JP2006218634A - Method and mold for molding hollow rectangular parallelepiped made of frp with opening on its one surface side - Google Patents

Method and mold for molding hollow rectangular parallelepiped made of frp with opening on its one surface side Download PDF

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JP2006218634A
JP2006218634A JP2005031468A JP2005031468A JP2006218634A JP 2006218634 A JP2006218634 A JP 2006218634A JP 2005031468 A JP2005031468 A JP 2005031468A JP 2005031468 A JP2005031468 A JP 2005031468A JP 2006218634 A JP2006218634 A JP 2006218634A
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mold
rectangular parallelepiped
frp
hollow rectangular
molding
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JP4616659B2 (en
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Kentaro Shima
健太郎 島
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Teijin Ltd
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Toho Tenax Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for efficiently molding a member, which requires a strict right-angle, being a hollow rectangular parallelepiped made of FRP with an opening on its one surface side, and also to provide a mold used therein. <P>SOLUTION: In molding the hollow rectangular parallelepiped made of FRP with an opening on its one surface side, a mold, which is composed of a main mold made of a metal for forming the outer surface of the hollow rectangular parallelepiped, and a core made of a metal for forming the inner surface of the hollow rectangular parallelepiped and having the coefficient of thermal expansion larger than that of the hollow rectangular parallelepiped, are used. For example, the main mold comprises carbon steel and the core comprises aluminum or an aluminum alloy. An auxiliary mold comprising a rubber substrate may be inserted in or arranged to the gap between the upper mold of the mold and the core. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、FRP製成形品あるいはその部品として使用される、一面が開口したFRP製の中空の直方体の成形方法、及び、それに用いる成形用金型に関する。 The present invention relates to a method for forming a hollow rectangular parallelepiped made of FRP, which is used as an FRP molded product or a part thereof, and a molding die used therefor.

繊維強化プラスチック(FRP)は、不飽和ポリエステル樹脂、エポキシ樹脂、ポリイミド樹脂等の熱硬化性樹脂や、ポリエチレン、ポリプロピレン、ポリアミド、PPS、PEEK等の熱可塑性樹脂のマトリックス樹脂と、炭素繊維、ガラス繊維、アラミド繊維等の強化繊維からなるものであり、軽量で且つ強度特性に優れるため、近年、航空宇宙産業から一般産業分野に至るまで、幅広い分野において利用されている。 Fiber reinforced plastic (FRP) is a thermosetting resin such as unsaturated polyester resin, epoxy resin and polyimide resin, matrix resin of thermoplastic resin such as polyethylene, polypropylene, polyamide, PPS, PEEK, carbon fiber, glass fiber In recent years, it is used in a wide range of fields from the aerospace industry to the general industrial field.

FRP製品を成形する場合、繊維強化材に樹脂を含浸させ、流動性や粘着性を除いて取り扱い性を良くしたシート状の成形中間体である、プリプレグが用いられる場合が多い。そして、プリプレグを用いて、中空の部材を成形するための方法としては、オートクレーブ成形法、ホットプレス成形法、真空バッグ成形法等が知られている(例えば、特許文献1参照)。
特開2003−334836号公報
When molding an FRP product, a prepreg, which is a sheet-shaped molding intermediate in which a fiber reinforcing material is impregnated with a resin and is easy to handle except for fluidity and adhesiveness, is often used. And as a method for shape | molding a hollow member using a prepreg, the autoclave shaping | molding method, the hot press shaping | molding method, the vacuum bag shaping | molding method etc. are known (for example, refer patent document 1).
JP 2003-334836 A

しかしながら、複雑あるいは精密な形状のFRP成形品を得ようとすると、従来の手段・手法では、必ずしも十分なものが得られない場合があった。例えば、一面が開口したFRP製の中空の直方体を成形する場合に、直方体に厳密な直角度が要求される場合には、従来の主型と入子を用いるプレス成形では、離型操作が難しいという問題がある。 However, when trying to obtain an FRP molded product having a complicated or precise shape, the conventional means / method may not always provide sufficient products. For example, when a hollow rectangular parallelepiped made of FRP having an opening on one side is formed, if a strict rectangularity is required for the rectangular parallelepiped, it is difficult to perform a mold release operation by the conventional press molding using the main mold and the insert. There is a problem.

本発明の課題は、FRP製成形品あるいはその部品として使用される、一面が開口したFRP製の中空の直方体であって、厳密な直角度が要求される部材を、効率良く成形する方法、及び、それに用いる成形用金型を提供することである。 An object of the present invention is a method for efficiently molding a FRP hollow rectangular parallelepiped having a single opening, which is used as an FRP molded product or a part thereof, and which requires a strict squareness, and It is to provide a molding die used therefor.

