JP2005067089A - Method for molding molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To solve the problem that a resin is apt to easily accumulate in a recessed part to be formed in the bent part of a molded product due to lack of consideration when the resin is injected and consequently, defects such as the generation of cracks inside the resin easily occur, in a molding method for the recessed part in an FRP structure to be molded by a conventional vacuum impregnation molding method. <P>SOLUTION: In the method for molding the molded product by injecting the resin after covering a loaded object in a molding tool doubly with a vacuum film and degassing the interior of the vacuum film, a local cover plate is formed in the recessed part to be formed in the bent part of the FRP molded product over the first vacuum film directly covering the loaded object. Further, the second vacuum film covering the first vacuum film is internally degassed then the cover plate is pressed from outside the second vacuum film and the resin is injected into the area covered by the first vacuum film. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a vacuum impregnation molding method for moldings such as FRP structures by a closed mold method using a vacuum film.

Conventional vacuum impregnation molding was performed as described in Patent Document 1 below.
“A core material 22 made of a foam or the like is disposed in the mold 21, and at least both surfaces of the reinforcing fiber base material 23 are disposed. The upper surface side of the mold of the reinforcing fiber base material 23 is a bag. Covered with a film 29 and the inside is evacuated by suction by the vacuum pump 30. Next, the valve 31 is opened, and the liquid resin 32 is injected into the mold 21 kept in the vacuum state.- As described above, the injected resin is diffused in the surface direction of the reinforcing fibers 23 along the large grooves 24 and the small grooves 25 of the core material 22, and is impregnated in the thickness direction of the reinforcing fiber base 23. ..The impregnated resin is cured at room temperature, in some cases by heating, to complete the FRP structure, and after curing, the bag film 29 is removed and the cured FRP structure is taken out of the mold 21. FRP structure is molded one shot. "(E.g., see Patent Document 1.)
Japanese Patent Application Laid-Open No. 11-235776 (pages 3 to 5, FIGS. 1 to 5)

  In the FRP structure molding by the conventional vacuum impregnation molding method, no consideration is given to the molding method of the concave portion formed in the bent portion of the molding. Therefore, by resin injection, the resin easily accumulates in such recesses, and defects such as generation of cracks inside the resin are likely to occur.

The present invention has been made to solve the above-described problems, and in the molding of a molded product having a recess, a molding method for preventing a resin from accumulating in the recess and causing a defect in advance is obtained. For the purpose.
Another object is to obtain a molding method with good dimensional accuracy.
Moreover, it aims at obtaining the shaping | molding method which can be implemented by simple construction and has good workability.

  The molding method of the present invention is a molding method of molding which covers a double layer with a vacuum film, deaerates the inside of the vacuum film, and then injects a resin, impregnates the mounted article and molds it. After placing the placing object on the mold and degassing the inside of the first vacuum film that directly covers the placing object, a local contact plate is formed on the concave portion formed in the bent portion of the molded article on the first vacuum film. The inside of the second vacuum film covering the first vacuum film is degassed, the backing plate is pressed from the outside of the second vacuum film, and the resin is injected into the first vacuum film. .

  Further, in the molding method of the molded product of the present invention, the concave portion is formed at the rising portion of the stiffening portion protruding from the plate-shaped molding, and the molded product has a plate-shaped FRP molding having the stiffening portion. It is.

  Further, in the molding method of the molded product of the present invention, the concave portion is formed in the bent portion of the plate-shaped molded product, and the molded product is a bent plate-shaped FRP molded product.

  In the molding method of the molded product of the present invention, the main structure of the mounted article as the molding material is a reinforcing material and a core material.

  Moreover, the molding method of the molded product of the present invention is an FRP molded product, a reinforcing material, and a core material obtained by molding the main structure of the mounted product, which is a molded material, in a separate process.

  In the molding method of the molded product of the present invention, the base plate is formed by applying a base plate forming material made of resin or a base plate forming material containing resin on the first vacuum film, and before the resin is cured. Are covered with a second vacuum film, and the inside of the second vacuum film is deaerated.

  In the molding method of the present invention, the resin is a photo-cured or ultraviolet-cured prepreg or putty.

