passage structure is disposed via the path medium, and the resin passage structures on the upper and lower surfaces and side surfaces are arranged. It is to manufacture a fiber reinforced resin structure by impregnating the supplied fluid resin into the fiber layer through the pass medium.
Still further, according to the present invention, another fiber layer is superimposed on the upper surface of the fiber layer, and the resin passage structure is arranged around the another fiber layer via the path medium, and supplied from the resin passage structure. An object of the present invention is to manufacture a fiber-reinforced resin structure in which a flat plate and a reinforcing girder are integrally formed by impregnating the flowable resin into the fiber layer through the pass medium.

Further, according to the present invention, a cavity is formed by a first mold and a film-shaped second mold, and a fluid resin is injected into the cavity by evacuating the cavity, and the cavity is formed in the cavity. In a manufacturing apparatus for manufacturing a fiber-reinforced resin structure by impregnating a flowable resin into a disposed fiber layer, a resin passage structure having a resin passage for supplying the flowable resin is disposed on both surfaces of the fiber layer. A path medium for amplifying the fluidity of the fluid resin is disposed between the resin passage structure and the fiber layer on the entire surface or on both sides of the fiber layer.
Further, in the present invention, a cavity is formed by the first mold and the film-shaped second mold, and a fluid resin is injected into the cavity by evacuating the cavity, and the cavity is formed in the cavity. In a manufacturing apparatus for manufacturing a fiber-reinforced resin structure by impregnating a flowable resin into a disposed fiber layer, a resin passage for supplying the flowable resin is provided on both surfaces and at least one pair of side surfaces of the fiber layer. A resin passage structure is disposed, and a pass media for amplifying the fluidity of the fluid resin is disposed between the resin passage structure and the fiber layer on all or both sides and side surfaces of the fiber layer. It is in. The first mold and the resin passage structure can be integrally formed.
In addition, another fiber layer is superimposed on the upper surface of the fiber layer, and the resin passage structure is disposed around the other fiber layer via the pass media, and a flat plate and a reinforcing girder are integrally molded. It is to manufacture a resin structure.

ADVANTAGE OF THE INVENTION According to the manufacturing method of the fiber reinforced resin structure by this invention, and its manufacturing apparatus, the following effects are produced.
A cavity is formed between the first mold and the second mold in the form of a film, a fluid resin is injected into the cavity, and a fiber layer disposed in the cavity is impregnated with the fluid resin, thereby reinforcing the fiber. In the manufacturing method for manufacturing a resin structure, a resin passage structure having a resin passage for supplying the fluid resin is disposed on both sides of the fiber layer, and between the resin passage structure and the fiber layer. A pass media for amplifying the fluidity of the fluid resin is disposed over the entire or a part of the fiber layer, and the fluid resin supplied from these resin passage structures is impregnated into the fiber layer through the pass medium to produce fibers. Since the reinforced resin structure is manufactured, the fibrous layer can be impregnated into the fibrous layer by uniformly diffusing the fluid resin three-dimensionally.
Further, a cavity is formed by the first mold and the film-shaped second mold, and a fluid resin is injected into the cavity by evacuating the inside of the cavity, and the fibers arranged in the cavity are formed. In a manufacturing method for manufacturing a fiber-reinforced resin structure by impregnating a layer with a flowable resin, a first resin passage structure having a resin passage formed in the first mold is placed, and the resin passage structure is mounted on the first mold. The fiber layer is disposed, a guide passage for guiding the fluid resin in a one-dimensional direction on the fiber layer, and a two-dimensional direction in which the flow of the fluid resin in the guide passage intersects the flow of the guide passage. Forming a second resin passage structure composed of a diffusion passage to be diffused, between the first resin passage structure and the fiber layer, and between the second resin passage structure and the fiber layer; , A path medium that amplifies the fluidity of the fluid resin The fiber reinforced resin structure is formed by disposing a fluid resin supplied from the first and second resin passage structures through the pass media and impregnating the fiber layer with the entire area or part of both surfaces of the fiber layer. Since the body is manufactured, the fibrous layer can be impregnated into the fibrous layer by diffusing the fluid resin uniformly in three dimensions.
Further, the resin passage structure is disposed on at least one pair of side surfaces of the fiber layer in addition to the upper and lower surfaces of the fiber layer via the path medium, and the flow supplied from the resin passage structures on the upper, lower, and side surfaces is provided. Since the fiber reinforced resin structure is manufactured by impregnating the fibrous layer with the conductive resin through the pass medium, the generation of unimpregnated defects can be prevented, and the FRP product can be molded in a short time. Therefore, it can be used in many product fields such as windmill blades, aircraft members, high-speed vehicle members, building members, bridges, and ships. In particular, even in a thick plate structure having a plate thickness exceeding 10 mm, the resin can be quickly impregnated, and the production time of a product can be significantly reduced.
Further, another fiber layer is superimposed on the upper surface of the fiber layer, and the resin passage structure is arranged around the another fiber layer via the pass medium, and the fluidity supplied from the resin passage structure is increased. Since the fiber layer is impregnated with the resin through the pass media to produce a fiber-reinforced resin structure in which the flat plate and the reinforcing girder are integrally formed, the occurrence of unimpregnated defects is prevented, and the resin is impregnated in a short time. The product can be molded. Since products of various shapes can be formed, they can be used in many product fields such as windmill blades, aircraft components, high-speed vehicle components, building components, bridges, and ships.
In particular, even in a thick plate structure having a plate thickness exceeding 10 mm, the resin can be quickly impregnated, and the production time of a product can be significantly reduced.
By using a net as the pass medium, the fluid resin can be diffused in the fiber layer.
In addition, by using a sheet having a void as the path medium, the fluid resin can be diffused into the fiber layer.
Furthermore, by using a glass fiber or carbon fiber mat of the same quality as the fiber layer for the pass media, it is not necessary to remove the pass media after molding the fiber reinforced resin structure.

