JP2004306398A - Method for manufacturing frp structure - Google Patents

Method for manufacturing frp structure Download PDF

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Publication number
JP2004306398A
JP2004306398A JP2003102420A JP2003102420A JP2004306398A JP 2004306398 A JP2004306398 A JP 2004306398A JP 2003102420 A JP2003102420 A JP 2003102420A JP 2003102420 A JP2003102420 A JP 2003102420A JP 2004306398 A JP2004306398 A JP 2004306398A
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Japan
Prior art keywords
core material
foam
reinforcing fibers
mold
unfoamed
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JP2003102420A
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Japanese (ja)
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JP4120445B2 (en
Inventor
Kyosuke Yasumi
恭介 八角
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Nissan Motor Co Ltd
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Nissan Motor Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To enhance the molding quality of an FRP structure using a preform obtained by surrounding a foaming core material by reinforcing fibers. <P>SOLUTION: The preform 11 is obtained by surrounding a foaming core 2, which is formed by holding reinforcing fibers 9 between two core material pieces 2a and 2b. Non-foamed sheets 7 are preliminarily embedded in the surface layers of the respective core material pieces 2a and 2b. The preform 11 is put in a heated mold 12 and, after the mold is clamped, the mold is filled with a thermosetting resin material as a matrix resin so as to impregnate reinforcing fibers 9 and 10 with the resin material to mold the FRP structure 1 wherein the reinforcing fibers 9 become ribs 4 and the reinforcing fibers become a skin layer 3. The reinforcing fibers 10 are pressed to the mold surface of the mold by the expansion of the non-foamed sheet 7 to prevent molding failure such as the occurrence of wrinkles, uneven wall thickness and the like. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【0001】
【発明の属する技術分野】
本発明は、複合材料の構造体として代表的なFRP(繊維強化プラスチックス)構造体の製造方法に関し、特に発泡芯材とこの発泡芯材を包囲している繊維強化樹脂製の表皮層とを有していて、発泡芯材の内部には表皮層と一体で且つその発泡芯材を横断するリブが形成されているFRP構造体の製造方法に関する。
【0002】
【従来の技術】
中空状で三次元形状をなすFRP構造体を製作する場合、芯材としていわゆる風船状の中空バッグを使用して一体成形を行う工法のほか、いわゆる最中構造として半割り状のプリフォームを成形した上でそのプリフォーム同士を接着接合する工法が多く採用されている。
【0003】
しかしながら、前者の工法では、構造体としての剛性や強度を高めるために内部に隔壁状のリブを設定したい場合にリブの位置決めや形状保持が困難であること、また後者の工法では、接着工程が増えることにより製作に要する時間が長くなるばかりでなく、プリフォーム同士の位置合わせ精度の確保等のために生産性が大きく低下する、等の理由から、第3の方法として、中空部を密度の小さい発泡材としてその周りを繊維強化樹脂で覆う方法が例えば特許文献1,2として試みられている。
【0004】
