JP2006289903A - Manufacturing method of hollow molding of fiber-reinforced plastic - Google Patents

Manufacturing method of hollow molding of fiber-reinforced plastic Download PDF

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JP2006289903A
JP2006289903A JP2005117050A JP2005117050A JP2006289903A JP 2006289903 A JP2006289903 A JP 2006289903A JP 2005117050 A JP2005117050 A JP 2005117050A JP 2005117050 A JP2005117050 A JP 2005117050A JP 2006289903 A JP2006289903 A JP 2006289903A
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core material
hollow
hollow core
prepreg
frp
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JP4696654B2 (en
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Hiroyuki Koyama
広幸 小山
Yasumi Miyashita
康己 宮下
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Toyota Motor Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a hollow molding of an FRP which can be easily performed without reducing the strength of the molding. <P>SOLUTION: Two members of the FRP are hermetically connected with each other to form a hollow core material 13. The hollow core material 13 has a communication hole 14 communicating with the inside and the outside of the hollow core material 13. The side face and the bottom face of the hollow core material 13 other than the communication hole 14 are covered with prepregs 17, 18, and the prepregs 17, 18 are hardened. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

本発明は繊維強化樹脂製中空成形体の製造方法に関する。   The present invention relates to a method for producing a fiber-reinforced resin hollow molded body.

可溶性中子の外周面を繊維強化樹脂シートで覆い、この繊維強化樹脂シートにプラスチック材料を適用した後このプラスチック材料を硬化させて成形体を形成し、この成形体に排出孔を穿ち、可溶性中子を溶剤により溶解させて排出孔から排出する、繊維強化樹脂製中空成形体の製造方法が公知である（特許文献１参照）。このようにして製造される中空成形体には例えばフレームやタンクなどが挙げられる。   Cover the outer periphery of the soluble core with a fiber reinforced resin sheet, apply a plastic material to the fiber reinforced resin sheet, and then cure the plastic material to form a molded body. A manufacturing method of a fiber-reinforced resin hollow molded body in which a child is dissolved with a solvent and discharged from a discharge hole is known (see Patent Document 1). Examples of the hollow molded body thus manufactured include a frame and a tank.

特開平７−２３２３３７号公報Japanese Patent Laid-Open No. 7-232337 特開平９−１２２２７７号公報JP-A-9-122277 特開平１−１５２０２１号公報Japanese Patent Laid-Open No. 1-152021

しかしながら、中子を取り出さなければならないので、製造方法が複雑になるという問題点がある。また、中子を効率的に排出させるためには排出孔を大きくし又は排出孔の数を多くする必要があるので、成形体の強度が低下するおそれもある。   However, since the core must be taken out, there is a problem that the manufacturing method becomes complicated. Further, in order to efficiently discharge the core, it is necessary to enlarge the discharge holes or increase the number of discharge holes, so that the strength of the molded body may be reduced.

そこで本発明は、成形体の強度を低下させることなく簡単に実施できる繊維強化樹脂製中空成形体の製造方法を提供することを目的とする。   Then, an object of this invention is to provide the manufacturing method of the fiber-reinforced resin hollow molded object which can be implemented easily, without reducing the intensity | strength of a molded object.

前記課題を解決するために本発明によれば、複数の繊維強化樹脂製部材を互いに封密に結合して中空芯材を形成し、該中空芯材は該中空芯材の内部と外部とを互いに連通する連通孔を有しており、該連通孔以外の該中空芯材の外面を少なくとも部分的にプリプレグで覆い、該プリプレグを硬化させる、各段階を含んでなる、繊維強化樹脂製中空成形体の製造方法が提供される。   In order to solve the above-mentioned problems, according to the present invention, a plurality of fiber reinforced resin members are hermetically coupled to each other to form a hollow core material, and the hollow core material has an inside and an outside of the hollow core material. Fiber-reinforced resin hollow molding, comprising communication holes that communicate with each other, each step covering at least partially the outer surface of the hollow core material other than the communication holes with a prepreg, and curing the prepreg A method of manufacturing a body is provided.

成形体の強度を低下させることなく簡単に実施できる繊維強化樹脂製中空成形体の製造方法を提供することができる。   It is possible to provide a method for producing a fiber-reinforced resin hollow molded body that can be easily implemented without reducing the strength of the molded body.