According to the present invention, a cavity is formed by the first mold and the film-shaped second mold, and a fluid resin is injected into the cavity by evacuating the cavity. In a manufacturing apparatus for manufacturing a fiber reinforced resin structure by impregnating a fibrous layer disposed therein with a flowable resin, a resin passage structure having a resin passage for supplying the flowable resin on both surfaces of the fiber layer. It is arranged, since the path media for amplifying the fluidity of the fluid resin is arranged between the resin passage structure and the fiber layer over the entire area or partially on both sides of the fiber layer, so that it is three-dimensionally uniform. The fluid resin can be diffused and impregnated in the fiber layer. INDUSTRIAL APPLICABILITY The apparatus for producing a fiber-reinforced resin structure according to the present invention has excellent diffusion uniformity and is particularly suitable for forming a large-sized or ultra-large-sized structure such as a next-generation wind turbine.
A cavity is formed by the first mold and the second mold in the form of a film, and a fluid resin is injected into the cavity by evacuating the inside of the cavity, and a fiber layer arranged in the cavity is formed. In a manufacturing apparatus for producing a fiber-reinforced resin structure by impregnating a flowable resin, a resin passage structure having a resin passage for supplying the flowable resin is disposed on both sides and at least one pair of side surfaces of the fiber layer. Further, since the pass media for amplifying the fluidity of the fluid resin is arranged between the resin passage structure and the fiber layer over the entire surface or on both sides and the side surfaces of the fiber layer, the generation of unimpregnated defects occurs. Can be prevented and the FRP product can be molded in a short time. Therefore, it can be used in many product fields such as windmill blades, aircraft members, high-speed vehicle members, building members, bridges, and ships.
In particular, even in a thick plate structure having a plate thickness exceeding 10 mm, the resin can be quickly impregnated, and the production time of a product can be significantly reduced.
In addition, another fiber layer is superimposed on the upper surface of the fiber layer, and the resin passage structure is disposed around the other fiber layer via the pass media, and a flat plate and a reinforcing girder are integrally molded. Since a resin structure can be manufactured, products of various shapes can be formed.
Furthermore, since the pass media uses a mat of glass fiber or carbon fiber of the same quality as the fiber layer, it is not necessary to remove the pass media after molding the fiber-reinforced resin structure, thereby improving the efficiency of the manufacturing operation. it can.
Furthermore, as the lower resin passage structure, resin guide passages are formed at equal intervals from each other, and a resin passage mold having a large number of through-holes opened from the resin guide passages to the upper surface is provided. Resin can be supplied.
Further, since the resin guide passages are connected to each other by the resin auxiliary passage, the resin can be uniformly supplied to the resin guide passages.
Further, as the upper resin passage structure, a plurality of structures having a concave shape on one surface are used as guide passages, and the concave portion of the structure is arranged toward the fiber layer. Can be improved.
Furthermore, since a bonded body arranged as a diffusion passage is used below the guide passage and a plurality of gaps forming a diffusion passage between the guide passage and the upper surface of the bonded body are formed, The fluid resin can be diffused uniformly and uniformly to impregnate the fiber layer.
Further, since a plate having an uneven top surface is used for the joined body, it is possible to form a diffusion path for the flowable resin at low cost.
Further, since a large number of holes serving as passages for the fluid resin are formed in the plate surface of the joined body, the fluid resin can be supplied also to the lower surface of the joined body.

Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
In the embodiment of the apparatus for manufacturing a fiber-reinforced resin structure according to the present invention, a vacuum sheet is used together with an undeformed mold.
As shown in FIGS. 1 to 3, the vacuum sheet (deformation mold) 1 serving as the second mold forms the cavity 3 with the non-deformation mold 2 serving as the first mold. The cavity 3 is depressurized by a vacuum pump (not shown). The vacuum sheet 1 is formed of a transparent resin film or a transparent resin sheet, is deformable in the direction of the normal line of each surface, and is transparent or translucent. The vacuum sheet 1 is light-transmissive, and a worker can control the injection position and the injection pressure to adjust the uniformity of the diffusion while watching the state of diffusion of the resin.

As shown in FIG. 4, a plurality of resin injection ports 4 are arranged on the vacuum sheet 1. The vacuum sheet 1 and the resin inlet 4 are in close contact with each other, and there is no air leakage between the vacuum sheet 1 and the resin inlet 4. The inlet end 5 of the flexible resin supply hose is detachable from the resin inlet 4. When the injection end 5 is inserted into the resin injection opening 4, the resin injection opening 4 is connected to the injection end 5, and when the injection end 5 is removed from the resin injection end 4, the resin injection opening 4 and the injection end 5 are detached. A type of coupling is used.

1 to 4 show an embodiment of a method for manufacturing a fiber-reinforced resin structure according to the present invention.
The non-deformable mold 2 serving as the first mold is disposed on a floor surface of a factory or the like. On the upper surface of the non-deformable mold 2, a first resin passage structure 6 having a flat plate shape is mounted. In the resin passage structure 6, a large number of resin passages 61 are formed at regular intervals from each other, and a large number of through holes 62 are formed at regular intervals from each of these resin passages 61 toward the upper surface of the resin passage structure 6. I have. These resin passages 61 are communicated with each other via a plurality of resin sub-passages 63. Each of the resin passages 61 is provided with an injection port 64 for injecting a resin.

A release agent is applied to the upper surface of the resin passage structure 6 to form a release agent layer 7. On the upper surface of the resin passage structure 6 on which the release agent layer 7 is formed, a pass medium 8 formed of a flexible material having excellent resin fluidity is arranged.

As the path medium 8, for example, a net or a sheet having continuous voids is used. The pass media 8 is arranged so as to cover the entire area or a part of the upper surface of the resin passage structure 6. The pass media 8 amplifies the fluidity of the fluid resin and is removed after the structure is formed.

A fiber laminate 9 is disposed on the pass media 8 as a fiber layer. As shown in FIG. 3, the fiber laminate 9 includes a plurality of fiber layers 10 and a plurality of foam resin layers 11. Have a laminated structure in which they are combined into a multilayer.
As the fibers of the fiber layer 10, glass fibers, carbon fibers, aramid fibers, and carbon tubes are used.
The fiber layer 10 is usually multilayered and reinforced. The fiber layer 10 is formed from matrix fibers in which a group of fibers extends in a lattice and is woven in a matrix. Preferably, a sandwich foam is interposed between the two fiber layers 10.

