JP2005271248A - Frp manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an FRP manufacturing method capable of allowing a resin to flow through a normal resin flow channel in a normal flow rate by preventing the short pass of the resin toward a vacuum suction port to prevent the non-impregnation of a molded product with the resin. <P>SOLUTION: The FRP manufacturing method is composed of at least a setting process (A) for installing a preform 2 comprising a reinforced fiber base material, a vacuum suction port 6 and a resin injection port 4 on a mold 1, a hermetically closing process (B) of a suction part for connecting the preform 2 and the vacuum suction port 6 by a ventilation material 7 and subsequently sealing the whole of the vacuum suction port and at least a part of the ventilation material 7 by an airtight material 9 to cover them, a hermetically sealing process (C) for sealing and covering the whole of the preform 2 on the mold, the vacuum suction port 6, the resin injection port 4, the ventilation material 7 and the suction port covering molding part with a bag material 10 to hermetically close the same, a vacuum process (D) for evacuating the whole of the molding part sealed and covered with the bag material 10 by the suction from the vacuum suction port 6 and a resin impregnating and curing process (E) for injecting a resin from the resin injection port 4 to impregnate the reinforcing fiber base material 2 with resin to cure the resin. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to an improvement in a method for producing a fiber reinforced plastic (hereinafter referred to as FRP) by a vacuum resin transfer molding (hereinafter referred to as RTM) molding method. It is related with the manufacturing method of FRP which can eliminate generation | occurrence | production of the unimpregnated part of this and can improve the stability of the quality of a molded object.

  As is well known, FRP is a lightweight material that can exhibit high mechanical properties, and is used in various fields. As one of typical methods for producing FRP, a vacuum RTM molding method is known. In the vacuum RTM molding method, a preform composed of at least a reinforcing fiber base is placed in a mold, the inside of the mold cavity is decompressed, and the pressure difference between the cavity internal pressure and the external pressure is reduced. Then, the resin is injected into the cavity, the injected resin is impregnated into the reinforcing fiber base, the resin is cured, and the mold is demolded after the curing to obtain FRP. The vacuum RTM method includes a molding method using a mold set in an upper and lower set, a method in which a preform is placed on a lower mold and covered with a bag material such as a film or a rubber sheet.

  In Patent Document 1, a preform and a resin diffusion medium are placed on the preform in the mold, a resin inlet and a vacuum suction port communicating with the preform are installed, and the whole is covered with a bag material and decompressed, A method for injecting and curing a resin is disclosed. However, with this method alone, when it takes time for the entire preform to be impregnated with the resin, for example, when the thickness of the preform is thick, before the injected resin impregnates the entire preform, A problem arises in that the pressure-removing suction path is closed by short-passing a gap in the cavity such as a wrinkle of the bag material and arriving at the pressure-reducing suction port by deviating from the resin impregnation path. In that case, there is a problem that the preform cannot be sufficiently sucked under reduced pressure, the flow rate of the resin passing through the reinforcing fibers is not maintained, and an unimpregnated portion of the resin remains.

  In Patent Document 2, as a method for improving the vacuum RTM molding method, a method is disclosed in which high-quality FRP can be produced by heating the entire molding part. That is, it is a method in which the viscosity of the resin is lowered by heating, the impregnation of the resin into the preform is improved, and a high-quality molded product is obtained. However, when the viscosity of the resin decreases, a short pass of the resin may occur more easily.

In Patent Document 3, as an improvement of a vacuum RTM molding method using a bag material, double bagging is further performed on a normal single bag for bagging a preform, and the inside of the single bag is sucked under reduced pressure. Discloses a technique for preventing air leakage. However, this method still has a problem that the resin short-passes from the preform to the vacuum suction port as described above.
U.S. Pat. No. 4,902,215 Japanese Patent Laying-Open No. 2003-48223 (FIG. 2) US Patent Application Publication No. 2002/0022422

  The object of the present invention is to solve the above-mentioned problems of the prior art in the FRP manufacturing method and prevent the resin from passing through to the vacuum suction port side of the injected resin so that the resin can be properly An object of the present invention is to provide an FRP manufacturing method capable of preventing generation of an unimpregnated resin portion in a molded product by flowing at a flow rate.