図１は本発明による繊維強化樹脂（ＦＲＰ）製中空成形体の製造方法を用いて製造されたＦＲＰ製中空フレーム１を示している。この中空フレーム１は平面状に拡がる面盤２上に固定されてその長手方向に延びている。また、図１に示される例では中空フレーム１の頂面に、中空フレーム１の内部と外部とを互いに連通する連通孔３が形成されている。   FIG. 1 shows an FRP hollow frame 1 manufactured using the method for manufacturing a fiber-reinforced resin (FRP) hollow molded body according to the present invention. The hollow frame 1 is fixed on a face plate 2 that extends in a planar shape and extends in the longitudinal direction. Further, in the example shown in FIG. 1, a communication hole 3 is formed on the top surface of the hollow frame 1 to communicate the inside and the outside of the hollow frame 1 with each other.

次に、図２から図４を参照しながら、本発明による実施形態の中空フレーム１の製造方法を説明する。   Next, a method for manufacturing the hollow frame 1 according to the embodiment of the present invention will be described with reference to FIGS.

まず、例えば二つのＦＲＰ製部材１１，１２が用意され、図２に示されるようにこれらＦＲＰ製成形体１１，１２が互いに封密に結合されて中空芯材１３が形成される。   First, for example, two FRP members 11 and 12 are prepared, and as shown in FIG. 2, these FRP molded bodies 11 and 12 are tightly coupled to each other to form a hollow core material 13.

図２に示されるＦＲＰ製部材１１，１２はそれぞれカップ状及び平板状をなしている。このように、中空芯材１３を単一の部材からではなく複数の部材１１，１２から形成しているので、中空芯材１３を簡単に形成できる。   The FRP members 11 and 12 shown in FIG. 2 have a cup shape and a flat plate shape, respectively. Thus, since the hollow core material 13 is formed not from a single member but from a plurality of members 11 and 12, the hollow core material 13 can be easily formed.

ＦＲＰ製部材１１，１２は例えば従来通り、プリプレグを型に入れ、加熱硬化することにより得ることができる。ここで、プリプレグは未硬化の熱硬化性樹脂を含浸させた強化繊維シートであり、強化繊維にはガラス、アラミド、カーボン等を、熱硬化性樹脂にはエポキシ、ビニルエステル等をそれぞれ用いることができる。   The FRP members 11 and 12 can be obtained, for example, by placing a prepreg in a mold and heat-curing as usual. Here, the prepreg is a reinforcing fiber sheet impregnated with an uncured thermosetting resin, and glass, aramid, carbon, etc. are used for the reinforcing fiber, and epoxy, vinyl ester, etc. are used for the thermosetting resin. it can.

ＦＲＰ製部材１１は例えば４層に積層されたプリプレグから形成されるのに対し、ＦＲＰ製部材１２は例えば１層又は２層に積層されたプリプレグから形成される。詳しくは後述するが、このようにＦＲＰ製部材１２をＦＲＰ製部材１１よりも薄くしているのは、ＦＲＰ製部材１２に可撓性を付与するためである。   The FRP member 11 is formed from, for example, a prepreg laminated in four layers, while the FRP member 12 is formed from, for example, a prepreg laminated in one or two layers. Although the details will be described later, the reason why the FRP member 12 is made thinner than the FRP member 11 in this way is to give the FRP member 12 flexibility.

ＦＲＰ製部材１１の頂部には、硬化後結合前に、例えば機械加工により直径１ｍｍ程度の連通孔１４が形成される。この連通孔１４は中空芯材１３の内部１５と外部とを連通する。なお、連通孔１４を部材１１，１２の結合後に形成することも可能である。   A communication hole 14 having a diameter of about 1 mm is formed at the top of the FRP member 11 by, for example, machining before bonding after curing. The communication hole 14 communicates the interior 15 and the exterior of the hollow core material 13. The communication hole 14 may be formed after the members 11 and 12 are joined.

