JP2005262613A - Intermediate substrate for frp structure and frp structure using the substrate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an intermediate substrate 1 for an FRP structure which is excellent in dimensional stability and handling properties and the intermediate substrate 1 of the FRP structure which can obtain excellent FRP physical properties to a molding end. <P>SOLUTION: In the intermediate substrate for the FRP structure, the intermediate substrate is made of a laminate 1 in which cut reinforcing fiber fabrics are laminated, a cut part lamination end surface formed by arranging/laminating the cut parts 6a of the fabrics is formed in a part of the intermediate substrate, and a cutting part 5 which moves from the fabrics around the cut part lamination end surface and surrounds the end surface is formed. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an intermediate substrate used as a reinforcing fiber when manufacturing fiber reinforced plastics (hereinafter referred to as FRP structure) used as a structure such as a vehicle body panel or a frame. Specifically, an intermediate substrate for an FRP structure capable of obtaining excellent FRP physical property values and excellent surface quality when resin-molded and excellent handling properties and dimensional accuracy, and this substrate were used. The present invention relates to an FRP structure.

  Conventionally, as the reinforcing fiber of the FRP structure, a reinforced fabric that is a so-called intermediate substrate made of a fabric using carbon fiber, glass fiber, polyaramid fiber yarn, or the like is frequently used. Since these are excellent in mechanical properties such as strength and rigidity after being formed into an FRP structure, they are frequently used as fishing rods, golf shafts and aircraft structural materials.

  In particular, recently, FRP structures have been put on the market as automobile parts such as outer panels for automobiles. In such an FRP structure, in a laminating operation at the time of molding, a reinforcing fiber fabric is laminated in a plurality of layers and placed in a mold, and a matrix resin such as an epoxy resin is injected and cured to produce a product.

  When molding these FRP structures, it is desirable to use a so-called preform that is an intermediate substrate of a laminate having a shape (near net shape) that is substantially the same as or close to the shape of the structure to be molded. There is a merit that post-processing such as cutting after FRP molding and deburring is greatly reduced, cost is reduced, and quality is stabilized.

  However, conventionally, when manufacturing an intermediate base material of a near net shape, the laminate is cut and dimensioned according to a predetermined shape, but the cut end surface of the cut reinforcing fiber fabric is in the form of the fabric cut section as it is. Or it is a form fixed by a binder, an adhesive, or the like.

  When the end face of the product is the same as the cut surface of the fabric, the fabric is not firmly held even during handling after cutting, and the fabric will be misaligned. When molded, there is a problem that the cutting dimensional accuracy is reduced and the fiber fabric is reduced around the end portion, the fiber content is reduced, and the local product rigidity and strength are reduced.

  Therefore, in order to maintain the dimensional accuracy and handling of the intermediate base material and the product physical properties of the FRP structure, the burrs around the product are sufficiently removed, and the post-processing after molding is used for a predetermined purpose. A method of processing into product dimensions is generally used. However, in this method, material costs and processing costs are wasted due to deburring. If post-processing is performed, the cut end face of the laminated fabric is exposed at the end of the molded product, not only deteriorating the appearance quality, but also causing problems of delamination between the laminated reinforcing fiber fabrics, degrading the strength and appearance of the end. Result.

  Conventionally, as a means for solving such a problem, Patent Document 1 proposes a method in which a thermoplastic polymer is provided as an adhesive between reinforcing fiber fabrics so that the fabrics are securely bonded and shape-retained. According to this method, fiber separation is prevented by the adhesive and the delamination is somewhat reduced, so that dimensional accuracy can be maintained. For example, the matrix resin is a thermosetting resin from the viewpoint of the necessary functions of the product. In this case, foreign matters other than the FRP structure composed of the fiber and the matrix resin are present, which causes a problem of reducing the rigidity and strength.

  On the other hand, Patent Document 2 proposes a method of forming a preform using the same binder as the matrix resin. Using a method that uses an adhesive with the same composition as the matrix resin can reduce the stiffness and strength reduction, but this stiffness is due to the presence of a clear interface between the adhesive and the matrix resin. And the problem of strength reduction cannot be solved completely.