この方法によれば、発泡材を芯材(コア)とすることにより、リブに相当する部分でその芯材を分割し、分割した芯材同士の間に強化繊維を挟み込むことにより精度の良好なリブを一体に成形することが可能となり、しかもこの中間成形体を成形型内に入れて成形することで外表面の良好な製品を得ることが可能となる。
【0005】
【特許文献1】
特開平11−254566号公報 (図2)
【0006】
【特許文献2】
特開2000−233464号公報 (第3頁および図4)
【0007】
【発明が解決しようとする課題】
しかしながら、発泡体はその特殊性として全体にわたり気泡が存在しているため、外部からの荷重を受けると表面が容易に窪んだり陥没しやすく、特により軽量な製品を成形するべく発泡材の密度を小さいものにするほど上記の傾向が顕著となる。
【0008】
そのため、発泡芯材を強化繊維で覆う際もしくは強化繊維で覆った発泡芯材を成形型内にセットする際に、その発泡芯材が窪んだり陥没してしまうと、含浸する樹脂の量が多くなって製品板厚が局部的に厚くなったり強度の低下を招くほか、強化繊維が余り気味となることによって製品表面にしわが発生する等の不具合が発生する。
【0009】
また、外部荷重に対して硬く且つ表面に窪みや陥没が発生しにくい発泡材の使用も可能ではあるが、そのタイプの発泡材は非常に高価であり、特に安価で且つ軽量な製品を製作したい場合には採用することができない。
【0010】
本発明はこのような課題に着目してなされたものであり、特に繊維強化樹脂製の表皮層で包囲されている発泡芯材の内部に表皮層と一体で且つその発泡芯材を横断するリブが形成されているFRP構造体を前提として、安価な発泡芯材の使用で品質の良好な製品を成形できるようにした方法を提供するものである。
【0011】
【課題を解決するための手段】
請求項1に記載の発明は、先に述べたように、発泡芯材とこの発泡芯材を包囲している繊維強化樹脂製の表皮層とを有していて、発泡芯材の内部には表皮層と一体で且つその発泡芯材を横断するリブが形成されているFRP構造体の製造方法であることを前提としている。その上で、少なくとも二分割された発泡芯材の表層部に未発泡の発泡材を埋め込む工程と、それら発泡芯材同士の間に強化繊維を挟み込んだ上で発泡芯材全体を強化繊維で包囲してプリフォームとする工程と、プリフォームを成形型内に入れて型締めした上で加熱して未発泡の発泡材を発泡させる工程と、上記加熱後もしくは加熱処理と並行して成形型内にマトリックス樹脂を充填して強化繊維に含浸させつつ表皮層を所定形状に成形する工程とを含むことを特徴としている。
【0012】
この場合、加熱する時期とマトリックス樹脂を充填する時期とを入れ換えて、請求項2に記載のように、プリフォームを成形型内に入れて型締めした後に、先ず成形型内にマトリックス樹脂を充填して強化繊維に含浸させ、その後に加熱して、強化繊維に含浸させたマトリックス樹脂を硬化させて表皮層を所定形状に成形しながら未発泡の発泡材を発泡させるようにしてもよい。
【0013】
また、構造体の表面品質を一段と高める上では、請求項3に記載のように、発泡芯材の表層部に未発泡の発泡材を受容する凹状部を予め形成しておき、この凹状部に未発泡のシート状の発泡材を配置したり、あるいは請求項4に記載のように、凹状部に未発泡のシート状の発泡材を配置した上で、発泡芯材と同材質の蓋体で発泡芯材の表面と面一状態となるように被覆することが望ましい。
【0014】
したがって、請求項1に記載の発明では、プリフォームを成形型内に入れて型締めした後に初めて未発泡の発泡材が発泡することになるので、発泡芯材を覆っている強化繊維を外側すなわち成形型に押し付ける効果が発揮される。これにより、強化繊維ひいては表皮層のしわの発生や肉厚をばらつき等を未然に防止できるようになる。
【0015】
【発明の効果】
請求項1に記載の発明によれば、未発泡の発泡材の発泡をもってその外側の強化繊維を成形型に押し付けるようにしているため、強化繊維を含む表皮層の板厚がばらつくことがなく、その厚み精度が向上するとともに強度的にも安定した構造体を成形できるほか、強化繊維のしわの発生を防止できるので表面品質も併せて向上する。また、上記のような品質向上によって安価で且つ軽量な発泡芯材の使用で足りることから、コストアップの少ない軽量な構造体を容易に成形できる利点がある。
【0016】
【発明の実施の形態】
図1〜3は本発明の好ましい実施の形態を示す図であり、特に図1は成形されたFRP構造体の概略構造を、図2はそのFRP構造体1となるべき発泡芯材(発泡コア)および未発泡の発泡材等との相互関係を分解斜視図としてそれぞれ示している。
【0017】
図1に示すFRP構造体1の全体形状は略中実角柱状もしくは直方体形状のものであって、発泡コア2を芯材としてその六面全面が熱硬化性の繊維強化樹脂からなる表皮層(スキン層)3にて覆われているとともに、内部中央には表皮層3と一体化されながら発泡コア2を横断する単一の隔壁状のリブ4が形成されている。このリブ4があるために発泡コア2は実質的に左右二つのもの2a,2bに分割されている。ここでは、表皮層3で覆われたコア全体を発泡コア2と呼び、リブ4の存在により二分された左右同一形状のコアのそれぞれをコア素片2a,2bと呼ぶものとする。
【0018】
各コア素片2a,2bは、図2に示すように例えば硬質ポリウレタンフォーム製のものであって、その外周面である六面それぞれの表層部には凹状部として矩形状の受容凹部5を個別に形成してあるとともに、その受容凹部5よりも一回り大きな段状部6をもって同じく矩形状の開口部6を個別に形成してある。なお、上記の硬質ポリウレタンフォームとしては、例えば東洋ゴム工業(株)社製の硬質ウレタンフォーム「ソフラン−R W−30」などの密度の小さな軽量なものが好ましい。また、受容凹部5や開口部6は必ずしも六面全面に設けることなく、製品機能の上で必要な面のみに設定することもできる。
【0019】