  In order to achieve the above object, the present invention comprises at least the following steps (A) to (E).

  (A) A setting step in which a preform made of a reinforcing fiber base, a vacuum suction port, and a resin injection port are installed on a mold.

  (B) A sealing step of a suction part that connects the preform and the vacuum suction port with a ventilation material, and then seals and covers the entire vacuum suction port and at least a part of the ventilation material with an airtight material.

  (C) A sealing step for the entire molding unit, in which the preform, the vacuum suction port, the resin injection port, the ventilation material, and the molding unit that covers the suction unit on the molding die are sealed with a bag material, and are covered and sealed.

  (D) A depressurization step of depressurizing the entire molded part covered with the bag material by suction from the depressurization suction port.

  (E) A resin impregnation and curing step in which a resin is injected from the resin injection port and the reinforcing fiber base material is impregnated with the resin, and then the resin is cured.

  According to the FRP manufacturing method of the present invention, the preform, the vacuum suction port, and the ventilation material are connected and covered with an airtight material, so that the vacuum degree of the suction port is reduced due to the resin short-passing from the regular flow path. Can be prevented. Therefore, generation | occurrence | production of the resin non-impregnation part in a FRP molded object can be prevented, and quality can be stabilized.

  Hereinafter, the best mode of the present invention will be described in the order of steps with reference to the drawings of one embodiment.

FIG. 1 is a cross-sectional view of a vacuum RTM apparatus for explaining the first embodiment of the manufacturing method of the present invention, in which the resin in the resin pot 5 is injected while the inside of the preform 2 is decompressed. It shows a state. FIG. 2 is a plan view of the vacuum RTM apparatus shown in FIG.
1. Setting Step In FIG. 1, first, a preform 2 is placed on a single-sided mold 1 having a surface on which a release agent is applied. The preform 2 is composed of at least a reinforcing fiber base material. The thicker the reinforcing fiber substrate of the preform 2, the longer the impregnation time in the plate thickness direction described in the impregnation / curing step 5 described later, the characteristics of the present invention can be exhibited.

  Although it does not specifically limit as a reinforced fiber base material which comprises the preform 2, For example, carbon fiber, glass fiber, an aramid fiber etc. can be used. In addition, the cross-sectional shape of the preform 2 is more complicated as a rectangular shape, a C shape, an I shape, an L shape, a Z shape, a T shape, or a hat shape. The features of the invention can be exhibited. It is preferable to dispose the peel ply 15 and the resin diffusion medium 3 having releasability on the preform 2 because it is necessary to quickly and evenly flow the resin into the preform 2. The material of the peel ply 15 is not particularly limited as long as the resin diffusion medium 3 can be easily released from the cured plate after curing. For example, a nylon woven fabric is preferably used. The resin diffusion medium 3 is not particularly limited as long as the resin flow resistance is lower than that of the preform 2. For example, it is preferable to use a mesh sheet or a flat plate with grooves as a resin flow path. You may install a press plate on the resin diffusion medium 3 as needed.

  Next, an injection port 4 for injecting resin into the preform 2 and a suction port 6 for decompressing the preform 2 are arranged. As shown in FIG. 1, a resin inlet 4 is disposed on the left side of the resin diffusion medium 3. As shown in FIG. 2, it is preferable to use a mold material that is open so as to be easily diffused in the width direction of the preform 2, and for example, an aluminum C channel can be used as the resin injection port 4. . Further, the groove for allowing the resin to flow in the width direction of the preform 2 may be processed into the single-sided mold 1. The resin pot 5 is installed near the resin injection port 4 and communicated with the injection line 16. The injection line 16 is not particularly limited, but a larger inner diameter is preferable in order to reduce pressure loss.

