JP2006167977A - Preform, preform manufacturing apparatus and preform manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a preform capable of being molded without getting out of shape when reinforcing fibers not impregnated with a resin are laminated to mold the preform and capable of accurately setting the amount ratio of reinforcing fibers and the resin even when an FRP molded product is manufactured from the preform impregnated with the resin, a preform manufacturing apparatus and a preform manufacturing method. <P>SOLUTION: An arranging device 2 for winding and arranging thermoplastic fibers is arranged to wind the thermoplastic fibers YA around a reinforcing fiber composition layer, wherein a plurality of reinforcing fiber layers are laminated by a braiding manufacturing method, and, after reinforcing fibers (yarns Y) and the thermoplastic fibers YA are alternately laminated, the thermoplastic fibers YA are heated and melted to fix a plurality of the composition layers of the reinforcing fibers (yarns Y). <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a preform, a preform manufacturing apparatus, and a manufacturing method therefor, in which a plurality of reinforcing fibers not impregnated with a resin are laminated in advance when a cylindrical preform is composed by a braider apparatus. is there.

  Recently, various composite panels have been manufactured with fiber reinforced plastics (FRP) made of high-strength yarns such as glass fiber, carbon fiber, or nylon fiber. It is also widely applied. Recently, applications for weight reduction of aircrafts and automobiles have been expanded.

  In general, when manufacturing a large composite panel, a tape-shaped prepreg (a reinforced fiber previously impregnated with a matrix resin) is laminated on a mold having a predetermined shape, and then heat-cured and molded. .

  Recently, a laminating method called a fiber placement method that automatically performs a laminating process is known, and a tape-shaped prepreg, which is a reinforcing fiber impregnated with a resin in advance, is laminated while being pressed on the mandrel surface, and is provided separately. This is a molding method in which a resin impregnated by a heating device or an autoclave is melted and fixed.

  In general, autoclave molding, which is known as a typical heat curing method for FRP, integrally accommodates a molded product obtained by laminating a prepreg obtained by impregnating a reinforcing fiber with a matrix resin in a mold having a desired shape. Are heated and pressurized to form FRP.

  However, after laminating these tape-shaped prepregs, in the method of producing a composite panel by heat-curing, the production of the prepreg is costly and large enough to accommodate a large composite panel. There was a problem that an autoclave was necessary.

  Therefore, RTM (resin transfer molding), which is an injection molding method that can significantly shorten the molding cycle, compared to a molding method in which a prepreg is molded and then heated and pressurized by an autoclave or the like to produce a structure. Vacuum suction inside the mold, Va-RTM method that assists resin impregnation, RIM (resin injection molding), etc., placed the reinforcing fiber base that is not impregnated with resin in a mold with a desired shape. A molding method is also known in which a resin is collectively impregnated later to produce an FRP molded product.

  Further, a braiding method is generally known as a method for producing FRP, and a plurality of reinforcing fiber yarns are disposed around a mandrel having various shapes such as a cylindrical shape, a T shape, an I shape, and a tetrapot shape. A braider apparatus is generally known in which a composition (reinforced fiber preform) having a composition structure is formed by intermingling the above.

  And the fiber reinforced composite member of composite shape is also manufactured by combining the obtained reinforcing fiber preforms of various shapes.

Furthermore, when laminating reinforcing fibers using the above-described braider device, a method for molding a reinforcing fiber preform that has been temporarily fixed with an adhesive film or a thermoplastic resin has already been filed (for example, see Patent Document 1). .
JP 2001-30361 A (page 1-4, FIG. 1)

  In the above fiber placement method, the tape-shaped prepreg can be automatically laminated while being heated and pressurized. However, a step of impregnating the reinforcing fibers with the resin in advance is necessary, and the molding cycle of the FRP composite member is performed. It cannot be shortened.

  Furthermore, it is difficult to store for a long time in the state of the preform impregnated with the resin, and there is a problem that the quality of the preform is deteriorated due to deterioration of the resin.