それぞれの受容凹部5には未発泡の発泡材として矩形状の未発泡シート7を配設するようになっているとともに、その上から各コア素片2a,2bと同材質(硬質ポリウレタンフォーム)の蓋体として同じく矩形状のカバーシート8をコア素片2a,2bの外周面と面一状態となるように開口部6に装着して未発泡シート7を隠蔽し、これをもって実質的に未発泡シート7を各コア素片2a,2b内に埋め込むようになっている。なお、未発泡シート7としては、例えばHexcel社製の発泡接着剤「REDUX206NA」を使用するものとするが、シート状のものであれば必ずしも接着剤である必要はない。
【0020】
したがって、上記の受容凹部5は未発泡シート7を受容し得る大きさに、開口部6はカバーシート8を受容し得る大きさにそれぞれ設定されている。なお、図2では、各コア素片2a,2bの六面のうち特定の一面にのみ装着されることになる未発泡シート7とカバーシート8を描いてあり、それ以外の各面の未発泡シート7とカバーシート8は図示省略してある。
【0021】
また、一対のコア素片2a,2b同士の間には図1のリブ4に相当するものとしてコア素片2a,2bのうちその最大面積の面と同サイズの強化繊維(単繊維層を何層か積層したもの)9を挟み込むものとする。
【0022】
図1に示したFRP構造体1の成形にあたっては、先に述べたように一対のコア素片2a,2bについてそれぞれの受容凹部5に未発泡シート7を置いた上で開口部6にカバーシート8をはめ込んで蓋をする。これにより、各コア素片2a,2bの表層部には実質的に未発泡シート7が埋め込まれたことになる。
【0023】
次いで、コア素片2a,2b同士の間に強化繊維9を挟み込みようにしてそのコア素片2a,2b同士を組み合わせて発泡コア2とする。さらにコア素片2a,2b同士を組み合わせてなる発泡コア2を包囲するようにして図3の(A)に示すようにその全周を強化繊維(単繊維層を何層か積層したもの)10で覆う。ここにいう強化繊維10は図1の表皮層3となるべきものであり、リブ4に相当する強化繊維9と同材質のものである。すなわち、リブ4となるべき強化繊維9を挟み込んだ発泡コア2をさらに表皮層3となるべき強化繊維10で覆うことで、図3の(A)に示すようなFRP構造体1となるべきプリフォーム11となる。
【0024】
ここで、発泡コア2を強化繊維10で包囲しただけでは図3の(A)に示すようにその表面にしわQや単繊維層間の隙間Gの発生が不可避であるが、ここでは特に問題としない。
【0025】
こうしてプリフォーム11が得られたならば、図3の(B)に示すように上下型(金型)13,14からなる成形型12のうちその下型14側のキャビティ15にプリフォーム11をセットして型締めする。この場合、プリフォーム11をセットするまでの間に予め成形型12そのものを加熱して、例えば100〜120℃前後の温度に調整しておく。
【0026】
成形型12内にプリフォーム11をセットして型締めすると、プリフォーム11内の未発泡シート7が成形型12からの熱を受けて発泡を開始する。それまで未発泡であったシート7の発泡はその体積膨張を伴うことから、図3の(B)に示すように発泡コア2の内部からその発泡コア2を介してコア外周の強化繊維10を成形型12のキャビティ面(型面)に押し付けることになる。
【0027】
続いて、成形型12に設けられたランナー16を通してキャビティ15内にマトリックス樹脂として例えばエポキシ樹脂等の熱硬化性樹脂の溶融樹脂材料を充填し、リブ4に相当する強化繊維9や表皮層3に相当する強化繊維10に含浸させる。この時、特に表皮層3となるべき強化繊維10は未発泡シート7の発泡によって予めキャビティ面に押し付けられることから、同図(A)に示したようなしわQが解消されて強化繊維10が弛むことはなく、また強化繊維10を形成しているところの積層した単繊維層間に大きな隙間G(図3の(A)参照)が発生することもない。
【0028】
そして、熱硬化性樹脂の溶融樹脂材料の充填を終えたならば所定の保圧状態としてその熱硬化性樹脂の硬化を促進させる。この硬化進行に伴い、図3の(B)に示すように親和性の良い各コア素片2a,2bとシート7およびカバーシート8の三者が一体化され、同時に各コア素片2a,2bと強化繊維9,10も一体化される。つまり、熱硬化性樹脂の溶融樹脂材料を含浸した強化繊維9相当部がリブ4となり、同様に熱硬化性樹脂の溶融樹脂材料を含浸した強化繊維10相当部が表皮層3となる。この後、所定時間経過後に脱型して製品としてのFRP成形品1を得る。
【0029】
ここで、熱硬化性樹脂の溶融樹脂材料を充填する際には成形型12を常温もしくは未発泡シート7が発泡しないような温度に設定しておき、溶融樹脂材料の充填を終えてから初めて未発泡シート7が発泡し且つ溶融樹脂材料が硬化する温度まで成形型12の温度を上昇させるようにしてもよい。つまり、熱硬化性樹脂の溶融樹脂材料の特性として、未発泡シート7が発泡する時間より遅れて硬化する性質のものとしておく。
【0030】
こうすることにより、熱硬化性樹脂の溶融樹脂材料を成形型12に充填する際には、未発泡シート7が未発泡であるが故に、表皮層3となるべき強化繊維10のキャビティ面に対する押し付け力が先に実施の形態のものより小さくなり、その結果として強化繊維10を形成している単繊維層間に隙間が存在して、充填された溶融樹脂材料がキャビティ15全体を流動しやすくなり、強化繊維10への含浸が均一且つ安定したものとなる。
【0031】
そのために、強化繊維10への溶融樹脂材料の含浸性の良い成形が可能となり、特に含浸性のばらつきに基づく偏肉等の成形不良の発生を未然に防止できるほか、従来では樹脂材料の流動性や含浸性が悪くて成形が困難であったFRP構造体の成形をも可能となる。
【図面の簡単な説明】
【図1】FRP構造体の一例としてその概略構造を示す斜視図。
【図2】図1のFRP構造体を形成することになるコア素片や未発泡シート等との相互関係を示す分解斜視図。
