JP2006205475A - Manufacturing method of fiber-reinforced resin product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a fiber-reinforced resin product capable of easily obtaining even a long length fiber-reinforced resin product, of which the transport to the job site is difficult, on the site as an integrated product. <P>SOLUTION: A semi-manufactured product wherein a part of length is constituted only of reinforcing fibers with respect to the fiber-reinforced resin product is transported to the job site and the part constituted only of the reinforcing fibers is impregnated with a resin solution on the site and the impregnated part is cured. Since the contour dimension of the semi-manufactured product can be contracted as a whole by bending or the like because of the flexibility of the part constituted only of the reinforcing fibers, the semi-manufactured product can be easily transported. Further, by returning the semi-manufactured product to the original form of the product in a transport destination and impregnating the part constituted only of the reinforcing fibers with the resin liquid/curing the impregnated part to form a completed product, even the long length fiber-reinforced resin product restricted in the transport to the job site can be used on the site by ensuring the handling in a factory or the easiness to handle at the time of transport while holding the advantage of the fiber-reinforced resin product based on the continuous reinforcing fibers. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for producing a fiber-reinforced resin product, and is useful, for example, for producing a long sleeper.

The production method of fiber reinforced resin products, in which the continuous continuous fibers are impregnated with a thermosetting resin and passed through a mold to cure the impregnated resin, is a continuous production method, and it is possible to produce long products. Yes (for example, Patent Document 1, Patent Document 2, etc.).
Japanese Patent Publication No. 48-36420 JP, 2002-347131, A However, when a product length is restricted for transportation and a fiber reinforced resin product having a length exceeding this limit is required, a product piece having a length less than the limit is transported to the use site. A plurality of product pieces are joined by bolt joining or an adhesive. For example, fiber reinforced resin sleepers may be used as sleepers, and a large number of strips cross at a railroad branch, so a long sleeper that spans multiple tracks is required. It is difficult to transport the product from the manufacturing plant to the branch site of the railway track as an integrated object due to transportation regulations. Therefore, the end surfaces of a plurality of short sleepers are butted together, and the butted portions are sandwiched from above and below with a metal plate and fastened with bolts and nuts.

  Therefore, in fiber reinforced resin products, continuous long fibers bear the tensile strength and bending strength in the longitudinal direction, and this strength sharing is not effectively performed at the above-mentioned joining locations, and in joining with bolts or adhesives It is difficult to ensure a strength comparable to the strength sharing, and it is difficult to satisfactorily express the original strength of the fiber-reinforced resin product.

  An object of the present invention is to provide a method for producing a fiber-reinforced resin product that can be easily obtained as an integrated product on site even if it is a long fiber-reinforced resin product that is difficult to transport to the site.

  The method for producing a fiber-reinforced resin product according to claim 1 transports a semi-finished product having a part of the length of only the reinforcing fiber to the fiber-reinforced resin product, and the resin liquid is applied to the portion of the reinforcing fiber only at the destination. It is characterized by being impregnated and cured.

  The method for producing a fiber-reinforced resin product according to claim 2 has portions having only reinforcing fibers and resin-impregnated cured portions alternately with respect to a fiber-reinforced resin product having a predetermined length, and the length is substantially the predetermined length. The semi-finished product is transported, and the resin liquid is impregnated / cured only in the reinforcing fiber at the transport destination.

  According to a third aspect of the present invention, there is provided a method for producing a fiber-reinforced resin product, which has alternately a portion of only reinforcing fibers and a resin-impregnated cured portion with respect to a fiber-reinforced resin product having a predetermined length, and the length is the number of the predetermined length. The semi-finished product which is doubled is transported, and cut into the predetermined length and impregnation / curing of the resin liquid into only the reinforcing fiber is performed at the transport destination.

  The method for producing a fiber reinforced resin product according to claim 4 is the method for producing a fiber reinforced resin product according to any one of claims 1 to 3, wherein the impregnation / curing of the resin liquid into at least one portion of only the reinforcing fiber is performed. It is characterized in that it is performed in a state where the part is bent or twisted.

Semi-finished products with a part of the length of the fiber reinforced resin product only with reinforcing fibers can be easily transported because the outer dimensions can be reduced overall by bending etc. due to the flexibility of the reinforcing fiber only part. In particular, in a semi-finished product having alternating reinforcing fiber-only portions and resin-impregnated cured portions, it is possible to further reduce the outer dimensions by shortening the resin-impregnated cured portions, thereby facilitating transportation. it can.
Then, return to the original form of the product at the transportation destination, and impregnate and cure the resin liquid only on the part of the reinforcing fiber to make a finished product. While maintaining the advantages of the fiber reinforced resin product based on the above, it can be used in the field by guaranteeing easy handling in the factory and handling during transportation.