  According to the molding method of the molded article of the present invention, a backing plate is formed in the concave portion formed in the bent portion on the first vacuum film that directly covers the placed article, and the backing plate is pressed from the outside of the second vacuum film. Then, since the resin is injected into the first vacuum film, the resin-rich portion is prevented from occurring in the concave portion of the molded product without damaging the resin permeability of the molded product, and defects such as cracks are generated. Can be prevented.

  Further, according to the molding method of the molded product of the present invention, the contact plate is formed in the concave portion formed at the rising portion of the stiffened portion of the plate-shaped FRP molded product having the stiffened portion, so the plate shape having the stiffened portion. By molding the FRP molded product, it is possible to prevent the plate-like FRP molded product from being bent and deformed, and to prevent the occurrence of defects due to the accumulation of resin in the recesses.

  In addition, according to the molding method of the molded product of the present invention, since the contact plate is formed in the concave portion formed in the bent portion of the plate-shaped molded product, defects due to accumulation of resin in the concave portion of the bent plate-shaped FRP molded product. Occurrence can be prevented.

  In addition, according to the molding method of the molded product of the present invention, the main components of the mounted product, which is a molded material, are the reinforcing material and the core material. Therefore, workability is improved by integrally molding the molded product.

  Moreover, according to the molding method of the molded product of the present invention, since the main configuration of the mounting material that is a molded material is an FRP molded product, a reinforcing material, and a core material molded in a separate process, by using the FRP molded product, The dimensional accuracy of the molded product after molding is improved.

  Further, according to the molding method of the molded product of the present invention, the base plate is formed by applying a base plate forming material containing resin or resin on the first vacuum film, and the second before the resin is cured. Covering with a vacuum film and deaeration in the second vacuum film, so that the contact plate forming material is in close contact with the recess through the first vacuum film and cured, the contact plate is in close contact with the recess, It is possible to reliably prevent the resin from accumulating in the recess.

  Further, according to the molding method of the molded product of the present invention, since the resin is a photo-cured or ultraviolet-cured prepreg or putty, it can be cured in a short time by irradiating light or ultraviolet light with a lamp, and workability is improved.

  FIG. 1 is a diagram for explaining a molding method for vacuum impregnation molding of an FRP structure, and is a cross-sectional view of a main part for explaining a molding method for a plate-like FRP molding having a stiffening portion. FIG. 2 is a view for explaining the implementation of the vacuum impregnation molding of the FRP structure, and is a cross-sectional view of the principal part for explaining the molding method of the bent plate-like FRP molding. FIG. 3 is a time chart showing the vacuum impregnation molding from the vacuum deaeration process to the pressing and molding process.

In FIG. 1, the molded product is a plate-shaped FRP molded product having a stiffening portion 9, and a plate-shaped first FRP molded portion 5 a that is the FRP molded portion 5 and a second FRP molded portion 5. It is comprised from the FRP shaping | molding part 5b and the stiffening part 9 which consists of the core material part 6. FIG. Here, the stiffening portion 9 is provided with one or a plurality of protruding portions on the first FRP molded portion 5a in order to prevent the plate-like first FRP molded portion 5a from being bent and deformed. It is. The stiffening portions 9 are usually formed on the surface of the first FRP molded portion 5a as a projecting portion having a low height from substantially one end to the other end (see FIG. 1 for stiffening). The section 9 extends in a direction perpendicular to the paper surface). In such a molded product, the concave portion 1 is formed in a bent portion where the stiffening portion 9 rises from the first FRP molded portion 5a.
The first FRP molded part 5a is an FRP molded body in which a reinforcing material is impregnated with a resin, and the shape thereof is a plate-shaped body. Further, the stiffening portion 9 is formed by an inner core material portion 6 and a second FRP molding portion 5 b that covers the outside of the core material 6. The core material portion 6 is obtained by impregnating the core material with resin, and the second FRP molded portion 5b is an FRP molded body obtained by impregnating the reinforcing material with resin.
The plate-like FRP molded product is molded integrally with the first FRP molded part 5a and the stiffened part 9.

  In FIG. 2, the present molded product is a bent plate-shaped FRP molded product including a third FRP molded part 5 c which is an FRP molded part 5 in which a reinforcing material is impregnated with a resin, and has a bent part. In this bent plate-shaped FRP molded product, the concave portion 1 is formed in the bent portion.