A pass media 18 similar to the pass media 8 is disposed on the upper surface of the fiber laminate 9, and a second resin passage structure 16 is placed on the pass media 18. The second resin passage structure 16 is composed of a resin diffusion promoting inlet group forming gutter 12 and a gutter receiver 13, and the resin is fed together with the first resin passage structure 6 from both the front and back surfaces of the fiber laminate 9. It is impregnated. In the second resin passage structure 16, a plurality of resin diffusion promoting injection port group forming gutters 12 serving as guide passages 12 </ b> A are arranged on the uppermost layer surface of the fiber laminate 9 on which the pass media 18 is arranged. The plurality of resin diffusion promoting injection port group forming gutters 12 are arranged in parallel with each other at regular intervals, and each extend in the same direction as the resin passage 61 of the first resin passage structure 6.

A gutter receiver 13 which forms a diffusion passage 12B together with the resin diffusion promoting inlet group forming gutter 12 is provided between the resin diffusion promoting inlet group forming gutter 12 and the fiber laminate 9 provided with the pass media 18. 13A, it is interposed and arranged. One gutter receiver 13 is arranged for one resin diffusion promotion inlet group forming gutter 12. The gutter receiver 13 is lightly fixed to the upper surface of the pass media 18 or the upper surface of the fiber laminate 9 with an adhesive. The diffusion passage 12B two-dimensionally diffuses the flow of the flowable resin having a large viscous resistance flowing one-dimensionally along the guide passage 12A from the large number of inlet groups 17 with a component orthogonal to the one-dimensional direction. Are diffused in a two-dimensional direction crossing the flow of the guide passage 12A.

As shown in FIG. 5, the gutter receiver 13 has an upper surface formed on a wave surface 14 or an uneven surface. Both end faces of the half-split resin diffusion promotion injection port group forming gutter 12 form a tangent plane 15 with respect to the wavefront 14 of the gutter receiver 13. The tangent plane 15 is preferably not parallel to a straight line extending in the axial direction of the surface of the fiber laminate 9 and is inclined at a small angle. A semi-cylindrical tube was used for the resin diffusion promoting inlet group forming gutter 12, but a half-square tube may be used, as long as the resin passage structure has a concave shape on one surface. However, it can be used.
In addition, each of the gaps of the injection roller group 17, which is a set of a plurality of gaps formed between the resin diffusion promoting inlet group forming gutter 12 and the gutter receiver 13, that is, the cross-sectional area of the diffusion passage 12 </ b> B is mutually different. It is preferred that they are not the same but are slightly different. It is preferable that the distance Dj between the apex regions of the adjacent wavefronts 14 is not the same but slightly different. Such a difference in the cross-sectional area or the interval makes the amount of the flowable resin introduced into the resin diffusion promoting inlet group forming gutter 12 out of the gap, that is, the diffusion passage 12B, to be uniform. The uneven surface is not limited to the smooth wave surface 14, but may be replaced by a zigzag surface formed in an arbitrary shape such as a triangle or a rectangle on the cross section. The gutter 12 and the gutter tray 13 can be integrated.

The next step of the multilayer forming step of forming the fiber laminate 9 is to dispose the pass media 18 on the fiber laminate 9 and then apply a vacuum to the upper side of the fiber laminate 9 and the resin diffusion promoting inlet group forming gutter 12. This is a manual sheet covering step of covering the use sheet 1. The sealing sheet 19 is placed on both upper surfaces of the undeformed mold 2, and the vacuum sheet 1 is placed on the fiber laminate 9, the resin diffusion promoting inlet group forming gutter 12, and the sealing sheet 19.
Then, the vacuum pump is operated to suck air from the vacuum evacuation pipes 20 arranged on both sides of the first resin passage structure 6, so that the space between the vacuum sheet 1 and the undeformed mold 2 is formed. The air is sucked and discharged to the outside, and a cavity 3 is formed between the vacuum sheet 1 and the non-deformable mold 2.