これらＦＲＰ製部材１１，１２は環状をなすフランジ状結合部１６において例えば速硬化型エポキシ接着剤により封密に結合される。このようにフランジ状結合部１６を設けることによって、ＦＲＰ製部材１１，１２間の正確な位置決めが不要となる。   These FRP members 11 and 12 are hermetically coupled with, for example, a fast-curing epoxy adhesive at an annular flange-shaped coupling portion 16. By providing the flange-like coupling portion 16 in this manner, accurate positioning between the FRP members 11 and 12 becomes unnecessary.

なお、図２から図５まででは、プリプレグが積層された状態が概略的に示してある。   2 to 5 schematically show the state in which the prepregs are stacked.

次いで、図３に示されるように、中空芯材１３の側面が例えば２層のプリプレグ１７により覆われ、中空芯材１３の底面が例えば４層のプリプレグ１８により覆われ、これにより中空芯材１３とプリプレグ１７，１８とからなる未硬化品１９が形成される。この場合、プリプレグ１７の底端とプリプレグ１８とが互いに接触し、それにより中空芯材１３の結合部１６がプリプレグ１７，１８により覆われるようになっている。   Next, as shown in FIG. 3, the side surface of the hollow core member 13 is covered with, for example, two layers of prepregs 17, and the bottom surface of the hollow core member 13 is covered with, for example, four layers of prepregs 18. And an uncured product 19 composed of the prepregs 17 and 18 is formed. In this case, the bottom end of the prepreg 17 and the prepreg 18 are in contact with each other, whereby the coupling portion 16 of the hollow core material 13 is covered with the prepregs 17 and 18.

中空芯材１３の頂面も、プリプレグにより覆ってもよい。ただし、この場合には、連通孔１４が閉鎖されないようにする必要がある。   The top surface of the hollow core material 13 may also be covered with a prepreg. However, in this case, it is necessary to prevent the communication hole 14 from being closed.

なお、図３及び図４では、各図面を参照して新たに説明される部材等が実線で示され、すでに説明した部材等が破線で示されている。   3 and 4, members and the like that are newly described with reference to the drawings are indicated by solid lines, and the members and the like that have already been described are indicated by broken lines.

次いで、図４に示されるように、プリプレグ１８を下にして、未硬化品１９が面盤２上に配置される。なお、面盤２に代えて、型上に未硬化品１９を配置することもできる。   Next, as shown in FIG. 4, the uncured product 19 is placed on the face plate 2 with the prepreg 18 facing down. Instead of the face plate 2, an uncured product 19 can be arranged on the mold.

次いで、連通孔１４を除いて未硬化品１９全体がポリアミド、ナイロン等の薄いフィルムないしバッグ２０により覆われる。この場合、面盤２上に設けられたシールテープ２１と、連通孔１４周りに設けられたシールテープ２２とによって目止めされる。   Next, the entire uncured product 19 except for the communication holes 14 is covered with a thin film or bag 20 such as polyamide or nylon. In this case, the seal tape 21 provided on the face plate 2 and the seal tape 22 provided around the communication hole 14 are used to seal.

フィルム２２には減圧ポート２３が設けられており、この減圧ポート２３に真空ポンプ（図示しない）が接続されてフィルム２２内が減圧される。これにより、未硬化品１９内の空気が除去される。   The film 22 is provided with a decompression port 23, and a vacuum pump (not shown) is connected to the decompression port 23 to decompress the inside of the film 22. Thereby, the air in the uncured product 19 is removed.

次いで、フィルム２２内を減圧したまま、面盤２及び未硬化品１９がオートクレーブ（図示しない）に投入されて加圧及び加熱条件化でプリプレグ１７，１８が加熱硬化される。このようにして、中空フレーム１が製造される。なお、中空芯材１３の連通孔１４は中空フレーム１の連通孔３を構成する。   Next, with the inside of the film 22 being decompressed, the face plate 2 and the uncured product 19 are put into an autoclave (not shown), and the prepregs 17 and 18 are heated and cured under pressure and heating conditions. In this way, the hollow frame 1 is manufactured. The communication hole 14 of the hollow core member 13 constitutes the communication hole 3 of the hollow frame 1.