Furthermore, as another method, there is a method of using a prepreg in which a reinforced fiber fabric is impregnated with an uncured resin in advance, and preventing misalignment between layers by the tackiness of the material itself. It is required to work carefully so as not to cause a deviation that occurs during lamination. Therefore, in the intermediate base material for an FRP structure, improving the lamination accuracy and improving the productivity are contradictory and cannot be achieved at the same time.
JP 2001-64406 A JP-A-9-141654

  The object of the present invention is to solve the above-mentioned problems of the prior art, have excellent dimensional accuracy, ensure high physical properties of the FRP structure even at the end of the product, and have excellent FRP structure for handling during manufacture and handling An object of the present invention is to provide a body intermediate substrate and an FRP structure using the same.

  In order to achieve the above object, an intermediate substrate for an FRP structure of the present invention is an intermediate substrate comprising a laminate in which a plurality of cut reinforcing fiber fabrics are laminated, and a part of the intermediate substrate includes A cut portion laminated end face is formed by laminating the cut portions of the reinforcing fiber woven fabrics together, and a cut processing portion is formed which surrounds and surrounds the cut portion laminated end surface from the reinforcing fiber woven fabric.

  The method for producing an intermediate substrate for an FRP structure of the present invention is characterized in that at least the following steps are sequentially performed.

  A. A base material preparation step in which a predetermined number of reinforced fiber fabrics are measured and cut to a predetermined size.

  B. A step of laminating reinforcing fiber fabrics in which the cut portions of each fabric are aligned and laminated to form a cut portion laminated end face on a part of the intermediate substrate.

  C. A processing step of the cut end laminated end face that wraps around the cut end laminated end face from the reinforcing fiber fabric and surrounds the laminated end face.

  The intermediate substrate for an FRP structure of the present invention includes an intermediate substrate for an FRP structure having a portion where a reinforcing fiber fabric wraps around the end surface at at least one side of the laminated end surface to form the laminated end surface, and an FRP structure using the intermediate substrate Since it is a body, a cut and measured shape can be obtained with high dimensional accuracy. Further, the end face of the reinforced fiber fabric laminate, which has been easily cut and deformed, is protected and the dimensions are maintained, so that high handling properties can be obtained and the productivity is improved.

  The FRP structure molded using this intermediate base material has less fiber turbulence and dropout at the molding end, so there are few resin-rich parts at the structure end, and the FRP structure has excellent FRP physical properties. Can be obtained.

  Hereinafter, an example in which the best embodiment of the present invention is applied to an automobile structure will be described with reference to the drawings.

  FIG. 1 is a perspective view of an intermediate substrate for an FRP structure of the present invention. In the figure, a laminate 1 as an intermediate substrate of the present invention is composed of a plurality of inner layer substrates 3 and a foam material 3 between them as a basic configuration. Among these, each inner layer base material 3 is a reinforced fiber woven fabric made of, for example, carbon fiber, glass fiber, aramid fiber, and the like, and the weaving configuration is preferably a plain weave where fibers are difficult to break, but may be a satin weave or a twill weave. In addition, the foam material 3 should be a core material when the FRP structure is formed. For example, a resin foam such as acrylic, polyurethane, vinyl chloride, polyolefin, polystyrene, or the like other than these foams has a desired shape. It consists of a hollow body or a honeycomb structure having a corresponding outer skin or outer shape. As for the stacking order of these members 3 and 4, the inner layer base material 3 is stacked on the top and bottom of the foam 4 as shown in the figure.

  By the way, as shown in the drawing, the intermediate base material 1 of the present invention has a left end portion formed in a convex shape along the cutting line 6a, and these cutting lines 6a are aligned in the vertical direction so that the cut portion laminated end face 6 ( A collecting surface formed by the cutting line 6a of each inner layer base material 3). And this cutting part lamination | stacking end surface 6 is enclosed so that it may cover with the outermost layer base material 2 which consists of a carbon fiber fabric, a glass fiber fabric, an aramid fiber etc., for example, and finally the I-type pin 11 so that a laminated body may be penetrated. The whole is fastened together. These members 3, 4, 6, 6 a, 11 constitute the cutting part 5. Although omitted in the figure, the cutting portions 5 are provided at a total of two places on the right side of the figure.

  FIG. 2 is a cross-sectional view showing another embodiment of the cutting unit 5 described above.