The next step after the sheet covering step is an injection step of injecting the fluid resin into the cavity 3.
The resin is supplied to each resin passage 61 from the injection port 64 to the resin passage structure 6, and is impregnated into the pass media 8 through the through hole 62. Then, the resin impregnated in the pass media 8 impregnates the fiber laminate 9.
The resin supplied to each of the resin passages 61 is sent to each of the resin passages 61 through the plurality of resin sub-passages 63, and is uniformly supplied to the path media 8 from the injection port 64 by the negative pressure in the cavity 3. You.
On the other hand, in the second resin passage structure 16, as shown in FIGS. 6 and 7, the resin injection port 4 shown in FIG. It is provided at a plurality of locations. The flowable resin introduced from the resin inlet 4 as shown by the arrow in FIG. 6 flows in the axial direction A in the resin diffusion promoting inlet group forming gutter 12 (see FIG. 6). The flowable resin receives strong viscous resistance from the resin diffusion promoting inlet group forming gutter 12 and flows through the resin diffusion promoting inlet group forming gutter 12 while being extruded in both directions B1 and B2 orthogonal to the axial direction A. It is injected into the cavity 3 (see FIGS. 6 and 7).

As described above, the cavity 3 is in a vacuum state, and the fluid resin receives the atmospheric pressure via the vacuum sheet 1 and smoothly enters the cavity 3. The double flow of the fluid resin extruded from the adjacent inlet group 17 diffuses and mixes, and further penetrates deep into the fiber laminate 9 so as to penetrate. The flowable resin injected from the resin diffusion promoting injection port group forming gutter 12 diffuses two-dimensionally, then three-dimensionally, and uniformly penetrates into the fiber laminate 9 through the pass media 18. Air is evacuated by evacuation from the evacuation pipe 20, and the fiber reinforced resin composed of the fiber laminate 9 and the resin permeated into the fiber laminate 9 does not contain air bubbles. As described above, the penetration rate of the fluid resin that penetrates at a high diffusion rate is high, and the production cycle is shortened.

The fiber reinforced resin formed in this manner is cured naturally or in an aggressively heated environment while being pushed to the atmospheric pressure through the vacuum sheet 1, and is transformed into a hard fiber reinforced resin structure. After the fiber reinforced resin structure is manufactured, the vacuum sheet 1 is removed, the resin diffusion promoting inlet group forming gutter 12 and the gutter receiver 13 are removed, and the pass media 18 is removed, so that the fiber reinforced resin structure is not deformed. Take out from the mold 2.

In the above embodiment, the pass media 8 and 18 were removed after the fiber-reinforced resin structure was manufactured. However, the fiber-reinforced resin structure was formed by molding with glass fiber or carbon fiber mat (felt) of the same quality as the fiber layer. It is not necessary to remove the pass media 8, 18 after the body is manufactured. In this case, the pass media 18 is completely integrated with the fiber reinforced resin structure, and forms a part of the reinforcing material.
As a result, the number of manufacturing steps can be reduced, and work efficiency can be improved.
It is preferable that the mat has a large porosity and a large thickness in order to secure a passage for the resin. However, if the mat is too thick, the material properties of the fiber-reinforced resin itself may be reduced. Therefore, the material is selected according to the purpose.

  According to the above embodiment, since the pass media 8 and 18 are arranged on the front surface and the back surface of the fiber laminate 9 at the time of manufacturing the fiber reinforced resin structure, the fluidity of the fluid resin can be amplified, and the fluid resin can be amplified. Can be produced to uniformly impregnate the fiber-reinforced resin structure.

  As shown in FIG. 8, by forming a large number of holes 13 a in the plate surface of the gutter support 13, the fluid resin can be passed from the holes 13 a to the lower surface side of the gutter support 13 to impregnate the fiber laminate 9. it can.

Further, in the injection step of the present invention, the flow rate can be made uniform as a whole by controlling the degree of opening and closing of the plurality of injection ports 4 of one resin diffusion promoting injection port group forming gutter 12. It is desirable that the operator makes the judgment while watching the flow situation from outside the transparent sheet 1.
Furthermore, although the FRP structure of the above-described embodiment is described as a flat plate, as a general feature of the resin molding technology, particularly the insert injection molding technology, a complex FRP structure having inner and outer curved surfaces that are variously compounded. Body shaping is possible. Such FRP molding methods are beneficially used for curved surface forming structures such as boats, yachts, ships, car bodies, aircraft fuselage, ship rotors, windmills where hardness and elasticity (flexibility) are simultaneously required. obtain.

