JP2006198790A - Manufacturing method of frequency selecting plate-laminated fiber-reinforced plastic panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a frequency selecting plate-laminated fiber-reinforced plastic panel effectively prevented from interlayer delamination without forming an air trap between a frequency selecting plate and a core material by a vacuum resin transfer molding method. <P>SOLUTION: A liquid adhesive 2 comprising a two-pack type epoxy resin or the like is uniformly applied to the upper and under surfaces of the core material 1 selected from a foam material, a syntactic foam material and wood and the frequency selecting plate 5 equipped with a plurality of through-holes 4 are laminated on the coated core material 1. After the liquid adhesive 2 is applied to the upper and under surfaces of the core material 1, the frequency selecting plates 5, each of which is obtained by respectively forming a plurality of the through-holes 4 to a metal foil 3 between the patterns thereof, are laminated on both surfaces of the core material 1 and the whole of the frequency selecting plates 5 is uniformly leveled by a brush or an iron to be integrally formed on the core material 1. At this time, the air bubbles, which get mixed in the gaps between the core material 1 and the frequency selecting plates 5 from the through-holes 4 formed to the selecting plates 5, or the air issued from the surface of the core material 1 is pushed to the sides opposite to the adhesive surfaces of the core material 1 along with the flow of the liquid adhesive 2. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a fiber reinforced plastic panel having a frequency selective surface laminated thereon, and more specifically, a frequency selective plate used for a ship radome (AEM / S: enclosed mast) or the like is laminated. The present invention relates to a method for manufacturing a fiber reinforced plastic panel in which frequency selective plates are manufactured by manufacturing a large-sized fiber reinforced plastic panel by a vacuum-assisted resin transfer molding method (VaRTM).

  Conventionally, when a resin molded product such as a fiber reinforced plastic (FRP) panel is manufactured, a resin transfer molding method (RTM) or a vacuum resin transfer molding method (VaRTM) is known. With the development of fiber reinforced plastic panels on the hull, there is a limit to molding large resin moldings in the autoclave method, so the development of fiber reinforced plastic panels by the vacuum resin transfer molding method (VaRTM) is underway. (For example, refer to Patent Document 1).

  Also, in recent years, ship radomes (AEM / S: Enclosed Mast) to which a frequency selective surface (FSS) is applied to stealth the ship's upper mast (to make it difficult to be captured by radar). ) Is also under development.

  However, in the case of ship radomes, the honeycomb core sandwich panel structure using GFRP (glass fiber reinforced plastic) as the skin material is a polyhedral structure that combines panels, and it cannot be molded by the autoclave curing equipment. Size. For this reason, a molding method based on a vacuum resin transfer molding method (VaRTM) is desirable, but a molding method in which a frequency selection plate as described above is incorporated in a ship radome has not yet been proposed.

By using the vacuum resin transfer molding method (VaRTM) described above, the frequency selection plate is pre-bonded to a core material (for example, foam material, syntactic foam material, wood), and this frequency selection plate core panel is used as the core material. Is possible. However, when the frequency selection plate is bonded to the core material via an adhesive, an air trap (air pocket) is generated between the frequency selection plate and the core material due to bubbles such as air coming out of the adhesive and the core material. This has become clear from the experimental results of the inventors of the present application and the like, and this air trap later caused delamination of the frequency selective plate core panel.
JP 2001-96611 A

  The present invention has been devised by paying attention to such a conventional problem. When the frequency selection plate and the core material are bonded through an adhesive, an air trap is provided between the frequency selection plate and the core material. A fiber reinforced plastic panel with laminated frequency selective plates that can effectively prevent the subsequent delamination of the frequency selective plate core panel and efficiently produce large resin moldings by the vacuum resin transfer molding method. An object of the present invention is to provide a manufacturing method.

  In order to achieve the above object, the present invention uniformly coats the surface of the core material with a liquid adhesive, and then laminates at least one or more frequency selective plates each having a through hole between the metal foil patterns to make the whole uniform. After the laminate is placed on a rubber-like elastic sheet laid on a metal base member, the fiber reinforced base material is laminated on the laminate, In a state where the laminated body in the vacuum bag is vacuumed, the reactive resin material is supplied from one side of the laminated body, and the reactive resin material is uniformly sucked from the other side of the laminated body, The gist of the invention is to uniformly impregnate the fiber-reinforced base material with the reactive resin material and to cure it.