  The vacuum impregnation molding apparatus for molding the molded product of the present embodiment has a resin injection means (not shown), a deaeration means (not shown), and a molding portion, and the resin is injected into the molding portion by the resin injection means. Forming mold 4, vacuum film 7 that covers the mounted material such as the reinforcing material and core material placed on the forming portion of forming die 4, and the periphery of forming die 4, the forming portion is externally covered with vacuum film 7. It is mainly composed of sealing means 10 for sealing.

The vacuum film 7 further covers the first vacuum film 7a and the first film 7a that directly covers the molding part of the mold 4; that is, the molding part is doubled together with the first vacuum film 7a. It consists of the 2nd vacuum film 7b which covers a shaping | molding part indirectly by covering.
The vacuum film 7 is also called a bag film and is an airtight film, and a nylon film, a polyester film, a polypropylene film, a polyimide film, or the like is used.

The resin injection means includes a resin tank (not shown) for storing the resin and an injection pipe with an on-off valve (not shown) connected to the resin tank. The injection pipes are the first vacuum film 7a and the second vacuum film 7a. Each of the vacuum films 7b is penetrated (the through portion is sealed), and the tip portion opens into the covering portion of the first vacuum film 7a.
Further, the deaeration means includes a first deaeration means for performing vacuum deaeration of the molding part of the mold 4 covered with the first vacuum film 7a, and a first vacuum film 7a and a second vacuum film 7b. The first degassing means and the second degassing means have a common vacuum pump and a trap connected to the vacuum pump by piping. Each has a pipe provided with an on-off valve. The trap is provided with a pressure gauge that detects the degree of vacuum when the deaeration means 2 is operated.
Each of the first deaeration unit and the second deaeration unit may be connected to a vacuum pump and a trap provided with a pressure gauge by a pipe having an on-off valve.

Further, the sealing means 10 includes a first sealing means 10a for sealing with a first vacuum film 7a that directly covers the molding portion, and a second vacuum film 7b between the first vacuum film 7a and the second vacuum film 7b. And second sealing means for sealing.
Therefore, the piping of the first degassing means passes through the first vacuum film 7a and the second vacuum film 7b (the through portion is sealed), and the degassing tip portion of the first vacuum film 7a Opened in the cover portion, the piping of the second degassing means penetrates the second vacuum film 7b (the through portion is sealed), and the degassing tip portion is formed by the first vacuum film 7a and the second vacuum film 7b. Open between the vacuum films 7b. Further, the second vacuum film covers the first seal portion which is the seal portion of the first vacuum film 7 a and is sealed by the second seal portion on the outer peripheral side of the mold 4.

Next, the molding operation of the molded product shown in FIGS. 1 and 2 using this vacuum impregnation apparatus will be described with reference to FIG.
First, a placement object that is a molding material is placed on the mold 4. That is, the reinforcing material for forming the first FRP molding part 5a or the third FRP molding part 5c is placed on the molding die 4 in accordance with the shape. For example, a sheet-like reinforcing material is appropriately cut and used.
In the case of the molded product of FIG. 1, a core material having a predetermined shape for forming the core material portion 6 is placed on the first FRP molded portion 5a, and the second material is formed so as to cover the outside of the core material. The reinforcing material forming the FRP molded portion 5b is placed in accordance with the shape by appropriately cutting the sheet-like reinforcing material.
In the case of the molded product of FIG. 2, the resin diffusion medium 8 is placed on the third FRP molded part 5c.

Here, as the reinforcing material, a woven fabric or mat such as carbon fiber, glass fiber, or aramid fiber is used.
Moreover, as a core material, the core material part 6 inside the stiffening part 9 is formed by resin impregnation, and the weight of the molded product is reduced. Independent foam or wood can be used. Is preferred. The material of the independent foam is polyurethane, polystyrene, polyethylene, polypropylene, silicon, polyvinyl chloride, or the like.
The resin permeation medium 8 promotes the diffusion of the injected resin in the molding part of the mold within the first vacuum film 7a, and uses a resin or metal mesh sheet. The resin permeation medium 8 may be a part of the molded product or may be removed from the molded product after molding.
In addition, as the 1st FRP shaping | molding part 5a, you may use the FRP molded product which carried out the resin impregnation of the reinforcement | strengthening material by another process instead of the reinforcement | strengthening material.