【図3】(A)は図2に示す要素をもって形成されたプリフォームと成形型との関係を示す断面図、(B)はFRP構造体の成形が完了した状態を示す断面図。
【符号の説明】
1…FRP構造体
2…発泡コア(発泡芯材)
2a,2b…コア素片
3…表皮層
4…リブ
5…受容凹部(凹状部)
6…開口部
7…未発泡シート(未発泡の発泡材)
8…カバーシート(蓋体)
9,10…強化繊維
11…プリフォーム
12…成形型
[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a method of manufacturing a typical FRP (fiber reinforced plastics) structure as a structure of a composite material, and particularly to a method of forming a foam core material and a skin layer made of fiber reinforced resin surrounding the foam core material. The present invention relates to a method for producing an FRP structure having a rib formed integrally with a skin layer and crossing the foam core inside the foam core.
[0002]
[Prior art]
When manufacturing a three-dimensional FRP structure with a hollow shape, in addition to the construction method using a balloon-shaped hollow bag as a core material, a half-shaped preform is formed as a so-called middle structure. After that, a method of adhesively bonding the preforms to each other is often used.
[0003]
However, in the former method, it is difficult to position and maintain the shape of ribs when it is desired to set partition ribs inside to increase the rigidity and strength of the structure.In the latter method, the bonding process is difficult. The third method is to increase the density of the hollow part by increasing the time required for the production, as well as greatly reducing the productivity for securing the alignment accuracy between the preforms. A method of covering the periphery with a fiber reinforced resin as a small foam material has been attempted, for example, in Patent Documents 1 and 2.
[0004]
According to this method, the foam material is used as the core material (core), the core material is divided at a portion corresponding to the rib, and the reinforcing fiber is sandwiched between the divided core materials, so that good accuracy can be obtained. The ribs can be integrally formed, and a product having an excellent outer surface can be obtained by placing the intermediate molded body in a molding die and molding.
[0005]
[Patent Document 1]
JP-A-11-254566 (FIG. 2)
[0006]
[Patent Document 2]
JP-A-2000-233364 (page 3 and FIG. 4)
[0007]
[Problems to be solved by the invention]
However, foams have a special property of having bubbles throughout, so that when subjected to an external load, the surface is easily dented or depressed, and the density of the foam material is particularly reduced in order to form a lighter product. The smaller the size is, the more remarkable the above tendency becomes.