  Here, the through hole formed between the metal foil patterns of the frequency selection plate has a diameter of 0.5 to 3.0 mm, and the core material is one selected from foam material, syntactic foam material, and wood. It is what you use.

  With such a manufacturing method, when the frequency selection plate and the core material are bonded via an adhesive, an air trap is not generated between the frequency selection plate and the core material. Peeling is effectively prevented, and a large resin molded product can be efficiently produced by a vacuum resin transfer molding method.

  In the present invention, after the liquid adhesive is uniformly applied to the surface of the core material as described above, at least one or more frequency selection plates each having through holes formed between the patterns of the metal foil are laminated to uniformly uniform the whole. After the laminate is placed on a rubber-like elastic sheet laid on a metal base member, the whole is filmed with a fiber reinforced base material laminated on the laminate. In the state where the laminated body in the vacuum bag is covered, the reactive resin material is supplied from one side of the laminated body, and the reactive resin material is uniformly sucked from the other side of the laminated body, thereby reinforcing the fiber. Since the base material is uniformly impregnated with the reactive resin material and cured, the air gap between the frequency selective plate and the core material is not generated, and the interlayer of the frequency selective plate core panel is later Away to effectively prevent, there a large molded resin product has the effect of that can be efficiently produced by a vacuum resin transfer molding method.

  Embodiments of the present invention will be described below with reference to the accompanying drawings.

  FIG. 1 is an exploded perspective view of a fiber reinforced plastic panel in which frequency selective plates according to the present invention are laminated, FIG. 2 is a front view of the frequency selective plate of the present invention, and FIG. 3 is a fiber reinforced laminated integrally. The perspective view of a plastic panel is shown, The said fiber reinforced plastic panel is a liquid adhesive 2 which consists of a two-component epoxy resin etc. on the front and back of the core material 1 selected from foam material, syntactic foam material, and wood. A uniform film is applied, and a frequency selective surface (FSS) 5 having a plurality of through holes 4 is laminated.

  As the lamination method, a frequency selection plate 5 (a plurality of through holes 4 are formed between the patterns of the metal foil 3 as shown in FIG. 2 after the liquid adhesive 2 is applied to the front and back surfaces of the core material 1 ( FSS: frequency selective surface) is laminated and the whole is uniformly and uniformly formed with a spatula or the like. At this time, air bubbles (air traps) mixed between the core material 1 and the frequency selection plate 5 from the through-hole 4 formed in the frequency selection plate 5, the air emitted from the surface of the core material 1, etc. are liquid. It pushes to the opposite side of the bonding surface with the flow of the adhesive 2, thereby effectively removing the delamination of the frequency selection plate core panel later without generating an air trap between the frequency selection plate 5 and the core material 1 later. It can be prevented.

  In addition, the frequency selective plate 5 (FSS: frequency selective surface) is formed of a light metal plate, and in order to transmit or block a specific frequency, for example, a small piece of metal (referred to as a patch) having the same shape. Can be arranged in an array, or can be used by forming a structure in which holes having the same shape (called apertures) are cut out from a metal plate in an array.

  The size of the through holes 4 formed between the patterns of the metal foil 3 is preferably 0.5 mm to 3.0 mm in diameter. By setting the size of the through hole 4 to a diameter of 0.5 mm to 3.0 mm, it is possible to satisfy both the dischargeability and adhesiveness of the liquid adhesive at a higher level.

  In this way, a large laminate S formed by laminating at least one frequency selection plate 5 through the liquid adhesive 2 is manufactured by a vacuum resin transfer molding method (VaRTM) as shown in FIG. Is.

  Next, a method for manufacturing a large fiber reinforced plastic panel incorporating the frequency selection plate 5 as described above by a vacuum resin transfer molding method (VaRTM) will be described in detail.