  As shown in the figure, in the form of FIG. 2A, the outer periphery of the inner layer base material 3 in which a plurality of layers are laminated in the vertical direction is covered with the outermost layer base material 2 as another member, and then the I-type pin 11 is used. The point to be fixed is the same as that of FIG. 1, but the outermost layer portion 2 is abutted and fixed. Further, as in the embodiment (a), a part of the outermost layer base material 2 may be overlapped for fixing, and a part of the inner layer base material 3 may be added to the outermost layer as illustrated in (c). It may be configured to be used as a base material and wrap all of them. As a fixing method, it is desirable to fix a plurality of inner layer base materials 3 using an I-type pin, and it is desirable because the influence on physical properties of the FRP structure is minimal, but a structure required as an FRP structure is required. If strength, rigidity, and manufacturing cost are satisfied, fixing methods such as stitching, sticking with a taping material, adhesion with a volatile resin dissolved in a solvent, or a commercially available adhesive may be adopted. .

  Even when the intermediate base material manufactured by these configurations is placed on the resin mold and the male and female dies are closed, the intermediate base material is unintentionally bitten into the parting, and the base material is disturbed. Therefore, an FRP structure that is fit in the mold and uniformly wraps around the resin and is stable in terms of surface quality, design, and strength is formed. Thereby, an improvement in yield and a reduction effect of repair work in the post-process can be obtained, and a significant improvement in productivity and a cost reduction effect can be obtained.

  3 and 4 are diagrams showing an embodiment of the intermediate substrate 1 of the present invention in a mode different from the intermediate substrate of FIG. 1, FIG. 3 is a perspective view thereof, and FIG. 4 is an end of the intermediate substrate of FIG. It is an enlarged view of a part.

  In the figure, the basic structure of the base material of this embodiment is substantially the same as that of the base material of FIG. 1, but the inner layer base material 3 of the reinforcing fiber fabric is laminated, and the outermost layer base material 2 of the outermost layer is The intermediate base material is configured by wrapping around the cut portion lamination end face 6 which is an assembly surface of the cutting lines 6a. The exterior surface in this configuration is only the surface from the top of the page, and in this configuration, the outermost base material 2 is wrapped around the upper surface and the end surface, thereby ensuring the design of the exterior by adopting a simple configuration. . In this way, if the desired FRP structure is plate-shaped, the intermediate base material 1 is formed by winding the fabric disposed in the outermost layer around the side face 6 to form the intermediate base material 1. In addition, it is possible to easily obtain effects such as prevention of the separation of the fibers constituting the fabric and the fabric, prevention of peeling of the end face, enhancement of physical properties, prevention of resin richness, and the like.

  FIG. 5 is a perspective view of the FRP structure 21 using the intermediate substrate 1 of the present invention.

  In the FRP structure 21 shown in the figure, the cut portions 5 located at both cut portions of the intermediate base material 1 shown in FIG. 1 are bent downward at about 45 degrees, and a matrix resin is injected and molded therein, and after resin molding, A mounting hole 22 is provided by post-processing. Applications of this molded product include, for example, rigid members having attachment parts such as stabilizers and arms, parts such as bonnets and trunk lids that have a hinge function, and fixing of fender members, spoilers, etc. It can be applied to outer plate parts.

  As described above, in forming the intermediate base material for the FRP structure, the cut portion laminated end surface 6a formed by the cutting lines of the plurality of inner layer base materials 3 is covered with the outermost layer base material 2, and the pin By fixing at 11, the dimensional accuracy of the cut portion is improved, and the inner layer base material is prevented from being peeled off. Further, in the subsequent molding process, the intermediate base material is not damaged even when it is transported to the subsequent process, or the woven fabric is not deformed to change the dimensions, so that an intermediate base material excellent in handling properties can be obtained. . Further, even after the molding, since the reinforcing fiber fabric is arranged without error at the cut ends, many mechanical properties required for the FRP structure are maintained.

  The result of molding an automotive part using the intermediate substrate according to the present invention described above will be described with reference to the drawings.

First, as an inner layer base material 3 which is a reinforcing fiber fabric of FIG. 1, a Toray CO6343B cloth having a weight per unit area of about 200 g / m ² was used and wound around a foam core. The material of the foam core is urethane resin, and the shape is approximately 1000 mm in length, 200 mm in width, and 20 mm in thickness. The reinforcing fiber woven fabric had a length of 1500 mm and a width of 1800 mm, and was laminated on each side of the lengthwise direction by providing a laminate portion of only the reinforcing fiber woven fabric not including the core at 250 mm and winding the reinforcing fiber woven fabric around the core. The cut portion 6 of the laminate of the reinforcing fiber fabric is cut into a shape as shown in FIG. 1, and then the cut portion 5 is covered with the outermost layer base material 2, and these are cut into an I with a long side length of 5 mm. The mold pin 11 was used for fixing. After completing the production of these intermediate substrates, RTM molding was performed. After the molding, the appearance and physical properties of the molded product were inspected. As a result, the fabric constituting the laminate that was harmful to the quality was not disturbed, and the resin rich at the end of the molded product did not occur. Therefore, a product having good mechanical properties was obtained.