Hereinafter, basic embodiments of the present invention will be described with reference to the drawings.
The fiber-reinforced resin product targeted in the present invention is a product manufactured by a continuous production method in which a continuous reinforcing fiber is impregnated with a thermosetting resin liquid and then passed through a mold to cure the impregnated resin liquid. The semi-finished product refers to an unfinished product in which a part of the length of the fiber-reinforced resin product is only a reinforcing fiber and the resin liquid is not impregnated. ) [Cross sectional view of (a) in FIG. 1-1] and (c) [Cross sectional view of (a) in FIG. 1-1] and (a) and (b) in FIG. [A cross section of (a) in FIG. 1-2] and (c) [Ha cross section of (a) in FIG. 1-2] show different examples of semi-finished products.
1-1 and 1-2, 1 is a continuous reinforcing fiber, 2 is an impregnated / cured resin, 10 is a part of the reinforcing fiber only, and 12 is a part of the reinforcing fiber impregnated / cured with resin. Show.
The continuous production method includes a step of attaching a thermosetting resin liquid to the aligned long fiber group, a step of impregnating the attached resin liquid into the long fiber group, and a step of molding and curing the resin liquid-impregnated long fiber group into a predetermined shape. For example, the following manufacturing method can be illustrated.
(1) As shown in FIG. 2A, the long fiber groups 1,... Are arranged in a band shape, and a resin liquid is dropped and supplied from the traverse nozzle 3 to the band-shaped long fiber group. To pass through.
In this impregnation mold 4, the internal passage is continuously changed from the entrance of the strip-shaped cross section to the exit of the cross section close to the product cross section, and the exit cross section is reduced to the cross section of the inlet. Squeezing pressure is generated and the resin liquid is uniformly impregnated.
Further, the resin liquid-impregnated long fiber group is passed through the mold 5 and heated as necessary to cure the impregnated resin liquid.
As the mold 5, one in which four endless belts are arranged so as to form a space that matches the product cross section can be used.
(2) For the manufacturing method of (1), instead of adhering the resin liquid to the long fiber group with a nozzle, as shown in FIG. Group 1 is allowed to pass through, and the adhering resin liquid is uniformly impregnated into the long fiber group by the impregnation mold in the same manner as in the manufacturing method of (1), and further, the impregnation resin liquid is cured by passing through the mold. Go.

  In order to implement the inventions of claims 1 and 2, first, production is performed by the above-described production method, and during that period, the dropping of the resin liquid from the nozzle is periodically stopped or the long fiber group is released from the presser roll. Thus, a semi-finished product having only the reinforcing fibers shown in FIGS. 1-1 and 1-2 is obtained by letting it escape onto the liquid surface of the resin liquid tank.

Next, the outer dimensions of the semi-finished product are reduced overall by folding only the reinforcing fiber.
As the reduced form of the semi-finished product, as shown in FIG. 3 (a), the reinforcing fiber-only parts 1 are alternately folded in the opposite direction and folded in the order of the resin impregnated cured parts 121, 122,. As shown in (b), a form in which the reinforcing fiber-only portion 1 is bent in the same direction and wound in the order of the resin-impregnated cured portions 121, 122,.
For example, in the case of a product with a relatively flat cross-section, the semi-finished product sent in a horizontal state (the cross-sectional major axis direction is horizontal) is twisted by 90 ° in the reinforcing fiber only portion to obtain a vertical state. 3 can be folded into the form shown in (a) or rolled up in the form shown in (b) of FIG. Moreover, the semi-finished product drawn out in the horizontal state can be lifted upward and folded.
In the collapsed configuration shown in (b) of FIG. 3, stacked thickness _{h m (m = 1, ...} n) the length of the portion of only the reinforcing fibers relative to _{L m (m = 1, ...} n) is, _{L m} ≧ It must be in the relationship of h _m.
Therefore, it is preferable to select a reduction mode in consideration of the difficulty of the mechanism for reducing the outline, the size of the semi-finished product, and the like.
The following method can be used to wrap the semi-finished product sent out continuously into the form shown in (a) of FIG. 3 or to fold it into the form shown in (b) of FIG.
For example, in the case of the winding form shown in FIG. 3B, assuming that the length of the reinforcing fiber only portion is a, the length of the resin-impregnated cured portion is b, and the production speed is v, the delivery position of the semi-finished product and the winding position It is possible to use a method in which the semi-finished product is loosened by a length of 2 (a + b) or more between the positions and the winding means is rotated once every 2 (a + b) / v time.
For example, in the case of the folded form shown in FIG. 3 (a), if the length of the reinforcing wire only portion is a, the length of the resin-impregnated cured portion is b, and the production speed is v, as in the above, It is possible to use a method in which the semi-finished product is slackened with a length of (a + b) or more between the feeding position and the folding position, and folded once every (a + b) / v time.
In any of the methods, if the product length is wound or folded, the product is cut and the above winding or folding is repeated.