本発明の中の請求項1の発明は、一面が開口したFRP製の中空の直方体を成形するに際し、該直方体の外面を形成する金属製の主型と、該直方体の内面を形成する、主型より熱膨張係数が大きい金属製の入子とからなる成形用金型を用いることを特徴とする一面が開口したFRP製の中空の直方体の成形方法である。 The invention according to claim 1 of the present invention is that when forming a hollow rectangular parallelepiped made of FRP having one open surface, a metal main mold that forms the outer surface of the rectangular parallelepiped and an inner surface of the rectangular parallelepiped, A molding method for a hollow rectangular parallelepiped made of FRP having an opening on one side, wherein a molding die comprising a metal insert having a thermal expansion coefficient larger than that of a mold is used.

そして、請求項2の発明は、主型の上型と入子との間に、ゴム基板からなる補助型を挿入することを特徴とする請求項1記載の一面が開口したFRP製の中空の直方体の成形方法である。 The invention according to claim 2 is characterized in that an auxiliary die made of a rubber substrate is inserted between the upper die of the main die and the insert. This is a rectangular parallelepiped molding method.

更に、請求項3の発明は、直方体が、開口部にフランジが付設されているものである請求項1又は2記載の一面が開口したFRP製の中空の直方体の成形方法である。 Further, the invention of claim 3 is a method for forming a hollow rectangular parallelepiped made of FRP having one open surface according to claim 1 or 2, wherein the rectangular parallelepiped has a flange attached to the opening.

請求項4の発明は、一面が開口したFRP製の中空の直方体を成形する金型であって、該直方体の外面を形成する金属製の主型と、該直方体の内面を形成する、主型より熱膨張係数が大きい金属製の入子とからなる成形用金型である。 The invention according to claim 4 is a mold for forming a hollow rectangular parallelepiped made of FRP having an open surface, a metal main mold forming the outer surface of the rectangular parallelepiped, and a main mold forming the inner surface of the rectangular parallelepiped This is a molding die composed of a metal insert having a larger coefficient of thermal expansion.

また、請求項5の発明は、主型の上型と入子との間に、ゴム基板からなる補助型が挿入されてなる請求項4記載の成形用金型であり、そして、請求項6の発明は、その中の特に好ましい態様を規定するもので、主型が炭素鋼からなり、入子がアルミニュウム又はアルミニュウム合金からなる請求項4又は5記載の成形用金型である。 The invention according to claim 5 is the molding die according to claim 4 in which an auxiliary die made of a rubber substrate is inserted between the upper die of the main die and the insert. The present invention defines a particularly preferred embodiment, wherein the main mold is made of carbon steel and the insert is made of aluminum or an aluminum alloy.

本発明によれば、FRP製成形品あるいはその部品として使用される、一面が開口したFRP製の中空の直方体であって、厳密な直角度を有するものを、効率良く成形することができる。 According to the present invention, a hollow rectangular parallelepiped made of FRP that is used as an FRP molded product or a part thereof and that has an opening on one side and that has a strict squareness can be efficiently molded.

本発明は、一面が開口したFRP製の中空の直方体を成形するに際し、中空の直方体の外面を形成する金属製の主型(少なくとも上型と下型から構成される)と、この直方体の内面を形成する、主型より熱膨張係数が大きい金属製の入子とからなる成形用金型を用いるものであるが、主型用の金属としては、好ましいのは、熱膨張係数が8〜11×10−6
程度の金属、例えば、耐熱鋼、高張力鋼、炭素鋼(S45C)、フェライト系ステンレス鋼(SUS430)、マルテンサイト系ステンレス鋼(SUS420J2)、チタン合金(6AL4V)が挙げられる。主型より熱膨張係数が大きい入子用の金属としては、好ましいのは、熱膨張係数が15〜25×10−6程度の金属、例えば、アルミニュウム、アルミ合金(2017)、銅合金、オーステナイト系ステンレス鋼(SUS304)が挙げられる。
特に好ましいのは、主型が炭素鋼からなり、入子がアルミニュウム又はアルミニュウム合金からなるものの組合せである。
The present invention provides a metal main mold (consisting of at least an upper mold and a lower mold) that forms the outer surface of a hollow rectangular parallelepiped, and an inner surface of the rectangular parallelepiped when forming a hollow rectangular parallelepiped made of FRP having an open surface. However, as the metal for the main mold, it is preferable that the coefficient of thermal expansion is 8 to 11 as a metal for the main mold. × 10 -6
Examples of such metals include heat-resistant steel, high-tensile steel, carbon steel (S45C), ferritic stainless steel (SUS430), martensitic stainless steel (SUS420J2), and titanium alloy (6AL4V). As a metal for nesting having a larger thermal expansion coefficient than the main mold, a metal having a thermal expansion coefficient of about 15 to 25 × 10 −6 , for example, aluminum, aluminum alloy (2017), copper alloy, austenitic series is preferable. Stainless steel (SUS304) is mentioned.
Particularly preferred is a combination of the main mold made of carbon steel and the insert made of aluminum or an aluminum alloy.