[0008]
Therefore, when covering the foamed core material with the reinforcing fiber or setting the foamed core material covered with the reinforcing fiber in the molding die, if the foamed core material is depressed or depressed, a large amount of resin is impregnated. In addition to this, the thickness of the product locally increases and the strength is reduced. In addition, when the reinforcing fibers become too weak, wrinkles are generated on the product surface.
[0009]
It is also possible to use a foam material which is hard against external loads and does not easily cause dents or depressions on the surface, but such type of foam material is very expensive, and it is particularly desirable to manufacture an inexpensive and lightweight product. Cannot be adopted in the case.
[0010]
The present invention has been made in view of such problems, and in particular, a rib that is integrated with a skin layer and crosses the foam core material inside a foam core material surrounded by a skin layer made of a fiber-reinforced resin. It is an object of the present invention to provide a method capable of molding a good quality product by using an inexpensive foamed core material on the premise of an FRP structure in which is formed.
[0011]
[Means for Solving the Problems]
As described above, the invention according to claim 1 has a foamed core material and a skin layer made of a fiber-reinforced resin surrounding the foamed core material, and the inside of the foamed core material has It is assumed that the method is a method of manufacturing an FRP structure in which ribs are formed integrally with the skin layer and cross the foamed core material. Then, a step of embedding an unfoamed foam material in the surface layer portion of the foam core material divided into at least two parts, and surrounding the entire foam core material with the reinforcement fibers after sandwiching the reinforcing fibers between the foam core materials. And forming a preform, placing the preform in a molding die, clamping and heating to expand an unfoamed foamed material, and after the heating or in parallel with the heat treatment, in the molding die. And forming a skin layer into a predetermined shape while impregnating the reinforcing fibers with a matrix resin.
[0012]
In this case, the time for heating and the time for filling the matrix resin are exchanged, and as described in claim 2, after the preform is placed in the mold and clamped, first, the matrix resin is filled in the mold. Then, the reinforcing fibers may be impregnated, and then heated to cure the matrix resin impregnated in the reinforcing fibers and foam the unfoamed foam while forming the skin layer into a predetermined shape.
[0013]
In order to further enhance the surface quality of the structure, a concave portion for receiving an unfoamed foam material is formed in advance on the surface layer of the foamed core material, and the concave portion is formed in the concave portion. After arranging an unfoamed sheet-like foam material, or as described in claim 4, after arranging an unfoamed sheet-like foam material in the concave portion, a cover made of the same material as the foam core material is used. It is desirable to coat so as to be flush with the surface of the foamed core material.
[0014]
Therefore, according to the first aspect of the present invention, since the unfoamed foamed material is foamed only after the preform is placed in the molding die and clamped, the reinforcing fibers covering the foamed core material are moved to the outside, ie, outside. The effect of pressing against the mold is exhibited. This makes it possible to prevent the occurrence of wrinkles and variations in wall thickness of the reinforcing fibers and thus the skin layer.
[0015]
【The invention's effect】
According to the invention as set forth in claim 1, since the outer reinforcing fibers are pressed against the mold by foaming of the unfoamed foam material, the thickness of the skin layer containing the reinforcing fibers does not vary, The thickness accuracy can be improved, and a structure that is stable in terms of strength can be formed, and wrinkles of the reinforcing fibers can be prevented, so that the surface quality is also improved. Further, the use of an inexpensive and lightweight foam core material is sufficient due to the quality improvement as described above, so that there is an advantage that a lightweight structure with little increase in cost can be easily formed.
[0016]
BEST MODE FOR CARRYING OUT THE INVENTION
1 to 3 are diagrams showing a preferred embodiment of the present invention. In particular, FIG. 1 shows a schematic structure of a molded FRP structure, and FIG. 2 shows a foamed core material (foamed core) to be the FRP structure 1. ) And an unexpanded foam material are shown in exploded perspective views.
[0017]
The overall shape of the FRP structure 1 shown in FIG. 1 is a substantially solid prismatic or rectangular parallelepiped, and a skin layer (a foam layer 2 made of a thermosetting fiber reinforced resin on the entire six surfaces of which is a core material). A single partition-like rib 4 is formed in the center of the interior and crosses the foam core 2 while being integrated with the skin layer 3. Due to the ribs 4, the foamed core 2 is substantially divided into two right and left parts 2a and 2b. Here, the entire core covered with the skin layer 3 is referred to as a foamed core 2, and each of the right and left cores having the same shape divided into two by the presence of the ribs 4 is referred to as core pieces 2 a and 2 b.