ところで、面盤２上に配置されたプリプレグ１８は中空フレーム１のいわゆる背面を構成することになる。従来の例えば中子を用いて中空フレームを製造する場合には、この背面にはオートクレーブ内の高圧がほとんど作用しないので、背面が平坦でない等の不具合が生ずるおそれがあった。   By the way, the prepreg 18 disposed on the face plate 2 constitutes a so-called back surface of the hollow frame 1. In the case of manufacturing a hollow frame using a conventional core, for example, the high pressure in the autoclave hardly acts on the back surface, so that there is a possibility that problems such as the back surface not being flat may occur.

これに対し、上述した本発明の実施形態によれば、連通孔１４を介して中空芯材１３の内部１５（図２）に高圧が作用し、中空芯材１３は硬化済みであるので、この高圧が中空芯材１３外に漏れることがない。その上で、ＦＲＰ製部材１２が可撓性を備えているので、プリプレグ１８に高圧を作用させることができる。その結果、中空フレーム１の背面を平坦にできる等、背面の良好な品質を確保することができる。   On the other hand, according to the above-described embodiment of the present invention, a high pressure acts on the inside 15 (FIG. 2) of the hollow core material 13 through the communication hole 14, and the hollow core material 13 has been cured. High pressure does not leak out of the hollow core material 13. In addition, since the FRP member 12 has flexibility, a high pressure can be applied to the prepreg 18. As a result, the back surface of the hollow frame 1 can be flattened, so that good quality of the back surface can be ensured.

一方、本発明の実施形態によれば、中空フレーム１を製造するために、上型を必要としない。従って、製造設備を簡素化することができる。   On the other hand, according to the embodiment of the present invention, no upper die is required to manufacture the hollow frame 1. Therefore, the manufacturing facility can be simplified.

パールボード（商品名）を型として、カーボン／エポキシプリプレグ（東邦テナックス社製、Ｗ３１０１／Ｑ−１１２Ｊ）を４層積層し、１３０℃で２時間加熱硬化させ、ＦＲＰ製部材１１を得た。次いで、ＦＲＰ製部材１１の頂面に直径１ｍｍの連通孔１４をボール盤により形成した。一方、アルミ平板上に、カーボン／エポキシプリプレグ（東邦テナックス社製、Ｗ３１０１／Ｑ−１１２Ｊ）を２層積層し、１３０℃で２時間加熱硬化させ、ＦＲＰ製部材１２を得た。   Four layers of carbon / epoxy prepreg (manufactured by Toho Tenax Co., Ltd., W3101 / Q-112J) were laminated using a pearl board (trade name) as a mold, and heat cured at 130 ° C. for 2 hours to obtain a member 11 made of FRP. Next, a communication hole 14 having a diameter of 1 mm was formed on the top surface of the FRP member 11 using a drilling machine. On the other hand, two layers of carbon / epoxy prepreg (manufactured by Toho Tenax Co., Ltd., W3101 / Q-112J) were laminated on an aluminum flat plate and heat-cured at 130 ° C. for 2 hours to obtain a member 12 made of FRP.

これらＦＲＰ製部材１１，１２を速硬化型エポキシ接着剤を用いて互いに結合し、中空芯材１３を得た。   These FRP members 11 and 12 were bonded to each other using a fast-curing epoxy adhesive to obtain a hollow core material 13.

次いで、中空芯材１３の各側面にプリプレグ１７としてカーボン／エポキシプリプレグ（東邦テナックス社製、Ｗ３１０１／Ｑ−１１２Ｊ）を２層積層した。一方、平板状の型上にプリプレグ１８としてカーボン／エポキシプリプレグ（東邦テナックス社製、Ｗ３１０１／Ｑ−１１２Ｊ）を４層積層した。   Next, two layers of carbon / epoxy prepreg (manufactured by Toho Tenax Co., Ltd., W3101 / Q-112J) as a prepreg 17 were laminated on each side surface of the hollow core material 13. On the other hand, four layers of carbon / epoxy prepreg (manufactured by Toho Tenax Co., Ltd., W3101 / Q-112J) were laminated as a prepreg 18 on a flat plate-shaped mold.

次いで、ＦＲＰ製部材１２が接触面となるように、中空芯材１３をプリプレグ１７と共に、プリプレグ１８上に配置した。   Next, the hollow core material 13 was placed on the prepreg 18 together with the prepreg 17 so that the FRP member 12 became a contact surface.