  In the RTM, Va-RTM method, RIM method, etc., a reinforcing fiber base not impregnated with resin is arranged inside a mold having a desired shape, and then the resin is forcibly injected. Thus, it is difficult to manufacture FRP products of the same quality by accurately aligning the proportions of the reinforcing fibers and the resin.

  An object of the present invention is to solve the above-mentioned problems, when forming a preform by laminating reinforcing fibers not impregnated with a resin, the preform can be formed without collapsing, and the resin is impregnated with the FRP. The object of the present invention is to provide a preform, an apparatus for manufacturing a preform, and a method for manufacturing the preform, which can accurately align the proportions of the reinforcing fibers and the resin when forming a molded product.

  In order to achieve the above object, the invention according to claim 1 is a method in which a plurality of layers are formed by alternately laminating reinforcing fibers and thermoplastic fibers so that the lowermost layer and the uppermost layer become reinforcing fiber layers. The preform is characterized in that the thermoplastic fiber is heated and melted to fix a plurality of composition layers of the reinforcing fibers.

  According to the invention according to claim 1 having the above-described configuration, the reinforcing fiber is composed independently of the thermoplastic fiber, so that the reinforcing fiber does not interfere with the thermoplastic fiber and become entangled. Furthermore, since the heat-melted thermoplastic fiber serves as an adhesive to fix the reinforcing fiber, the molded preform does not lose its shape.

  The invention according to claim 2 is such that the reinforcing fiber is composed by a braiding method, the thermoplastic fiber is wound around the composition layer of the reinforcing fiber, and the distribution amount thereof becomes a predetermined value. It is characterized by being set in advance.

  According to the invention according to claim 2 having the above-described configuration, since the preform contains a predetermined amount of the thermoplastic fiber between the reinforcing fibers, the ratio of the amount of the reinforcing fiber and the thermoplastic fiber is accurately determined. An FRP molded product with a stable component can be obtained.

  The invention according to claim 3 is a preform manufacturing apparatus in which reinforcing fibers are sequentially formed on the surface of a mandrel serving as a preform mold by a braiding method, and a plurality of reinforcing fiber layers are laminated. An arrangement device for winding and arranging thermoplastic fibers on a fiber composition layer is provided.

  According to the invention which concerns on Claim 3 which has said structure, a thermoplastic fiber can be comprised independently of the composition of a reinforced fiber.

  According to a fourth aspect of the present invention, the mandrel is reciprocated back and forth in the axial direction to braid a plurality of reinforcing fiber layers, and the arrangement device is disposed on both sides of the composition part for braiding the reinforcing fibers. The winding speed of each of the arranging devices and the reciprocating speed of the mandrel can be individually set to control the distribution amount of the thermoplastic fibers.

  According to the invention which concerns on Claim 4 which has said structure, while being able to laminate | stack and comprise a thermoplastic fiber irrespective of the moving direction of a mandrel, it can mix | blend the amount of desired thermoplastic fibers. .

  In the invention according to claim 5, after the thermoplastic fibers are wound between the respective layers of the reinforcing fibers that are laminated by a braiding method and the reinforcing fibers and the thermoplastic fibers are alternately laminated, A preform manufacturing method in which plastic fibers are heated and melted to fix a plurality of layers of reinforcing fibers, and a mandrel as a preform mold is reciprocated back and forth in the axial direction to form a plurality of reinforcing fiber layers. When performing the wrapping, the thermoplastic fibers are sequentially wound between the layers of the reinforcing fibers by an array device for winding and arranging the thermoplastic fibers, and the reciprocating speed of the mandrel and the winding speed of the array device are individually set. The distribution amount of the thermoplastic fiber can be controlled.

  According to the invention concerning Claim 5 which has said structure, it can be set as the manufacturing method of the preform which contains a predetermined ratio thermoplastic fiber and can be comprised without damaging a reinforced fiber.

  According to the present invention, when a reinforcing fiber not impregnated with a resin is composed, a plurality of layers can be laminated stably and reliably. Furthermore, it is possible to obtain a preform, a preform manufacturing apparatus, and a manufacturing method thereof that can be molded without losing shape and can accurately control the ratio between the amount of reinforcing fiber and the amount of thermoplastic fiber contained. it can.