[0018]
As shown in FIG. 2, each of the core pieces 2a and 2b is made of, for example, a hard polyurethane foam, and has a rectangular receiving concave portion 5 as a concave portion on each surface layer of the six outer peripheral surfaces. And a rectangular opening 6 having a stepped portion 6 slightly larger than the receiving recess 5 is also formed. As the above-mentioned rigid polyurethane foam, for example, a lightweight polyurethane having a small density such as a rigid urethane foam “Sofran-RW-30” manufactured by Toyo Tire & Rubber Co., Ltd. is preferable. Further, the receiving recess 5 and the opening 6 are not necessarily provided on the entire six surfaces, but may be set only on the surfaces necessary for product functions.
[0019]
A rectangular unfoamed sheet 7 is arranged in each receiving recess 5 as an unfoamed foam material, and the same material (hard polyurethane foam) as each of the core element pieces 2a and 2b is disposed thereon. A cover sheet 8 having the same rectangular shape as a cover is attached to the opening 6 so as to be flush with the outer peripheral surfaces of the core pieces 2a and 2b, thereby concealing the unfoamed sheet 7 and thereby substantially unfoamed. The sheet 7 is embedded in each of the core pieces 2a and 2b. As the non-foamed sheet 7, for example, a foam adhesive “REDUX206NA” manufactured by Hexcel is used. However, the adhesive is not necessarily required as long as it is a sheet.
[0020]
Therefore, the receiving recess 5 is set to a size capable of receiving the unfoamed sheet 7, and the opening 6 is set to a size capable of receiving the cover sheet 8. In FIG. 2, an unfoamed sheet 7 and a cover sheet 8 which are to be attached to only one specific surface out of the six surfaces of each of the core element pieces 2a and 2b are shown, and the unfoamed sheets 7 The sheet 7 and the cover sheet 8 are not shown.
[0021]
In addition, between the pair of core pieces 2a and 2b, reinforcing fibers having the same size as the surface of the maximum area of the core pieces 2a and 2b (corresponding to the rib 4 in FIG. 9) are sandwiched.
[0022]
In molding the FRP structure 1 shown in FIG. 1, as described above, the unfoamed sheet 7 is placed in each of the receiving recesses 5 for the pair of core pieces 2a and 2b, and the cover sheet is placed in the opening 6. Fit 8 and cover. Thereby, the non-foamed sheet 7 is substantially embedded in the surface layer of each of the core pieces 2a and 2b.
[0023]
Next, the reinforcing fibers 9 are sandwiched between the core pieces 2a and 2b so that the core pieces 2a and 2b are combined to form the foamed core 2. Further, as shown in FIG. 3A, the entire circumference of the foamed core 2 formed by combining the core pieces 2a and 2b with each other is reinforced fiber (a single fiber layer is laminated several times). Cover with. The reinforcing fibers 10 referred to here are to be the skin layers 3 in FIG. 1 and are made of the same material as the reinforcing fibers 9 corresponding to the ribs 4. That is, by covering the foamed core 2 sandwiching the reinforcing fibers 9 to be the ribs 4 with the reinforcing fibers 10 to be the skin layer 3, the FRP structure 1 as shown in FIG. It becomes a reform 11.
[0024]
Here, by merely surrounding the foamed core 2 with the reinforcing fibers 10, it is inevitable that wrinkles Q and gaps G between the single fiber layers are generated on the surface thereof as shown in FIG. do not do.
[0025]
When the preform 11 is obtained in this manner, the preform 11 is placed in the cavity 15 on the lower mold 14 side of the molding die 12 composed of the upper and lower dies (dies) 13 and 14 as shown in FIG. Set and tighten the mold. In this case, before the preform 11 is set, the mold 12 itself is heated in advance and adjusted to a temperature of, for example, about 100 to 120 ° C.
[0026]
When the preform 11 is set in the molding die 12 and clamped, the unfoamed sheet 7 in the preform 11 receives the heat from the molding die 12 and starts foaming. Since the foaming of the sheet 7, which has not been foamed before, involves its volume expansion, the reinforcing fibers 10 on the outer periphery of the core are removed from the inside of the foamed core 2 through the foamed core 2 as shown in FIG. It is pressed against the cavity surface (mold surface) of the molding die 12.