After shrinking the semi-finished product by folding or entraining in this way, the semi-finished product is transported to the site, and the part of the semi-finished product that contains only the reinforcing fiber is impregnated with the resin solution, and the impregnated resin solution is cured. Get the goods.
The resin liquid may be the same or different from the resin liquid used in the manufacture of the semi-finished product, a mold may be used for curing, and heated to reduce the curing time. Also good.
In order to effectively share the longitudinal tensile force and bending tensile force acting on the product with the continuous reinforcing fiber, it is effective to keep the fiber free of slack, and the product has a large tensile strength and bending strength. When required, it is desirable to cure the resin liquid in a state where the reinforcing fibers are stretched.
For impregnation of resin liquid with semi-finished reinforcing fibers only, a method of supplying the resin liquid while scrubbing the fibers, a method of immersing in a resin liquid bath to squeeze out the excess resin liquid, and a vacuum container equipped with a pressure vessel In addition, a method of press-fitting a resin solution can be used.

When the resin liquid impregnated only in the reinforcing fiber is cured, the resin liquid can be cured in a state where the portion is bent at a desired bending angle or a state where the portion is twisted at a desired twisting angle.
Thus, the finished product has a form in which the overall length is straight, a form in which at least one part is bent as shown in FIG. 4 (a), and a form in which at least one part is twisted as shown in FIG. 4 (b). As shown in FIG. 4C, at least two straight portions, bent portions, and twisted portions are mixed.

In order to carry out the invention of claim 3, the length of only the reinforcing fiber of the semi-finished product is a, the length of the resin impregnated cured portion is b, the portion of the semi-finished product is only the reinforcing fiber and the resin impregnated cured portion Alternately, if the length of the semi-finished product is m (a + b) [m is an integer], a long semi-finished product of length n × m (a + b) [n is an integer] is wound or folded in the same manner as described above. In the site, cutting into a semi-finished product of length m (a + b) and impregnating and curing the resin liquid only on the reinforcing fiber portion of the semi-finished product are performed.
The same method as described above can be used for the impregnation and curing of the resin liquid.
The on-site cutting is preferably performed only in the portion of the reinforcing fiber before the resin solution is impregnated and cured, but can also be performed after the resin solution is impregnated and cured.

  In the present invention, if the part of the semifinished product which is only the reinforcing fiber is too long, a large amount of resin liquid is required for impregnation with the resin liquid in the field, which is disadvantageous in operation, and if it is too short, the above-described folding or folding is impossible. Become. Thus, although it is difficult to determine the length of the reinforcing fiber only portion depending on the cross-sectional area and thickness of the resin-impregnated portion, it is usually preferably 100 mm to 2000 mm.

  If the length of the resin liquid-impregnated cured portion of the semi-finished product is too long, the dimensions are considerably large even in the reduced form described above, which is disadvantageous for handling in the factory and transporting to the site. The length of the reinforcing fiber alone is relatively long, which is disadvantageous for on-site resin liquid impregnation / curing work, and the advantage of quality stability by factory production is greatly reduced. Thus, the length of the resin liquid impregnated cured portion in the semi-finished product is preferably 2 m to 10 m.

  In the present invention, the transportation destination of the semi-finished product includes not only the site where the product is used but also an area near the site where the transport of the finished product to the site is not substantially subject to transportation regulations.

The reinforcing fiber used in the present invention is preferably a continuous fiber such as roving or yarn, but a mat or woven fabric can also be used.
Glass fiber, carbon fiber, organic fiber (synthetic fiber such as vinylon, polyamide, polyester, polyolefin, rayon, or natural fiber) can be used as the material of the reinforcing fiber, but glass fiber is used from the viewpoint of cost and strength. preferable.