FIG. 9 shows another embodiment of the present invention. The same parts as those in FIG. 1 are denoted by the same reference numerals, and the description of the same parts will be omitted. Note that the drawings and explanations described in the embodiment of FIG. 1 are applied to this embodiment as they are.
In this case, a pass media 18 similar to the pass media 8 is disposed on the upper surface of the flat fiber laminate 9, and the second resin passage structure 16 is placed on the pass media 18. . The second resin passage structure 16 has the structure shown in FIG. 3, and is also arranged on at least one pair of side surfaces 9 a of the fiber laminate 9, and the path medium 28 is arranged similarly to the upper and lower surfaces of the fiber laminate 9. Have been.
Through the second resin passage structure 16 together with the first resin passage structure 6, the resin is impregnated from both front and back surfaces and side surfaces of the fiber laminate 9. As a result, even in a thick plate structure having a plate thickness exceeding 10 mm, the resin can be quickly impregnated, and the production time of a product can be significantly reduced.

FIG. 10 shows another embodiment of the present invention, similarly to FIG. 9, and this embodiment is a manufacturing method in a case where a reinforcing girder is formed together with a flat plate at a time. The same parts as those in FIG. 9 are denoted by the same reference numerals, and the description of the same parts will be omitted.
In this case, a flat fiber laminate 29 is stacked on the upper surface of the fiber laminate 9, and a flat fiber laminate 39 is erected on the fiber laminate 29 to form a reinforcing girder. The path medium 38 is disposed on at least one pair of side surfaces (end surfaces) of the fiber laminate 29, the path medium 48 is disposed on the upper surface, the path medium 58 is disposed on both surfaces of the fiber laminate 39, and the path medium 68 is disposed on the upper end surface. Has been established. The second resin passage structure 26 is provided on the side of the fiber laminate 29 where the pass media 38 is provided. In addition, on both surfaces of the fiber laminate 39, the second resin passage structure 36 is disposed from above the path medium 58. The vacuum pipe 20 is disposed on the pass media 68 on the upper end face of the fiber laminate 39.
Then, at the time of manufacturing, first, a resin is poured into the first resin passage structure 6 and impregnated into the fiber laminate 9. After the fiber laminate 9 has been impregnated with the resin to some extent, next, the resin is poured into the second resin passage structure 16 provided on the side surface and the upper surface of the fiber laminate 9. Then, the resin is poured into the second resin passage structure 26 of the fiber laminate 29, and the resin is impregnated from the upper and lower surfaces and side surfaces of the fiber laminate 29. Next, the resin is poured into the second resin passage structures 36 provided on both surfaces of the fiber laminate 39, and the resin is impregnated from both surfaces of the fiber laminate 39.

Also in this embodiment, the resin is fiber-laminated through the second resin passage structure 26 and the second resin passage structure 36 together with the first resin passage structure 6 and the second resin passage structure 16. 9 is impregnated from both the front and back surfaces and the side surfaces, the side surfaces and the upper surface of the fiber laminate 29, and both surfaces of the fiber laminate 39. In this way, the resin is rapidly impregnated into the fiber laminate 9, the fiber laminate 29, and the fiber laminate 39, and the production time of a product including a flat plate and a reinforcing girder can be reduced.
ADVANTAGE OF THE INVENTION According to this invention, generation | occurrence | production of an unimpregnated defect can be prevented and an FRP product can be shape | molded in a short time. Therefore, it can be used in many product fields such as windmill blades, aircraft members, high-speed vehicle members, building members, bridges, and ships.
As a result, even in a thick plate structure having a plate thickness exceeding 10 mm, the resin can be quickly impregnated, and the production time of a product can be significantly reduced.

The present invention is not limited to the above embodiment. For example, as shown in FIG. 11, the first resin passage structure 6 is integrated with the undeformed mold 2 serving as the first mold. By molding, a structure in which the resin passage 61 and the through hole 62 are formed in the first mold 2 can be obtained. Thereby, the first resin passage structure 6 can be omitted. Although the first resin passage structure 6 has a flat plate shape, it may have a corrugated top surface. Further, the number and diameter of the resin passage 61, the through hole 62, and the resin sub-passage 63 formed in the resin passage structure 6 may be set as needed.
Further, the number and material of the resin diffusion promoting inlet group forming gutter 12 and the gutter tray 13 may be selected as necessary, and the gutter tray 13 may have a structure that covers the entire fiber laminate 9. good. Further, the pass media 8 and 18 may cover the whole or a part of the fiber laminate 9, and the thickness thereof can be arbitrarily set depending on the material. In addition, it goes without saying that the present invention can be appropriately modified and implemented without departing from the scope of the present invention.