Next, the molding part of the molding die 4 is covered with the first vacuum film 7a from above the placed object, and the peripheral part of the first vacuum film 7a is sealed by the first sealing means 10a.
Then, the first degassing means is operated, the inside covered with the first vacuum film 7a is evacuated, and the first vacuum film 7 is brought into close contact with the FRP molded bodies 5a and 5b (first degassing in FIG. 3). Degassing step by air means).
Next, on the first vacuum film 7 a, the contact plate forming material is locally applied to the recess 1 along the recess 1 to form the contact plate 2. Here, as a specific example of the contact plate forming material, a material obtained by impregnating a reinforcing material with a resin, a putty-like resin, or the like is used.
And before this resin hardens | cures, the whole is covered with the 2nd vacuum film 7b, and the peripheral part of the 2nd vacuum film 7b is sealed by the 2nd sealing means 10b.
Next, the second degassing means is operated, the inside covered with the second vacuum film 7b is evacuated, and the second vacuum film 7b is brought into close contact with the coating resin 2 and the first vacuum film 7a.
In this state, the coating resin 2 is cured at normal temperature or by heating (molding plate 2 molding step in FIG. 3).

Thereafter, the on-off valve of the resin injection means is opened, a predetermined amount of resin stored in the resin tank is injected into the first vacuum film 7a, and the FRP molded body 5 and the core material 6 are impregnated with resin. And a 1st deaeration means is stopped and the on-off valve of a resin tank is closed. During this time, the second degassing means continues the degassing operation (resin injection / impregnation step in FIG. 3).
By continuing the degassing operation of the second degassing means, the resin-impregnated reinforcing material (FRP molded product when using the FRP molded product) and the core material, which are molded products in the first vacuum film 7a, The second vacuum film 7b is pressed against the mold 4 by external pressure from the outside, and is integrally formed. Then, after confirming the gelation of the injected resin, the second degassing means is stopped (pressing and molding step in FIG. 3).
Finally, after the injection resin is cured by normal temperature or heating, the vacuum film 7 is removed, and the molded product is taken out from the mold 4.

Here, the injection resin serves as a matrix resin for the molded product, and is a thermosetting resin such as an epoxy resin, a vinyl ester resin, or an unsaturated polyester resin. The resin of the base plate forming material to be applied to the concave portion 1 by application or the like is also the same type of resin as the injection resin. However, the base plate forming material to be applied to the concave portion 1 by application or the like is a photocuring or ultraviolet curable prepreg (as a reinforcing material). Sheets impregnated with UV curable resin) or photo-curing or UV-curing putty, and these are applied by pasting, coating, etc., and are usually cured by irradiating light or ultraviolet light with natural light or a lamp. The time can be shortened compared to curing the resin at room temperature or by heating, and the formation of the backing plate 2 is facilitated.

According to such a molding method, before injecting the impregnating resin for the molded product, the contact plate 2 is locally formed on the first vacuum film 7a of the concave portion 1 formed in the bent portion, and the first The vacuum film 7a is degassed and the second vacuum film 7b is degassed, whereby the backing plate 2 is placed in the second FRP molding part 5b or FRP molding part 5c in the first vacuum film 7a. When the impregnating resin is injected into the first vacuum film 7a by bringing it into close contact with the upper resin diffusion medium 8 via the first vacuum film 7a, the injected resin impairs the resin permeability to the mounted object. Without being accumulated in the concave portion 1 formed in the bent portion of the molded product. Then, it can prevent that a crack defect arises because resin accumulates. Further, in order to prevent bending deformation, it is possible to prevent the resin from accumulating in the concave portion 1 formed in the rising portion of the stiffened portion 9 of the plate-like molded product having the stiffened portion 9 and to generate crack defects. Further, it is possible to prevent the occurrence of bending deformation and poor dimensional accuracy.
Moreover, the occurrence of these defects and defects can be prevented by simple construction.

  Further, in addition to degassing the inside of the first vacuum film 7a and bringing the backing plate 2 into close contact with the internal FRP molding portion 5b or the resin diffusion medium 8, the second vacuum film is cured before the backing plate 2 is cured. 7b, the inside of the second vacuum film 7b is evacuated, and the backing plate 2 is pressed through the first vacuum film 7a by pressing from the outside of the second vacuum film 7b or the resin diffusion medium inside By making it harden | cure after making it closely_contact | adhere to 8, it can prevent reliably that resin accumulates in the recessed part 1. FIG.