  On the other hand, a ventilation material 7 is arranged on the right side of the preform 2 so that a part of the left side is in contact with the preform 2 and the right side is connected to the suction port 6 so as to be sucked under reduced pressure. The vacuum suction port 6 is communicated with a vacuum trap 12 and a vacuum pump 13 in this order through a vacuum suction line 11. The vacuum suction port 6 only needs to be open at the bottom as in 4 above.

  The form of the ventilation material 7 is not particularly limited as long as the preform 2 can be sucked under reduced pressure. It suffices that at least a part is in contact with the preform 2, and it can be arranged over the entire end of the preform.

The material of the ventilation material 7 is not particularly limited, and organic fiber cloth, inorganic fiber cloth, mesh material, and the like can be used. For example, a glass fiber woven fabric or mat material having a low basis weight, or a material having low ventilation resistance such as a synthetic fiber nonwoven fabric is preferable from the viewpoint of performing vacuum suction. Alternatively, a net-like sheet material used as the resin diffusion medium 3 is a preferable form in terms of low resin diffusion resistance and ventilation resistance. Alternatively, using a material having high ventilation resistance and flow resistance, when the resin reaches the ventilation material in the impregnation / curing process of 5 described later, the inside of the ventilation material up to the vacuum suction port is reached when it reaches the ventilation material. The resin pressure in the preform can be stabilized by flowing at a low flow rate. For example, it is also an embodiment of the present invention to treat a part of the fiber reinforced base material constituting the preform as a ventilation material.
2. Step of sealing the vacuum suction port 6 Next, a seal 8a is disposed so as to surround the vacuum suction port 6 and at least a portion of the ventilation material 7 that is not in contact with the preform 2, and the vacuum suction port is sealed at the seal 8a with the airtight material 9. 6 and the ventilation material 7 are covered. The airtight material 9 is not particularly limited as long as it has a function of not allowing the resin to permeate. However, a highly airtight film material used in the bag material 10 is preferable from the viewpoint of shape followability. A highly airtight resin sheet such as an elastic sheet or a Teflon (registered trademark) sheet may be used. Moreover, although there is no shape follow-up property, a metallic or resin processed product may be used.

  As the seal 8a, an adhesive tape or an elastic seal may be used, and a sealant tape is preferably used to further improve the sealing performance. It is also possible to use two or more types of seals by using them functionally.

  Further, by using a tape material such as an adhesive tape made of polyethylene, for example, as the airtight material 9, it is preferable in terms of simplifying the operation that the end portion of the tape also serves as the seal 8a and is hermetically sealed. . Further, the vacuum suction port 9 may have a wide opening, for example, similar to the airtight material 9 so as to have the function of the airtight material 9, for example, made of metal, nylon, polyethylene, etc. It is also possible to seal the periphery with a seal 8a using a pipe material or a channel material made of a resin material having a high sensitivity. Alternatively, an elastic material such as silicon can be used to have the function of the seal 8 a in addition to the functions of the vacuum suction port 6 and the airtight material 9.

  As shown in FIG. 1, the seal 8a can be disposed on the right side surface of the preform 2 to prevent a short path that passes through the fuzz of reinforcing fiber on the right side of the preform 2 or the gap between the films. More preferred. Further, in the case of the structure shown in FIG. 1, in order to prevent the seal 8a from filling the gap of the ventilation material 7 and closing the suction pressure reducing path, is the airtight material disposed between the seal and the ventilation material? More preferably, an airtight material is placed under the seal.