[0027]
Subsequently, a molten resin material of a thermosetting resin such as an epoxy resin is filled as a matrix resin into the cavity 15 through a runner 16 provided in the mold 12, and the reinforcing fibers 9 and the skin layer 3 corresponding to the ribs 4 are filled into the cavity 15. The corresponding reinforcing fibers 10 are impregnated. At this time, since the reinforcing fibers 10 to be the skin layers 3 are pressed against the cavity surface in advance by foaming of the unfoamed sheet 7, the wrinkles Q as shown in FIG. There is no loosening, and no large gap G (see FIG. 3A) is generated between the laminated single fiber layers where the reinforcing fibers 10 are formed.
[0028]
Then, when the filling of the molten resin material of the thermosetting resin is completed, a predetermined pressure-holding state is set to accelerate the curing of the thermosetting resin. With the progress of the curing, as shown in FIG. 3B, the core pieces 2a and 2b having good affinity and the sheet 7 and the cover sheet 8 are integrated, and at the same time, the core pieces 2a and 2b And the reinforcing fibers 9 and 10 are also integrated. In other words, the portion corresponding to the reinforcing fibers 9 impregnated with the molten resin material of the thermosetting resin becomes the rib 4, and the portion corresponding to the reinforcing fibers 10 impregnated with the molten resin material of the thermosetting resin becomes the skin layer 3. Thereafter, after a predetermined time has passed, the mold is removed to obtain the FRP molded product 1 as a product.
[0029]
Here, when filling the molten resin material of the thermosetting resin, the molding die 12 is set at room temperature or at a temperature at which the unfoamed sheet 7 does not foam, and only after the filling of the molten resin material is completed. The temperature of the mold 12 may be increased to a temperature at which the foam sheet 7 foams and the molten resin material hardens. That is, as a characteristic of the molten resin material of the thermosetting resin, the uncured sheet 7 is set to have a property of being cured later than the foaming time.
[0030]
Thus, when the mold 12 is filled with the molten resin material of the thermosetting resin, since the unfoamed sheet 7 is not foamed, the reinforcing fibers 10 to be the skin layer 3 are pressed against the cavity surface. The force is smaller than that of the first embodiment, and as a result, there is a gap between the single fiber layers forming the reinforcing fibers 10, so that the filled molten resin material easily flows through the entire cavity 15, The impregnation into the reinforcing fibers 10 becomes uniform and stable.
[0031]
For this reason, it is possible to form the reinforcing fiber 10 with good impregnating property of the molten resin material. In particular, it is possible to prevent the occurrence of molding defects such as uneven thickness due to the variation in impregnating property. Also, it is possible to form an FRP structure that has been difficult to mold due to poor impregnation.
[Brief description of the drawings]
FIG. 1 is a perspective view showing a schematic structure as an example of an FRP structure.
FIG. 2 is an exploded perspective view showing a mutual relationship with a core element, an unfoamed sheet, and the like that form the FRP structure of FIG. 1;
3A is a cross-sectional view showing a relationship between a preform formed using the elements shown in FIG. 2 and a molding die, and FIG. 3B is a cross-sectional view showing a state in which molding of an FRP structure has been completed.
[Explanation of symbols]
1: FRP structure 2: Foam core (foam core material)
2a, 2b: core element 3: skin layer 4, rib 5, receiving recess (concave portion)
6 Opening 7 Unfoamed sheet (unfoamed foam material)
8. Cover sheet (lid)
9, 10 ... reinforcing fiber 11 ... preform 12 ... molding die

Claims (4)

発泡芯材とこの発泡芯材を包囲している繊維強化樹脂製の表皮層とを有していて、発泡芯材の内部には表皮層と一体で且つその発泡芯材を横断するリブが形成されているFRP構造体の製造方法であって、
少なくとも二分割された発泡芯材の表層部に未発泡の発泡材を埋め込む工程と、
それら発泡芯材同士の間に強化繊維を挟み込んだ上で発泡芯材全体を強化繊維で包囲してプリフォームとする工程と、
プリフォームを成形型内に入れて型締めした上で加熱して未発泡の発泡材を発泡させる工程と、
上記加熱後もしくは加熱処理と並行して成形型内にマトリックス樹脂を充填して強化繊維に含浸させつつ表皮層を所定形状に成形する工程と、
を含むことを特徴とするFRP構造体の製造方法。