  DESCRIPTION OF EMBODIMENTS Hereinafter, embodiments of a preform and a preform manufacturing apparatus and a manufacturing method thereof according to the present invention will be described in detail with reference to FIGS. 1 to 5.

  First, a configuration example of a braider will be described with reference to FIGS. 1 and 2. The braider BR according to the present embodiment includes a braider body Bb, a mandrel moving device Bm, and an arrangement device 2 on the machine base 1.

  The mandrel moving device Bm is a device that supports a mandrel M, which is a mold for forming a preform by molding reinforcing fibers by a braiding manufacturing method, such that the mandrel M can be moved horizontally, and the braider body Bb is the mandrel moving device. The yarn Y (reinforcing fiber such as glass fiber or carbon fiber) is braided (composed) on the mandrel M supported by Bm. In addition, the arrangement device 2 is a device for composing another yarn (for example, thermoplastic fiber YA) that is not a reinforcing fiber. In this embodiment, the arrangement device 2 is arranged on both sides of the composition position P of the yarn Y. The arrangement devices 2A and 2B can be driven independently.

  That is, while the mandrel M is moved in one direction (A direction in the figure), the yarn Y composed of reinforcing fibers is further composed, and the thermoplastic fiber YA is wound by the arranging device 2A so as to be laminated thereon. can do. After that, the second layer yarn Y is composed while moving the mandrel M in the reverse direction (B direction in the figure), and further, the thermoplastic fiber YA is wound and laminated thereon by the arrangement device 2B. Can do. In this manner, a plurality of layers of the yarn Y and the thermoplastic fiber YA, which are reinforcing fibers, can be alternately stacked while moving the mandrel M to the left and right in the horizontal direction.

  The braider body Bb has a curved upper plate U having a radius of curvature R disposed in a substantially cylindrical machine base Fb having a horizontal axis and having an opening e on one side, and is formed in the circumferential direction of the upper plate U. A bobbin carrier C that travels along the track, a driving device D that causes the bobbin carrier C to travel along the track, and a yarn guide device G.

  Then, the yarn Y (reinforcing fiber) drawn out from the bobbin placed on the bobbin carrier C in the axial direction of the bobbin gathers at substantially the center of the upper plate U, and the position of the mandrel M attached to the mandrel moving device Bm is The composition position P formed on the mandrel M is positioned at the center of the upper plate U.

  When braiding, the bobbin carrier C performs a braiding composition while moving on the raceway surface, but the driving device D is configured so that the moving speed of the bobbin carrier C can be changed individually and freely. Yes. Therefore, when laminating a plurality of layers, the braid angle (combination angle) can be changed between the inner layer and the outer layer, and the physical characteristics of the braiding composition to be molded can be freely set.

  Thus, the bobbin carrier C is caused to travel along the track by the driving device D, and the position of the mandrel M is controlled by the mandrel moving device Bm. As a result, the braiding in which a large number of yarns Y are mixed at a predetermined set angle. A composition is formed. Further, when the triaxial composition is formed by combining the center yarn y, which is an axial fiber having a set angle of 0 °, in addition to the yarn Y, which is a circumferential fiber formed at a predetermined set angle, it is further strengthened. A braiding composition (preform) can be formed.

  That is, by interlacing the central yarn y from the bobbin carrier C arranged almost horizontally on the frame Fb ′ of the machine base Fb and the yarn Y unwound and assembled from the bobbin carrier C traveling along the track, A triaxial composition can be obtained.

  After the production of the braid by the braiding method is completed, the yarn Y and the central yarn y are cut by an appropriate cutting device, and the braiding composition is cut in the radial direction and taken out as a single preform.

  Here, the assembly angle will be described. Braid angle refers to the angle formed by the braid with respect to the axial direction, small braid angle refers to the angle at which the braid is nearly parallel to the axial direction (close to 0 °), and large braid angle refers to the direction orthogonal to the axial direction. It is the angle that approaches. The center yarn y is parallel to the axis and the set angle is 0 °.

  Next, the arrangement device 2 will be described with reference to FIGS. 3 and 4.