本発明の金型においては、主型より熱膨張係数が大きい入子を用い、入子の熱膨張圧を利用して、プリプレグ等のFRPを主型の内壁に密着させるものであるが、更に、主型の上型と入子との間に、ゴム基板からなる補助型を挿入することによって、ゴムの膨張圧も付加することもできる。ゴム基板の材質は、金型の加熱温度に耐えるものである限り、特に問わない。 In the mold of the present invention, an insert having a larger thermal expansion coefficient than that of the main mold is used, and the FRP such as a prepreg is brought into close contact with the inner wall of the main mold using the thermal expansion pressure of the insert. The expansion pressure of rubber can also be applied by inserting an auxiliary mold made of a rubber substrate between the upper mold of the main mold and the insert. The material of the rubber substrate is not particularly limited as long as it can withstand the heating temperature of the mold.

本発明において成形加工される成形品は、中空の直方体の開口部にフランジが付設されているものであっても良い。この様な成形品で厳密な直角度が要求されるものは、従来のプレス成形では、特に成形が困難であるが、本発明の金型、方法を用いると、通常の硬化炉を用いて容易に製造することができる。その他、中空の直方体の開口部には、用途に応じて種々の加工をしたり、種々の部品を設置することができる。また、直方体の壁面やフランジ部には、必要に応じて、例えば、ボルト孔を設けることもできる。そして、部品の設置やボルト孔の穴あけ等は、直方体を成形した後行っても良く、あるいは、成形と同時に行っても良い。 The molded product molded in the present invention may be one in which a flange is attached to an opening of a hollow rectangular parallelepiped. Such a molded product that requires a strict perpendicularity is difficult to form by conventional press molding, but it is easy to use a normal curing furnace when using the mold and method of the present invention. Can be manufactured. In addition, various processes or various parts can be installed in the opening of the hollow rectangular parallelepiped depending on the application. Moreover, a bolt hole can also be provided in the wall surface and flange part of a rectangular parallelepiped as needed, for example. And installation of parts, drilling of bolt holes, etc. may be performed after molding a rectangular parallelepiped or may be performed simultaneously with molding.

本発明において、FRP製の中空の直方体を成形するためには、成形中間基材としてプリプレグを使用するのが適当である。プリプレグとしては、補強用のガラス繊維、炭素繊維、アラミド繊維等の繊維強化材の織物、不織布等のシート状物に、熱硬化性樹脂や熱可塑性樹脂等のマトリックス樹脂を含浸させて得られたプリプレグが挙げられる。繊維強化材やマトリックス樹脂に関しては特に制限はないが、繊維強化材として好ましいのはガラス繊維と炭素繊維であり、その織物が好ましい。織物としては、例えば、平織、綾織、朱子織等の経糸と緯糸から構成されるものの他、繊維束を一方向に引き揃えシート状とし、これを直角方向にステッチ糸で縫合した一軸織物、一方向に引き揃えたシート状物を角度を変えて複数積層し、これを直角方向にステッチ糸で縫合した多軸織物等が挙げられる。繊維強化材とマトリックス樹脂の割合は、繊維強化材が全体の30〜70重量%であるものが好ましい。 In the present invention, in order to mold a hollow rectangular parallelepiped made of FRP, it is appropriate to use a prepreg as a molding intermediate substrate. The prepreg was obtained by impregnating a matrix material such as a thermosetting resin or a thermoplastic resin into a fiber-reinforced fabric such as glass fiber, carbon fiber or aramid fiber for reinforcement, or a sheet-like material such as a nonwoven fabric. A prepreg is mentioned. Although there is no restriction | limiting in particular regarding a fiber reinforcing material and matrix resin, What is preferable as a fiber reinforcing material is a glass fiber and a carbon fiber, The textile fabric is preferable. Examples of the woven fabric include, for example, a plain woven fabric, a twill woven fabric, a satin weaving fabric, and the like, a uniaxial woven fabric in which fiber bundles are aligned in one direction and stitched in a perpendicular direction with stitch yarn, Examples thereof include a multi-axis woven fabric in which a plurality of sheet-like materials aligned in the direction are stacked at different angles and stitched with a stitch thread in a perpendicular direction. The ratio of the fiber reinforcing material to the matrix resin is preferably 30 to 70% by weight of the total fiber reinforcing material.