It has a foam core material and a skin layer made of fiber reinforced resin surrounding the foam core material, and a rib is formed inside the foam core material integrally with the skin layer and crossing the foam core material. A method for manufacturing an FRP structure, comprising:
Embedding an unfoamed foam material in the surface layer of the foam core material divided into at least two parts,
A step of sandwiching the reinforcing fibers between the foamed core materials and surrounding the entire foamed core material with the reinforcing fibers to form a preform;
A step of heating the unfoamed foam material by heating the preform in a mold, clamping the mold and heating,
A step of forming the skin layer into a predetermined shape while filling the matrix resin in the mold and impregnating the reinforcing fibers after the heating or in parallel with the heat treatment,
A method for producing an FRP structure, comprising:
発泡芯材とこの発泡芯材を包囲している繊維強化樹脂製の表皮層とを有していて、発泡芯材の内部には表皮層と一体で且つその発泡芯材を横断するリブが形成されいているFRP構造体の製造方法であって、
少なくとも二分割された発泡芯材の表層部に未発泡の発泡材を埋め込む工程と、
それら発泡芯材同士の間に強化繊維を挟み込んだ上で発泡芯材全体を強化繊維で包囲してプリフォームとする工程と、
プリフォームを成形型内に入れて型締めする工程と、
成形型内にマトリックス樹脂を充填して強化繊維に含浸させる工程と、
マトリックス樹脂の充填後に加熱して、強化繊維に含浸させたマトリックス樹脂を硬化させて表皮層を所定形状に成形しながら未発泡の発泡材を発泡させる工程と、
を含むことを特徴とするFRP構造体の製造方法。
It has a foam core material and a skin layer made of fiber reinforced resin surrounding the foam core material, and a rib is formed inside the foam core material integrally with the skin layer and crossing the foam core material. A method of manufacturing an FRP structure, comprising:
Embedding an unfoamed foam material in the surface layer of the foam core material divided into at least two parts,
A step of sandwiching the reinforcing fibers between the foamed core materials and surrounding the entire foamed core material with the reinforcing fibers to form a preform;
A step of placing the preform in a mold and clamping the mold,
A step of filling the mold resin with a matrix resin and impregnating the reinforcing fibers,
Heating after filling the matrix resin, curing the matrix resin impregnated in the reinforcing fibers and foaming the unfoamed foam while forming the skin layer into a predetermined shape,
A method for producing an FRP structure, comprising:
発泡芯材の表層部に未発泡の発泡材を受容する凹状部を予め形成しておき、この凹状部に未発泡のシート状の発泡材を配置することを特徴とする請求項1または2に記載のFRP構造体の製造方法。A concave portion for receiving an unfoamed foam material is previously formed in a surface layer portion of the foamed core material, and an unfoamed sheet-like foam material is arranged in the concave portion. A manufacturing method of the FRP structure according to the above. 凹状部に未発泡のシート状の発泡材を配置した上で、発泡芯材と同材質の蓋体で発泡芯材の表面と面一状態となるように被覆することを特徴とする請求項4に記載のFRP構造体の製造方法。5. An unfoamed sheet-like foam material is arranged in the concave portion, and then covered with a lid made of the same material as the foam core material so as to be flush with the surface of the foam core material. 3. The method for producing an FRP structure according to item 1.
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007130801A (en) * 2005-11-08 2007-05-31 Fuji Heavy Ind Ltd Molding method and molding jig
WO2013089235A1 (en) 2011-12-16 2013-06-20 倉敷紡績株式会社 Fibre-reinforced resin moulding, and vehicle interior material using same

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH05462A (en) * 1991-04-15 1993-01-08 Teijin Ltd Manufacture of light composite molded material
JPH11254566A (en) * 1998-01-06 1999-09-21 Toray Ind Inc Frp structure and manufacture thereof
JP2000233464A (en) * 1999-02-16 2000-08-29 Toray Ind Inc Frp structure and manufacture thereof

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH05462A (en) * 1991-04-15 1993-01-08 Teijin Ltd Manufacture of light composite molded material
JPH11254566A (en) * 1998-01-06 1999-09-21 Toray Ind Inc Frp structure and manufacture thereof
JP2000233464A (en) * 1999-02-16 2000-08-29 Toray Ind Inc Frp structure and manufacture thereof

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2007130801A (en) * 2005-11-08 2007-05-31 Fuji Heavy Ind Ltd Molding method and molding jig
WO2013089235A1 (en) 2011-12-16 2013-06-20 倉敷紡績株式会社 Fibre-reinforced resin moulding, and vehicle interior material using same

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