In this process, the vacuum suction port 6 and the ventilation material 7 are completely cut off from the cavity in the bag formed in the bagging process 3 for the entire molded part described later, and only the preform 2 serves as a vacuum suction / resin flow channel. It becomes a connected structure.
3. Next, the sealant 8b is disposed around the entire molded portion set up to the above-described steps, and the bag material 10 covers the entire bagging process. The bag material 10 is not particularly limited as long as it is a highly airtight and flexible material. For example, a nylon film material may be used.
4). Depressurization Step Next, the suction side valve 14 a is opened, and the inside of the bag is depressurized from the depressurization suction port 6. In order not to leave air in the molded body, the pressure is preferably reduced to 10 torr or less. In order to prevent air leakage into the bag, the inside of the cavity may be decompressed by double bagging the first bag.
5). Resin impregnation / curing step Next, the injection side valve 14 b is opened, and the resin in the resin pot 5 flows in from the resin injection port 4 due to the differential pressure between the atmospheric pressure and the degree of vacuum in the preform 2. The resin is first filled in the full length direction of the injection port 4 (the width direction of the preform 2), and then diffuses in the resin diffusion medium 3 in the direction of the arrow in the figure. Here, in the case of the prior art, after diffusion in the diffusion medium 3, the resin flow front has a gap in the cavity such as wrinkles of the bag material 10 or fiber fluff on the side of the preform 2. Since these generally have lower flow resistance than the preform 2, they pass through the path 106 indicated by the broken line arrow from the regular resin impregnation path, and as a result of a short path to the vacuum suction port 6, the vacuum suction port 6 is blocked. There was a problem that the degree of vacuum on the vacuum suction port 6 side was lowered. As a result, the impregnation speed in the preform 2 is slowed down, and an unimpregnated part may remain in the end.

  However, in the method of the present invention, in order to prevent a short path of the resin with the airtight material 9, the degree of vacuum on the decompression suction port 6 side is maintained, and the resin in the diffusion medium 3 flows inside the preform 2 through the flow front 101, It becomes possible to impregnate a regular path | route with a regular flow volume in order of 102,103, and generation | occurrence | production of the non-impregnation part of a molded object can be prevented.

  In addition, as resin to be used, thermosetting resins, such as an epoxy, unsaturated polyester, phenol, and vinyl ester, are preferable in terms of moldability and cost.

  When the resin impregnation into the preform 2 is completed, the injection side valve 14b is closed. The valve 14a on the suction side may be left open when volatile gas is desired to be removed or when the fiber volume content of the molded body is desired to be increased, but may be closed if surface smoothness is required. good. Next, if necessary, the temperature of the molded part is raised to the curing temperature to solidify the molded body.

  According to the present invention, that is, the degree of vacuum on the side of the vacuum suction port 6 is maintained by sealing the vacuum suction side and preventing the short path of the resin. It became possible to manufacture FRP without an impregnation part.

Example 1
In FIG. 1, first, a unidirectional carbon fiber woven fabric ("Torayca" T800S × 190 g / m ² basis weight, size 300 mm × 100 mm, manufactured by Toray Industries, Inc.) on an aluminum flat mold 1 whose surface is coated with a release material. ) 32 ply laminated Preform 2 was placed. Next, a peelable ply 15 (nylon taffeta) having releasability and a # 400 mesh polypropylene mesh as the resin diffusion medium 3 were placed on the preform 2.

  Next, on the left side of the resin diffusion medium 3, a resin injection port 4 with an opening of an aluminum C-channel material positioned downward is disposed. The resin pot 5 was installed near the resin injection port 4 and communicated with an injection tube 16 made of nylon having an inner diameter of φ6 mm. On the other hand, on the right side, a # 400 mesh polypropylene net with 20 mm of the left end laid on the mold side of the preform 2 is arranged as the ventilation material 7, and an aluminum C channel material is placed on the right side of the ventilation material 7. A vacuum suction port 6 with the opening portion down was disposed. The vacuum suction port 6 communicated with the vacuum trap 12 and the vacuum pump 13 through a vacuum suction line 11 using a nylon tube having an inner diameter of φ6 mm.