本発明の実施態様の一つを図を用いて説明する。図1は、開口部にフランジが付設された中空の直法体を成形する場合の、金型の断面図を示している。図1において、1は金型の主型の下型であり、2は同じく上型であり、3は入子である。図1は、開口部にフランジが付設された中空の直法体5(プリプレグからなる)を成形する場合であるから、入子3は断面がT字形のものである。4は、ゴム基板からなる補助型である。先ず、主型の下型1の内壁に沿ってプリプレグ5を敷設し、次いで、入子3を挿入・配置し、そして、入子3のT字形上面にゴム基板4を介して主型の上型を設置し、金型を型締めする。型締めした金型は、例えば、硬化炉に入れ、90〜180℃で1〜2時間加熱される。加熱による主型1、2と入子3の熱膨張圧の差により、更に補助型のゴム基板の膨張圧も加わって、プリプレグ5は下型の内壁に強く押し付けられた状態で硬化する。そして、金型の冷却後、成型品である直方体5は、金型から容易に離型し取り出すことができる。 One embodiment of the present invention will be described with reference to the drawings. FIG. 1 is a sectional view of a mold when a hollow straight body having a flange attached to an opening is formed. In FIG. 1, 1 is a lower mold of the main mold, 2 is an upper mold, and 3 is a nesting. Since FIG. 1 shows a case where a hollow straight body 5 (made of a prepreg) having a flange attached to an opening is formed, the insert 3 has a T-shaped cross section. Reference numeral 4 denotes an auxiliary mold made of a rubber substrate. First, the prepreg 5 is laid along the inner wall of the lower mold 1 of the main mold, then the insert 3 is inserted and arranged, and the upper surface of the main mold is placed on the T-shaped upper surface of the insert 3 via the rubber substrate 4. Install the mold and tighten the mold. The mold clamped is placed in, for example, a curing furnace and heated at 90 to 180 ° C. for 1 to 2 hours. Due to the difference in thermal expansion pressure between the main molds 1 and 2 and the insert 3 due to heating, the expansion pressure of the auxiliary type rubber substrate is further applied, and the prepreg 5 is hardened while being strongly pressed against the inner wall of the lower mold. And after cooling a metal mold | die, the rectangular parallelepiped 5 which is a molded product can be easily released from a metal mold | die and taken out.

図1にその断面を示した金型を用いて、開口部にフランジが付設された中空の直法体を成形した。炭素鋼(S45C)製の主型の下型1のキャビティ内面に、プリプレグ5を敷設した。プリプレグとしては、炭素繊維HTA3K(東邦テナックス社製、汎用グレードの炭素繊維、3000フィラメント)を経糸緯糸とした平織物(東邦テナックス社製、W−3101/Q−195)に、エポキシ樹脂を含浸させたものを用いた(樹脂含有率:40%)。このプリプレグを5枚、積層パターンが(0/90)、(±45)、(30/120)、(±45)、(0/90)となる様に重ねて、金型に敷設した。 A hollow straight body having a flange attached to the opening was formed using a mold whose cross section was shown in FIG. A prepreg 5 was laid on the cavity inner surface of the lower mold 1 of the main mold made of carbon steel (S45C). As the prepreg, a plain fabric (Toho Tenax Co., Ltd., W-3101 / Q-195) with a warp weft made of carbon fiber HTA3K (Toho Tenax Co., Ltd., general-purpose grade carbon fiber, 3000 filaments) is impregnated with an epoxy resin. Was used (resin content: 40%). Five prepregs were stacked so that the laminated pattern would be (0/90), (± 45), (30/120), (± 45), (0/90), and laid on the mold.