プリプレグ１８の外周を囲むように、型上にシールテープ２１を配置し固定した。また、中空芯材１３の連通孔１４の周りにもシールテープ２２を配置し固定した。   A seal tape 21 was placed and fixed on the mold so as to surround the outer periphery of the prepreg 18. Further, a sealing tape 22 was also arranged around the communication hole 14 of the hollow core member 13 and fixed.

次いで、連通孔１４を除いて、中空芯材１３及びプリプレグ１７，１８をナイロン製バッグ２０で覆い、上述のシールテープ２１，２２で固定した。次いで、バッグ２０に真空ラインを接続し、真空ポンプで減圧し、３０分放置した。   Next, except for the communication hole 14, the hollow core material 13 and the prepregs 17 and 18 were covered with a nylon bag 20 and fixed with the above-described seal tapes 21 and 22. Next, a vacuum line was connected to the bag 20, the pressure was reduced with a vacuum pump, and the bag 20 was left for 30 minutes.

次いで、減圧したまま、中空芯材１３及びプリプレグ１７，１８をオートクレーブ内に投入し、６気圧、１３０℃で２時間、加圧及び加熱硬化し、中空フレーム１を得た。   Next, with the pressure reduced, the hollow core material 13 and the prepregs 17 and 18 were put into an autoclave and pressurized and heat-cured at 6 atm and 130 ° C. for 2 hours to obtain a hollow frame 1.

中空フレームの（Ａ）斜視図、及び（Ｂ）線Ｂ−Ｂに沿ってみた断面図である。It is the (A) perspective view of a hollow frame, and (B) Sectional drawing seen along line BB. 本発明の中空フレームの製造方法を説明する図である。It is a figure explaining the manufacturing method of the hollow frame of this invention. 本発明の中空フレームの製造方法を説明する図である。It is a figure explaining the manufacturing method of the hollow frame of this invention. 本発明の中空フレームの製造方法を説明する図である。It is a figure explaining the manufacturing method of the hollow frame of this invention.

符号の説明Explanation of symbols

１ 中空フレーム
２ 面盤
３ 連通孔
１１，１２ ＦＲＰ製部材
１３ 中空芯材
１７，１８ プリプレグ DESCRIPTION OF SYMBOLS 1 Hollow frame 2 Face board 3 Communication hole 11,12 FRP member 13 Hollow core material 17,18 Prepreg

Claims (1)

複数の繊維強化樹脂製部材を互いに封密に結合して中空芯材を形成し、該中空芯材は該中空芯材の内部と外部とを互いに連通する連通孔を有しており、該連通孔以外の該中空芯材の外面を少なくとも部分的にプリプレグで覆い、該プリプレグを硬化させる、各段階を含んでなる、繊維強化樹脂製中空成形体の製造方法。
A plurality of fiber reinforced resin members are hermetically bonded to each other to form a hollow core material, and the hollow core material has a communication hole that communicates the inside and the outside of the hollow core material. A method for producing a fiber-reinforced resin hollow molded body comprising the steps of covering at least partially the outer surface of the hollow core material other than the holes with a prepreg and curing the prepreg.
JP2005117050A 2005-04-14 2005-04-14 Manufacturing method of hollow molded body made of fiber reinforced resin Expired - Fee Related JP4696654B2 (en)

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Cited By (2)

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Publication number Priority date Publication date Assignee Title
JP2008168489A (en) * 2007-01-10 2008-07-24 Toyota Motor Corp Method of manufacturing frp hollow structure
CN108484198A (en) * 2018-04-03 2018-09-04 湖南南方搏云新材料股份有限公司 A kind of preparation method of carbon/carbon composite cored slab

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JPS6434725A (en) * 1987-07-30 1989-02-06 Toyota Motor Corp Manufacture of frp construction object with hollow cross section
JP2001150465A (en) * 1999-11-30 2001-06-05 Toyota Motor Corp Method for manufacturing hollow molding and device therefor

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Publication number Priority date Publication date Assignee Title
JP2008168489A (en) * 2007-01-10 2008-07-24 Toyota Motor Corp Method of manufacturing frp hollow structure
CN108484198A (en) * 2018-04-03 2018-09-04 湖南南方搏云新材料股份有限公司 A kind of preparation method of carbon/carbon composite cored slab

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