  First, a rubber-like elastic sheet 7 is laid on a metal base member 6. A fiber-reinforced resin sheet 8 (fiber-reinforced base material) and a frequency selection plate 5 are placed on the rubber-like elastic sheet 7 with a liquid adhesive 2. Then, the core material 1 made of a nonmetallic material adhered to the front and back surfaces is placed, and at least one or more fiber reinforced resin sheets 8 (fiber reinforced base materials) are sequentially laminated to form a laminate W.

  Thereafter, a tapered dam 9 is disposed on the side surface of the laminated body W on the rubber-like elastic sheet 7, and a spiral hose 10 covered with an air weave is disposed on the suction side so that the entire laminated body W is made of resin. The material inlet and the suction pipe 11 connected to the hose 10 are covered with a film-like vacuum back 12 disposed on the periphery, and the periphery is sealed on the base member 6 with an adhesive tape 13 or the like.

  Thereafter, the laminated body W in the vacuum back 12 is uniformly vacuumed by the vacuum pump P connected to the vacuum pipe 14, and the laminated body is connected to the resin material supply tank 15 from the resin material supply port 15 in a vacuum state. A normal temperature curable reaction resin material Q (for example, a thermoplastic material such as vinyl ester) is supplied to the fiber reinforced resin sheet 8 and uniformly impregnated, and impregnated and cured by reaction heat of the reaction resin material Q.

  Thus, since the reaction resin material Q is uniformly supplied at a uniform pressure to be impregnated and cured, the reaction resin material Q does not directly contact the metal base member 6 having a large heat capacity. As a result, resin molding is performed. The reaction heat generated by the object is not absorbed by the metal base member 6 and the curing failure can be effectively prevented, and a product with no unevenness can be manufactured.

  Thus, when producing a large fiber-reinforced resin molded product, the reaction resin material Q is extracted using the spiral hose 10 covered with the air weave as described above, so that the resin material is given a time difference. The reaction resin material Q can be uniformly impregnated.

As an embodiment of the present invention,
For example, the size (vertical × horizontal × thickness) of the laminated body W made of a fiber reinforced resin molded product: 4 m × 7 m × 10 mm, suction pressure by the vacuum pump P: 0.1 Mpa
Resin material supply amount of reaction resin material Q from resin material supply tank 15: 420 kg
It should be noted that the flow rate is initially high and gradually decreases.

It is a disassembled perspective view of the fiber reinforced plastic panel which laminated | stacked the frequency selection board which implemented this invention. It is a front view of the frequency selection board of this invention. It is a perspective view of the fiber reinforced plastic panel laminated | stacked integrally. It is a partially expanded sectional view of a fiber reinforced plastic panel.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Core material 2 Liquid adhesive 3 Metal foil 4 Through-hole 5 Frequency selection board 6 Base member 7 Rubber-like elastic sheet 8 Fiber reinforced resin sheet 9 Dam 10 Hose 11 Suction pipe 12 Vacuum back 13 Adhesive tape 14 Vacuum piping 15 Resin material supply Tank W Laminate Q Reactive resin material

Claims (3)

After uniformly applying the liquid adhesive to the surface of the core material, at least one layer of frequency selection plates each having a through hole formed between the patterns of the metal foil is laminated and uniformly formed as a whole. After this laminate is placed on a rubber-like elastic sheet laid on a metal base member, the whole is covered with a film-like vacuum back in a state where a fiber reinforced base material is laminated on the laminate, While the laminated body in the vacuum back is vacuumed, the reactive resin material is supplied from one side of the laminated body, and the reactive resin material is uniformly sucked from the other side of the laminated body, so that the reactive resin material is uniformly applied to the fiber reinforced substrate. A method of manufacturing a fiber reinforced plastic panel in which a frequency selective plate that is impregnated and cured is laminated. The method for manufacturing a fiber-reinforced plastic panel in which frequency selection plates are laminated according to claim 1, wherein the through holes formed between the metal foil patterns of the frequency selection plates have a diameter of 0.5 to 3.0 mm. The manufacturing method of the fiber reinforced plastic panel which laminated | stacked the frequency selection board of Claim 1 or 2 using the said core material selected from foam material, syntactic foam material, and wood.

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