主型の下型1のキャビティ内に、プリプレグ5を介してアルミ合金(2017)製の入子3を挿入・配置し、次いで、入子3のT字形上面にゴム基板4を介して主型の上型2を設置し、金型を型締めした。型締めした金型を、硬化炉内に置き、120〜130℃で1.5時間加熱した。金型を取り出し冷却後、開口部にフランジが付設された中空の直法体5は、金型から簡単に離型して取り出すことができた。得られた成形品は、厳密な直角度を有するフランジ付の中空の直方体であった。 An insert 3 made of aluminum alloy (2017) is inserted and arranged in the cavity of the lower mold 1 of the main mold through the prepreg 5, and then the main mold is inserted into the T-shaped upper surface of the insert 3 through the rubber substrate 4. The upper mold 2 was installed and the mold was clamped. The clamped mold was placed in a curing furnace and heated at 120 to 130 ° C. for 1.5 hours. After the mold was taken out and cooled, the hollow straight body 5 with the flange attached to the opening could be easily removed from the mold and taken out. The obtained molded product was a hollow rectangular parallelepiped with a flange having a strict squareness.

ガラス繊維の織物(目付:200g/m、WE18K、日東紡社製)にエポキシ樹脂を含浸させたプリプレグ(樹脂含有率:38%)を8枚積層して用いる以外は、実施例1と同様にして、肉厚が3.5mmのフランジ付の中空の直方体を得た。このものも厳密な直角度を有していた。 Example 1 except that 8 prepregs (resin content: 38%) impregnated with an epoxy resin are laminated and used on a glass fiber fabric (weight per unit: 200 g / m 2 , WE18K, manufactured by Nittobo). Thus, a hollow rectangular parallelepiped with a flange having a thickness of 3.5 mm was obtained. This also had a strict squareness.

[比較例1]
比較のために、主型も入子も炭素鋼(S45C)製の金型を用いて、実施例1と同じ様に成形を行ったところ、金型の冷却後に、成形品を金型から取り出すのが非常に困難であった。
[Comparative Example 1]
For comparison, both the main mold and the insert were molded in the same manner as in Example 1 using a carbon steel (S45C) mold. After cooling the mold, the molded product was taken out from the mold. It was very difficult.

本発明の一つの実施態様の説明図(金型の断面図)である。It is explanatory drawing (sectional drawing of a metal mold | die) of one embodiment of this invention.

符号の説明Explanation of symbols

1 金型の主型の下型
2 金型の主型の上型
3 金型の入子
4 ゴム基板の補助型
5 プリプレグ(又は成形品の直方体)
1 Lower mold of the main mold 2 Upper mold of the main mold 3 Insert of the mold 4 Auxiliary mold of the rubber substrate 5 Prepreg (or rectangular parallelepiped of the molded product)

Claims (6)

一面が開口したFRP製の中空の直方体を成形するに際し、該直方体の外面を形成する金属製の主型と、該直方体の内面を形成する、主型より熱膨張係数が大きい金属製の入子とからなる成形用金型を用いることを特徴とする一面が開口したFRP製の中空の直方体の成形方法。 When forming a hollow rectangular parallelepiped made of FRP having one open surface, a metal main mold that forms the outer surface of the rectangular parallelepiped, and a metal insert that forms the inner surface of the rectangular parallelepiped and has a larger thermal expansion coefficient than the main mold A molding method for a hollow rectangular parallelepiped made of FRP having one open surface, wherein a molding die comprising: 主型の上型と入子との間に、ゴム基板からなる補助型を挿入することを特徴とする請求項1記載の一面が開口したFRP製の中空の直方体の成形方法。 2. A method for forming a hollow rectangular parallelepiped made of FRP having one side open, wherein an auxiliary die made of a rubber substrate is inserted between an upper die of a main die and a nest. 直方体が、開口部にフランジが付設されているものである請求項1又は2記載の一面が開口したFRP製の中空の直方体の成形方法。 3. A method for forming a hollow rectangular parallelepiped made of FRP having one surface opened, wherein the rectangular parallelepiped is provided with a flange at an opening. 一面が開口したFRP製の中空の直方体を成形する金型であって、該直方体の外面を形成する金属製の主型と、該直方体の内面を形成する、主型より熱膨張係数が大きい金属製の入子とからなる成形用金型。 A metal mold for forming a hollow rectangular parallelepiped made of FRP having an open surface, a metal main mold forming the outer surface of the rectangular parallelepiped, and a metal having a larger coefficient of thermal expansion than the main mold forming the inner surface of the rectangular parallelepiped Mold for molding made of metal inserts. 主型の上型と入子との間に、ゴム基板からなる補助型が挿入されてなる請求項4記載の成形用金型。 The molding die according to claim 4, wherein an auxiliary die made of a rubber substrate is inserted between the upper die of the main die and the insert. 主型が炭素鋼からなり、入子がアルミニュウム又はアルミニュウム合金からなる請求項4又は5記載の成形用金型。 The molding die according to claim 4 or 5, wherein the main mold is made of carbon steel and the insert is made of aluminum or an aluminum alloy.
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