FIG. 3 is a cross-sectional view taken along the line XX of FIG. 2 illustrating the apparatus for manufacturing a fiber-reinforced resin structure according to the embodiment of the present invention. It is a top view showing the manufacturing device of the fiber reinforced resin structure by an embodiment of the invention. It is the elements on larger scale sectional view of FIG. FIG. 2 is a cross-sectional view illustrating a resin injection port of FIG. 1. FIG. 4 is a sectional view taken along line YY of FIG. 3. FIG. 2 is an enlarged plan view of FIG. 1. FIG. 7 is a conceptual diagram showing the whole of FIG. 6. It is a conceptual diagram which shows the removal method of an unimpregnated part. It is sectional drawing of the same part as FIG. 1 which shows the manufacturing apparatus of the fiber reinforced resin structure by other embodiment of this invention. It is sectional drawing which shows the manufacturing apparatus of the fiber reinforced resin structure by other embodiment of this invention. It is sectional drawing which shows the manufacturing apparatus of the fiber reinforced resin structure by the modification of this invention. It is sectional drawing which shows the conventional shaping | molding apparatus. It is a top view of FIG.

Explanation of reference numerals

1 Vacuum sheet (deformation mold, second mold)
2 Non-deformable mold (first mold)
Reference Signs List 3 cavity 6 first resin passage structure 8, 18, 28, 38, 48, 58, 68 pass media 9 fiber laminate (fiber layer)
DESCRIPTION OF SYMBOLS 10 Fiber layer 12 Resin diffusion promotion inlet group formation gutter 12A Guide passage 12B Diffusion passage 13 Gutter tray (corrugated plate)
13A Joint 14 Wavefront 16, 26, 36 Second resin passage structure 17 Inlet group (gap)
DESCRIPTION OF SYMBOLS 19 Seal 20 Vacuum pipe 29, 39 Fiber laminated body A1 One-dimensional direction B1, B2 Two-dimensional direction 61 Resin passage 62 Through hole 63 Resin auxiliary passage

Claims (18)