  In this embodiment, as the arrangement device 2, the arrangement devices 2A and 2B are arranged on both sides of the composition position P of the yarn Y (see FIG. 1), respectively, and the reinforcing fiber composition layer is formed by the braiding method. The thermoplastic fiber YA is wound around the top. The arrangement devices 2A and 2B are each configured to be driven independently, and the thermoplastic fibers YA can be wound around the reinforcing fiber layer formed regardless of the moving direction of the mandrel M. Therefore, the reinforcing fiber and the thermoplastic fiber YA can be alternately laminated. Since the arrangement devices 2A and 2B are the same device, the arrangement device 2 will be described using the same reference numerals.

  The arrangement device 2 includes a drive body 20 configured to be rotatable around a mandrel M, a thread supply device 22 disposed on one side of the disk frame 21 constituting the drive body 20, and the power of the disk frame 21. And a drive motor 25 as a source.

  FIG. 4 shows an example in which three yarn supply devices 22 are equally arranged on the circumference, but the number of the yarn supply devices 22 can be increased or decreased depending on the yarn amount of the thermoplastic fiber YA to be wound. A predetermined number of yarn supply devices 22 may be installed on the circumference of the disk frame 21.

  The drive body 20 includes a disk frame 21, a receiving member 23 on which the disk frame 21 is rotatably fitted, and a stop member 24. The disk frame 21 is formed in a substantially circular shape, and a through hole 21a is provided at the approximate center thereof, and a receiving member 23 is loosely fitted in the through hole 21a.

  The receiving member 23 is inserted into the through hole 21 a from the other side surface of the disk frame 21, and a stopper member 24 is fitted from one side surface of the disk frame 21 to an end portion protruding from the disk frame 21. The receiving member 23 and the stopper member 24 are fixed to the braider base 1 so that the relative position cannot be changed by a frame or the like (not shown).

  Projecting ribs 23 a and 24 a for positioning the disk frame 21 loosely fitted to the receiving member 23 are formed on the end portion of the receiving member 23 and the stopper member 24 so as to protrude along the respective outer peripheral surfaces. The disk frame 21 is positioned by the array device 2 by the protruding ribs 23a and 24a, and is rotated by the drive motor 25 so that the relative position cannot be changed. The receiving member 23 and the stopper member 24 are similarly provided with the above-described through hole 21a at substantially the center thereof, and the mandrel M is inserted in the left and right direction at the approximate center of the through hole 21a. By setting it as such a structure, the yarns, such as a thermoplastic fiber, can be stably paid out from the yarn supply apparatus 22 to the mandrel M.

  Note that the receiving member 23 and the stopper member 24 are not separate members as described above, and may be integrally formed as long as the disk frame 21 is freely loosely fitted. Further, the receiving member 23 and the stopping member 24 are not limited to the configuration and arrangement shown in the present embodiment.

  On one side surface of the disk frame 21, the yarn supply device 22, guide ribs 27, and a counterweight 28 are disposed. The yarn supply device 22 includes a bobbin frame 22a and a bobbin 22b around which a thermoplastic fiber YA is wound. The bobbin 22b is rotatably supported by the bobbin frame 22a and rotates while feeding out the thermoplastic fiber YA. The guide rib 27 is disposed between the yarn supply device 22 and the through hole 21a, and the guide portion 27a of the thermoplastic fiber YA protrudes substantially perpendicularly from the front surface of the disk frame 21. A guide groove 27b is formed in the guide portion 27a, and the thermoplastic fiber YA fed out from the bobbin 22b is inserted into the guide groove 27b. Thus, by providing the guide rib 27, the thermoplastic fibers YA fed out from the yarn supplying device 22 are prevented from interfering with each other.

  The counter weight 28 is disposed at a symmetrical position of the yarn supply device 22 with respect to the central axis of the disk frame 21, and is balanced with the weight of the yarn supply device 22 in order to balance the rotational state of the disk frame 21. It has been adjusted. Since the disk frame 21 is rotationally driven by the drive motor 25 and further provided with the yarn supply device 22 in the radial direction, the disk frame 21 can be stably rotated by providing this counterweight 25. The thermoplastic fiber YA can be stably fed out from the yarn supply device 22.