The curable resin liquid is not particularly limited, and examples thereof include urethane resins, phenol resins, unsaturated polyester resins, urea resins, epoxy resins, diallyl phthalate resins, and the like. A resin is preferable because it is excellent in durability and mechanical strength.
A foamable resin liquid obtained by adding a foaming agent such as gas or a pyrolytic foaming agent to these resin stock solutions can also be used.
Since impregnation becomes difficult when the viscosity of these resin liquids is too high, it is preferable to use a resin having a viscosity of 10,000 cps or less in a molten state, and more preferably using a resin having a viscosity of 3000 cps.
When using a foamable resin liquid, the resin liquid foams and expands at the time of curing. Therefore, it is preferable to use a mold in which the above-described endless belt is arranged in four directions.
A filler (for example, inorganic powder such as silica sand, organic powder such as resin cutting powder), a colorant, an ultraviolet absorber, an antioxidant, a flame retardant, and the like can be added to the resin liquid as necessary. .

As the reinforcing fiber, roving obtained by twisting 13800 E glass fiber was used.
The curable resin liquid includes a polyfunctional MDI (viscosity at 25 ° C. of 500 cps, Sumika Bayer Urethane Co., Ltd., trade name: 44V20) and polyether polyol (Suika Bayer Urethane Co., Ltd., trade name: Sumidur). 1703, viscosity at 600Cps at 25 ° C.) 100 parts by weight, silicon foam stabilizer (manufactured by Toray Dow Corning, product number: SRX-295) 0.6 part by weight, dibutyltin laurate 0.03 part by weight and water (foaming agent) A composition having a composition of 0.8 part by weight was used.
The continuous production method shown in FIG. 2-1 is used, the dropping of the resin liquid from the nozzle is stopped every predetermined time, the glass fiber only parts are four places, the length of each of these parts is about 500 mm, the resin A semi-finished product having 5 impregnated foam-cured portions, a length of about 3 m, and a total length of 17 m was obtained. The resin: glass fiber weight ratio of the resin-impregnated foam-cured portion was 1: 1, the specific gravity was 0.74, and the cross-sectional dimensions were 30 mm thick × 600 mm wide.
This semi-finished product is twisted 90 ° in the glass fiber only portion and rolled up horizontally [FIG.
(See (b))] and conveyed to the machining operation.
This semi-rolled product was unwound and stretched in a straight line, and the same foamable urethane resin solution as described above was applied and impregnated while squeezing only the glass fiber. The amount of the resin solution impregnated was about 1.5 times that of the semi-finished product.
Next, a mold having an inner dimension of 30 mm × 600 mm which is the same as the outer dimension of the resin-impregnated foam-cured portion is attached, and the impregnated resin liquid is foam-cured at a mold heating temperature of 80 ° C. A straight line finished product having a length of 17 m was obtained by cutting and removing with a sander.

A curved linear finished product having a bending angle of 30 ° × 4 (120 °) was obtained in the same manner as in Example 1 except that a 30 ° bend die was used as the die for Example 1.

A twisted finished product having a twist angle of 90 ° × 4 (360 °) was obtained in the same manner as in Example 1 except that a 90 ° twisted mold was used as the mold for Example 1.

It is drawing which shows an example of the semi-finished product in this invention. It is drawing which shows another example of the semi-finished product in this invention. It is drawing which shows the manufacturing apparatus of the fiber reinforced resin semi-finished product used in this invention. It is drawing which shows another example of the resin liquid adhesion apparatus in the manufacturing apparatus of the fiber reinforced resin semi-finished product used in this invention. It is drawing which shows the reduced form of the semi-finished product in this invention. It is drawing which shows the example from which the fiber reinforced resin product in this invention differs.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Reinforcing fiber 10 Part consisting only of reinforcing fiber 2 Impregnated cured resin 12 Resin liquid impregnated cured part 3 Resin liquid supply nozzle 4 Impregnation mold 5 Mold

Claims (4)

Manufacturing of fiber reinforced resin products characterized by transporting a semi-finished product with only a part of the reinforcing fiber to the fiber reinforced resin product and impregnating and curing the resin liquid only in the part of the reinforcing fiber at the destination. Method. For a fiber reinforced resin product of a predetermined length, a semi-finished product having a length of the predetermined length is transported in a semi-finished product having portions of only reinforcing fibers and resin-impregnated hardened portions. A method for producing a fiber-reinforced resin product, comprising impregnating and curing a resin solution in the portion of the fiber. A semi-finished product having a reinforcing fiber-only portion and a resin-impregnated cured portion alternately with a length of several times the predetermined length is transported for a fiber-reinforced resin product of a predetermined length, and the predetermined destination is transported at the destination. A method for producing a fiber-reinforced resin product, comprising cutting to length and impregnating and curing a resin liquid only on a portion of reinforcing fiber. The fiber-reinforced resin product according to any one of claims 1 to 3, wherein the resin liquid is impregnated and cured in at least one portion of only the reinforcing fibers in a state where the portion is bent or twisted. Production method.

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