  A cavity is formed between the first mold and the second mold in the form of a film, a fluid resin is injected into the cavity, and a fiber layer disposed in the cavity is impregnated with the fluid resin, thereby reinforcing the fiber. In the manufacturing method for manufacturing a resin structure, a resin passage structure having a resin passage for supplying the fluid resin is disposed on both sides of the fiber layer, and between the resin passage structure and the fiber layer. A pass media for amplifying the fluidity of the fluid resin is disposed over the entire or a part of the fiber layer, and the fluid resin supplied from these resin passage structures is impregnated into the fiber layer through the pass medium to produce fibers. A method for producing a fiber-reinforced resin structure, characterized by producing a reinforced resin structure.   A cavity is formed by the first mold and the second mold in the form of a film, and a fluid resin is injected into the cavity by evacuating the inside of the cavity, and a fiber layer arranged in the cavity is formed. In a manufacturing method for manufacturing a fiber-reinforced resin structure by impregnating a flowable resin, a first resin passage structure having a resin passage formed in the first mold is placed, and the fiber is mounted on the resin passage structure. A guide passage for guiding the flowable resin in the one-dimensional direction on the fiber layer, and a flow of the flowable resin in the guide passage is diffused in a two-dimensional direction intersecting with the flow of the guide passage. Forming a second resin passage structure composed of a diffusion passage; forming a second resin passage structure between the first resin passage structure and the fiber layer, and between the second resin passage structure and the fiber layer; Pass media that amplifies the fluidity of fluid resin The fiber reinforced resin structure is disposed by arranging the entire or partial area of both surfaces of the fiber layer, and impregnating the fiber layer with the fluid resin supplied from the first and second resin passage structures through the path medium. A method for producing a fiber-reinforced resin structure, characterized by being produced.   In addition to the upper and lower surfaces of the fiber layer, the resin passage structure is disposed on at least one pair of side surfaces of the fiber layer via the path medium, and the fluid resin supplied from the resin passage structures on the upper, lower, and side surfaces is provided. 3. The method for producing a fiber-reinforced resin structure according to claim 1, wherein the fiber layer is impregnated into the fiber layer through the pass medium to produce a fiber-reinforced resin structure.   While another fiber layer is superimposed on the upper surface of the fiber layer, the resin passage structure is arranged around the another fiber layer via the path medium, and the fluid resin supplied from the resin passage structure is supplied with the resin. The fiber reinforced resin structure according to any one of claims 1 to 3, wherein the fiber layer is impregnated into the fiber layer through a pass medium to produce a fiber reinforced resin structure integrally formed with a flat plate and a reinforcing girder. Manufacturing method.   The method for manufacturing a fiber-reinforced resin structure according to any one of claims 1 to 4, wherein a net is used as the pass medium.   The method for producing a fiber-reinforced resin structure according to any one of claims 1 to 4, wherein a sheet having a void is used as the pass medium.   The method for producing a fiber-reinforced resin structure according to any one of claims 1 to 4, wherein a glass fiber or carbon fiber mat of the same quality as the fiber layer is used for the pass medium. A cavity is formed by the first mold and the second mold in the form of a film, and a fluid resin is injected into the cavity by evacuating the inside of the cavity, and a fiber layer arranged in the cavity is formed. In a manufacturing apparatus for producing a fiber reinforced resin structure by impregnating a flowable resin, a resin passage structure having a resin passage for supplying the flowable resin is disposed on both surfaces of the fiber layer, and the resin passage structure is provided. An apparatus for manufacturing a fiber-reinforced resin structure, characterized in that a pass media for amplifying the fluidity of the fluid resin is disposed on the entire surface or partially on both sides of the fiber layer between the fiber layer and the fiber layer. A cavity is formed by the first mold and the second mold in the form of a film, and a fluid resin is injected into the cavity by evacuating the inside of the cavity, and a fiber layer arranged in the cavity is formed. In a manufacturing apparatus for producing a fiber-reinforced resin structure by impregnating a flowable resin, a resin passage structure having a resin passage for supplying the flowable resin is disposed on both sides and at least one pair of side surfaces of the fiber layer. A fiber reinforced material comprising: a path medium that amplifies the fluidity of the fluid resin between the resin passage structure and the fiber layer; Equipment for manufacturing resin structures.   The apparatus for manufacturing a fiber-reinforced resin structure according to claim 8 or 9, wherein the first mold and the resin passage structure are integrally formed.   A fiber reinforced resin structure in which another fiber layer is overlaid on the upper surface of the fiber layer, the resin passage structure is disposed around the other fiber layer via the path medium, and a flat plate and a reinforcing girder are integrally formed. The apparatus for manufacturing a fiber-reinforced resin structure according to any one of claims 8 to 10, which manufactures a body.   12. The apparatus for manufacturing a fiber reinforced resin structure according to claim 8, wherein a mat of glass fiber or carbon fiber of the same quality as the fiber layer is used for the pass medium. A resin passage type wherein resin guide passages are formed at equal intervals from each other as the lower resin passage structure, and a plurality of through-holes formed on the upper surface of the resin guide passages are formed. 12. The apparatus for producing a fiber-reinforced resin structure according to any one of 8 to 11.   14. The apparatus for manufacturing a fiber-reinforced resin structure according to claim 13, wherein the resin guide passages are connected to each other by a resin auxiliary passage. 15. The upper resin passage structure, wherein a plurality of structures having a concave shape on one surface are used as guide passages, and a concave portion of the structure is arranged toward the fiber layer. An apparatus for producing a fiber-reinforced resin structure according to any one of the above. A joint body disposed as a diffusion passage below the guide passage is used, and a plurality of gaps forming a diffusion passage between the joint body and the guide passage are formed on an upper surface of the joint body. The apparatus for producing a fiber-reinforced resin structure according to any one of 8 to 15.   The apparatus for manufacturing a fiber-reinforced resin structure according to any one of claims 8 to 16, wherein a plate having an uneven upper surface is used for the joined body.   18. The apparatus for manufacturing a fiber reinforced resin structure according to claim 15, wherein a number of holes serving as passages for the flowable resin are formed in a plate surface of the joined body.

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