  The thermoplastic fiber YA fed out from the yarn supply device 22 is extended to the outer peripheral surface of the triaxial composition 10 formed around the mandrel M, and is wound so as to cover the outer periphery of the triaxial composition 10. Then, the stacked body 11 is formed. That is, the thermoplastic fiber YA is drawn out from the direction substantially perpendicular to the central axis of the mandrel M through the guide rib 27 toward the winding position PA.

  The drive motor 25 is a power source for rotating the disk frame 21, and rotationally drives the disk frame 21 via an endless belt 29. Specifically, the drive motor 25 is mounted on the machine base 1 of the braider BR via the frame base 30, projects an output shaft 31 as a power transmission shaft from the side, and a pulley 32 is provided at the end of the output shaft 31. It is fixed. On the other hand, on the other side surface of the disc frame 21, a rib portion 21b projects substantially perpendicularly along the edge of the through hole 21a of the disc frame 21, and the endless belt 29 is interposed between the rib portion 21b and the pulley 32. It is installed.

  With the configuration described above, the driving force of the driving motor 25 is transmitted to the rib portion 21b of the disk frame 21 via the endless belt 29, and the disk frame 21 is rotationally driven. The drive mechanism for rotating the disk frame 21 is not only a belt drive type using an endless belt 29 but also a gear type that directly transmits a driving force by providing a gear on the output shaft 31 and the rib portion 21b. There may be.

  Here, the arrangement mechanism of the thermoplastic fibers YA by the arrangement device 2 will be described.

  When the disk frame 21 is rotated by the drive motor 25, the thermoplastic fiber YA is fed out from the bobbin 22b toward the winding position PA while the yarn supply device 22 disposed in the disk frame 21 is also rotated. . In the mandrel M located at the winding position PA, the triaxial composition 10 is already formed on the outer peripheral surface by the yarn Y and the center yarn y. When the mandrel M moves in the X direction, the portion of the mandrel M located at the winding position PA gradually shifts in the X direction, and the yarn supplying device 22 rotates while rotating around the central axis of the mandrel M in this state. By feeding out the plastic fibers YA, the thermoplastic fibers YA can be wound and arranged on the outer periphery of the triaxial composition 10 from a state substantially perpendicular to the central axis of the mandrel M. At this time, the moving speed of the mandrel M and the rotational speed of the driving body 20 can be controlled to adjust the orientation and distribution amount of the thermoplastic fiber YA.

  As described above, according to the present invention, the winding speed of each of the arranging devices 2A and 2B arranged on both sides of the composition part for braiding the reinforcing fiber (yarn Y), and the reciprocating speed of the mandrel M are as follows. Since the distribution amount of the thermoplastic fiber YA can be controlled by individually setting the value of the fiber, it is possible to accurately adjust the blending of the reinforcing fiber and the thermoplastic fiber to a predetermined value. Moreover, since it is controllable for each winding layer and the thermoplastic fiber wound between the composition layers of a plurality of reinforcing fibers can be set to a desired yarn amount, the component of the resulting reinforcing fiber preform Can be controlled between the inner layers, and the product quality can be stabilized.

  An example of the composition structure is shown in FIG. 5. In FIG. 5A, the mandrel M has a first reinforcing fiber layer Y 1, a first thermoplastic fiber layer YA 1, a second reinforcing fiber layer Y 2, and a second thermoplastic fiber. The place which laminated | stacked layer YA2 and the 3rd reinforcement fiber layer Y3 in order is shown.

  FIG. 5B shows the cross section, and it can be seen that the reinforcing fibers Y and the thermoplastic fibers YA are sequentially laminated. At this time, as described above, the distribution amount of the thermoplastic fiber YA can be adjusted to a predetermined yarn amount according to a desired product component.

  When a predetermined heat is applied to the preform formed on the mandrel M with a heater or high-temperature steam, the thermoplastic fiber dissolves and acts as an adhesive between the respective reinforcing fiber layers, thus forming a strengthened composition. The fiber can be fixed and the shape of the preform can be maintained.