Further, in the formation of the plate-like FRP molding having the stiffening portion 9, the reinforcing material is placed on the molding die 4 for forming the first FRP molding portion 5a and the second FRP molding portion 5b, respectively. The molding workability is improved by integrally molding a molded product including the first FRP molding part 5a, the second FRP molding part 5b, and the core material part 6.
At this time, if an FRP molded product obtained by molding the first FRP molded part 5a in a separate process is used, the dimensional accuracy of the molded product after molding is improved.

  Furthermore, if the backing plate 2 is formed using a photocuring or ultraviolet curing prepreg or putty and cured by irradiating light or ultraviolet rays with a lamp, the time can be shortened compared to normal temperature or heat curing. Improves.

  The molded product of FIG. 1 is an example of a single plate-like molded product having a so-called stiffening portion 9 by the first FRP molded portion 5a. A sandwich-like plate-like product having a stiffening portion 9 provided with a stiffening portion 9 on a sandwich-like plate-like product sandwiching the core material portion 6 can be formed in the same manner. Can prevent the accumulation of resin.

Even if a vacuum leak arises in the 1st vacuum film 7a by using the 1st, 2nd vacuum film 7a, 7b and covering twice, the shaping | molding method of the FRP structure of this invention is 2nd. The vacuum film 7b can prevent problems due to vacuum leakage. That is, in the resin injection / impregnation process, it is possible to prevent entrainment of bubbles, and in the pressing / molding process, proper pressing and molding are possible.
In addition, the method for molding the FRP structure of the present invention is characterized by the method of molding a molded product having the concave portion 1 formed in the bent portion, using the double vacuum film 5 and the backing plate 2. As the resin injecting means, degassing means, sealing means 10 and materials used for molding in vacuum impregnation molding, known materials and known methods can be widely used.

  The molding method of the present invention is a so-called vacuum impregnation molding method for molding an FRP structure, which is used for molding a plate-like FRP molding having a stiffening portion, a bent plate-like FRP molding having a bending portion, and the like. .

It is principal part sectional drawing explaining the shaping | molding method of the plate-shaped FRP molding which has a stiffening part of this invention. It is principal part sectional drawing explaining the shaping | molding method of the bending plate-shaped FRP molding of this invention. It is a time chart figure which shows from the vacuum deaeration process of a vacuum impregnation shaping | molding method of this invention to a pressing and shaping | molding process.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Recessed part, 2 Contact plate, 4 Mold, 7a 1st vacuum film, 7b 2nd vacuum film, 9 Stiffening part.

Claims (7)

Place the object as a molding material on the molding die, cover it twice with a vacuum film, degas the inside of the vacuum film, and then inject resin, impregnate the above-mentioned object and mold the molded object A method,
After placing the above-mentioned figurine on the molding die and degassing the inside of the first vacuum film that directly covers the putty, the concave portion formed in the bent portion of the molding is locally formed on the first vacuum film. Forming a specific backing plate, degassing the inside of the second vacuum film covering the first vacuum film, pressing the backing plate from the outside of the second vacuum film, and in the first vacuum film A method for forming a molded product, comprising injecting a resin into the mold.   2. The concave portion is formed at a rising portion of a stiffening portion protruding from a plate-shaped molded product, and the molded product is a plate-shaped FRP molded product having a stiffening portion. The molding method of the molded product as described in 2.   2. The molding method according to claim 1, wherein the concave portion is formed in a bent portion of a plate-shaped molded product, and the molded product is a bent plate-shaped FRP molded product.   The method for forming a molded product according to any one of claims 1 to 3, wherein a main component of the mounted article as the molded material is a reinforcing material and a core material.   The molded article according to any one of claims 1 to 3, wherein the main structure of the mounted article, which is the molded article, is an FRP molded article, a reinforcing material, and a core material that are molded in a separate process. Molding method.   The backing plate is formed by applying a backing plate forming material made of resin or a backing plate forming material containing a resin on the first vacuum film, and is covered with the second vacuum film before the resin is cured. And the deaeration in this 2nd vacuum film is performed, The shaping | molding method of the molded product in any one of Claims 1-5 characterized by the above-mentioned. The method for molding a molded product according to any one of claims 1 to 6, wherein the resin is a photo-curing or ultraviolet-curing prepreg or putty.

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