  Next, a sealant 8a is disposed along the right side surface of the preform 2 so as to surround the decompression suction port 6 and the portion of the ventilation material 7 that is not in contact with the preform 2, and a nylon film is used as the airtight material 9. Was used to cover a part of the vacuum suction port 6 and the ventilation material 7 from the sealant 8a.

  In the above process, the reduced pressure suction port 6 and the ventilation material 7 are cut off from the cavity in the bag and connected to the preform 2 only.

  Next, the sealant 8b was disposed around the molded portion set up to the above-described steps, and the bag material 10 was entirely covered with a nylon film. The suction side valve 14a was opened, and the pressure in the bag was reduced to 1 torr from the reduced pressure suction port.

  Next, after the temperature of the preform 2 was heated to 60 ° C., the injection side valve 14 b was opened, and the resin in the resin pot 5 was injected from the resin injection port 4. As the resin, Toray RTM epoxy resin TR-A36 was used. The resin is instantaneously filled in the resin injection port 4 and diffused in the resin diffusion medium 3 in about 5 minutes, and then impregnated in the plate thickness direction of the preform 2. The outflow (arrival) of the resin was confirmed. Since the resin was completely impregnated into the preform 2, the injection side valve 14b was closed.

  Next, the temperature of the preform 2 was raised to 130 ° C. while the suction side valve 14a was opened, and the resin in the preform 2 was cured. After confirming the curing of the resin, the molded product was demolded. The molded product which was removed from the mold was a non-impregnated resin-free product.

It is sectional drawing of the vacuum RTM apparatus which concerns on 1st Example of the manufacturing method of this invention, and shows a mode that resin in the resin pot 5 is inject | poured, depressurizing the inside of the preform 2. FIG. It is a top view of the vacuum RTM apparatus of FIG.

Explanation of symbols

1: Mold 2: Preform 3: Resin diffusion medium 4: Injection port 5: Resin pot 6: Suction port 7: Ventilation material 8a: Seal (seal that seals the suction side)
8b: Sealant 9: Airtight material 10: Bag material 11: Suction line 12: Vacuum trap 13: Vacuum pump 14a: Suction side valve 14b: Injection side valve 15: Peel ply 16: Injection line 101: Flow front 1
102: Flow front 2
103: Flow front 3
106: Short path route

Claims (6)

A method for producing FRP, comprising at least the following steps (A) to (E):
(A) A setting step in which a preform made of a reinforcing fiber base, a vacuum suction port, and a resin injection port are installed on a mold.
(B) A sealing step of a suction part that connects the preform and the vacuum suction port with a ventilation material, and then seals and covers the entire vacuum suction port and at least a part of the ventilation material with an airtight material.
(C) A sealing step for the entire molding unit, in which the preform, the vacuum suction port, the resin injection port, the ventilation material, and the molding unit that covers the suction unit on the molding die are sealed with a bag material, and are covered and sealed.
(D) A depressurization step of depressurizing the entire molded part covered with the bag material by suction from the depressurization suction port.
(E) A resin impregnation and curing step in which a resin is injected from the resin injection port and the reinforcing fiber base material is impregnated with the resin, and then the resin is cured. 2. The method for producing FRP according to claim 1, wherein a material having a function of a vacuum suction port is used as an airtight material in the sealing step of the suction part of (B). The organic fiber fabric, inorganic fiber fabric, mesh material, resin diffusion medium, or a part of a fiber reinforced base material constituting the preform is used as the ventilation material. FRP manufacturing method. The method for producing FRP according to claim 1, wherein at least a part of the preform is sealed. The method for producing FRP according to any one of claims 1 to 4, wherein an airtight material is inserted into at least a part between the preform and the ventilation material. 6. The FRP production according to any one of claims 1 to 5, wherein a cross-sectional shape of the preform is rectangular, C-type, I-type, L-type, Z-type, T-type, or hat-type. Method.

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