  Also, if the configuration is such that the thermoplastic fiber YA is not wound around the outermost layer portion, the thermoplastic fiber does not exist on the surface of the composition base material, so the thermoplastic fiber dissolves and sticks to the preform surface when heated. And the surface can be kept clean.

  Since the reinforcing fiber Y is not previously impregnated with resin, the preform to be molded is a dry preform. According to the present invention, a preform that can be transferred and handled in the state of a molded product is obtained. Can do.

  As described above, the preform according to the present invention is obtained by alternately laminating reinforcing fibers and thermoplastic fibers so that the lowermost layer and the uppermost layer become reinforcing fiber layers, and then molding the thermoplastic fibers. And a plurality of composition layers of the reinforcing fibers are fixed.

  Further, according to the device of the present invention, the reinforcing fiber and the thermoplastic fiber are separately composed or wound, so that the reinforcing fiber and the thermoplastic fiber do not rub against each other during the composition. Therefore, it is also easy to mold a preform using carbon fibers that are easily fluffed. Furthermore, since the composition is heated after the composition to melt the thermoplastic fibers between the composed reinforcing fiber layers and fix the reinforcing fibers, the preform can be handled without deforming. Can do.

  As described above, according to the present invention, when a reinforcing fiber not impregnated with a resin is composed, a plurality of layers can be laminated stably and reliably without thread breakage or entanglement. Furthermore, the preform can be molded into a preform that does not lose its shape, and the ratio between the amount of reinforcing fiber and the amount of resin (dissolved thermoplastic fiber) can be accurately controlled, and a preform manufacturing apparatus and its A manufacturing method can be obtained.

It is a schematic side view of a braider machine provided with the arrangement device concerning the present invention. It is a schematic front view of a braider machine. It is a schematic side view of the arrangement device according to the present invention. It is a schematic front view of the arrangement device concerning the present invention. The composition laminated structure is shown, (a) is a schematic explanatory drawing which shows the whole laminated structure, (b) has shown the cross section of the laminated part.

Explanation of symbols

1 machine (blader's)
2 Arrangement device 22 Yarn supply device BR Braider M Mandrel Y Reinforcing fiber YA Thermoplastic fiber

Claims (5)

  After forming a plurality of layers by alternately laminating reinforcing fibers and thermoplastic fibers so that the lowermost layer and the uppermost layer are reinforcing fiber layers, the thermoplastic fibers are heated and melted to form a plurality of reinforcing fibers. A preform having a composition layer fixed thereto.   The reinforcing fiber is composed by a braiding method, and the thermoplastic fiber is wound around a composition layer of the reinforcing fiber, and the distribution amount is set in advance so as to be a predetermined value. The preform according to claim 1. A preform manufacturing apparatus in which reinforcing fibers are sequentially formed on a mandrel surface, which is a preform mold, by a braiding method, and a plurality of reinforcing fiber layers are laminated.
An apparatus for manufacturing a preform, comprising an arrangement device for winding and arranging thermoplastic fibers on the reinforcing fiber composition layer.   The mandrel is reciprocated back and forth in the axial direction to braid a plurality of reinforcing fiber layers, and the arraying devices are arranged on both sides of the composition part for braiding the reinforcing fibers, 4. The preform manufacturing apparatus according to claim 3, wherein the rotational speed and the reciprocating speed of the mandrel can be individually set, and the distribution amount of the thermoplastic fibers can be controlled. A thermoplastic fiber is wound on each composition layer of the reinforcing fibers that are laminated in a plurality of layers by the braiding method, and the reinforcing fibers and the thermoplastic fibers are alternately laminated, and then the thermoplastic fibers are heated and melted. A method for producing a preform for fixing a plurality of layers of the reinforcing fibers,
When braiding a plurality of reinforcing fiber layers by reciprocating a mandrel as a preform mold back and forth in the axial direction, the thermoplastic fibers are arranged between the reinforcing fibers by an arrangement device that winds and arranges the thermoplastic fibers. And the reciprocating speed of the mandrel and the winding speed of the arrangement device can be individually set to control the distribution amount of the thermoplastic fiber. Method.

Images