(Comparative example)
As a comparative example, a laminate structure similar to that of FIG. 1 was used, but with the structure excluding the outermost layer base material 2, an intermediate base material was manufactured with the same dimensions, and a molded product was produced as a prototype. As a result, the reinforced fiber fabric of the cut surface is disturbed and broken, the local fiber content is reduced and the resin is rich, and the appearance quality is greatly reduced, making it impossible to obtain a good molded product. It was.

  The intermediate substrate for FRP structure according to the present invention and the FRP structure using the same can be applied not only to automobile structural members but also to various general industries, aircrafts, medical structures, etc. The application range is not limited to these.

It is the perspective view and side view of the laminated body of the reinforced fiber fabric which concern on one embodiment of this invention. It is sectional drawing which illustrated the various form of the cutting process part of the laminated body of FIG. It is a perspective view of the laminated body of the reinforced fiber fabric which concerns on another embodiment of this invention. It is the elements on larger scale of the laminated body of FIG. It is a perspective view of the product (FRP structure) obtained by resin-molding the intermediate base material of FIG.

Explanation of symbols

1 ... Laminated body (intermediate base material)
2 ... Outermost layer base material 3 ... Inner layer base material 4 ... Foam 5 ... Cutting part 6 ... Cutting part lamination end face 6a ... Cutting part 11 ... I-type pin 21 ..FRP structure 22 ... Hole for mounting

Claims (10)

  An intermediate base material composed of a laminate in which a plurality of cut reinforcing fiber fabrics are laminated, and a cut end laminated end face in which the cut portions of the reinforcing fiber fabrics are aligned and laminated is formed on a part of the intermediate base material. In addition, an intermediate substrate for an FRP structure, characterized in that a cut processed portion is formed which surrounds and surrounds the cut portion laminated end face from the reinforcing fiber fabric.   2. The FRP structure according to claim 1, wherein the cutting portion is a portion in which the reinforcing fiber fabric disposed in the outermost layer of the intermediate base material wraps around the cutting end laminated end surface and surrounds the laminated end surface. Intermediate base material for body.   The intermediate substrate for an FRP structure according to claim 2, wherein the cut portions of the reinforcing fiber fabrics are cut to the same size to form a cut portion laminated end face.   The intermediate group for an FRP structure according to claim 2 or 3, wherein the outermost reinforcing fiber woven fabric is continuously bent and bent in order from the front side of the laminate to the end face of the laminate and further to the back side of the laminate. Wood.   5. The intermediate base for an FRP structure according to claim 2, wherein in the cut portion of the laminate, the front and back surfaces and end faces of the laminate are covered with and covered with the outermost reinforcing fiber fabric. Wood.   The intermediate base material for an FRP structure according to claim 4 or 5, wherein the cut portion of the laminated body is fixed using means that penetrates in the thickness direction of the laminated body.   The intermediate substrate for an FRP structure according to claim 6, wherein the means penetrating in the stacking thickness direction is an I-type pin.   A FRP structure, wherein the intermediate substrate for an FRP structure according to any one of claims 1 to 7 is impregnated with a matrix resin. A method for producing an intermediate base material for an FRP structure, comprising at least the following steps sequentially.
A. A base material preparation step in which a predetermined number of reinforced fiber fabrics are measured and cut into predetermined dimensions.
B. A step of laminating reinforcing fiber fabrics, in which the cut portions of each fabric are aligned and laminated, and a cut portion laminated end face is formed on a part of the intermediate substrate.
C. A processing step of the cut end laminated end face that wraps around the cut end laminated end face from the reinforcing fiber fabric and surrounds the laminated end face. In the processing step of the cut end laminated end face, the outermost layer of the reinforcing fiber fabric constituting the laminate of the intermediate base material is continuously surrounded in order from the front side of the laminate through the cut end laminated end face to the back side of the laminate. The method for producing an intermediate substrate for an FRP structure according to claim 9, further comprising a step of fastening the laminate using a means penetrating in the thickness direction of the laminate.

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