JP2007176163A - Manufacturing process of fiber-reinforced plastic - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To prevent a decline in diffusion efficiency of a pass medium due to a bag film without increasing amount of resin waste or refuse. <P>SOLUTION: The process for manufacturing a fiber-reinforced plastic comprises arranging a reinforced fiber substrate on a molding die, covering the whole substrate with a bag film, forming a cavity by sealing a gap between the substrate and the molding die, pouring a liquid resin into the cavity while decompressing its inside, and impregnating the substrate with the resin. The process is characterized by disposing between the pass medium and the bag film, an auxiliary sheet having the Young's modulus E<SB>s</SB>and thickness T<SB>s</SB>satisfying the formula (I), E<SB>S</SB>T<SB>S</SB><SP>3</SP>>E<SB>b</SB>T<SB>b</SB><SP>3</SP>when the Young's modulus of the bag film is defined as E<SB>b</SB>and thickness as T<SP>b</SP>. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to an improvement in a method for producing a fiber-reinforced plastic (hereinafter abbreviated as FRP), and more specifically, vacuum assisted resin transfer molding (vacuum assisted resin injection molding method: hereinafter) in which a cavity is formed by a lower mold and a bag film. The present invention relates to a method for improving the resin diffusion efficiency of pass media used in (abbreviated as VaRTM).

  As is well known, FRP is a lightweight material that can exhibit high mechanical properties, and is used in various fields. As one of typical methods for producing FRP, a vacuum assisted resin transfer molding (vacuum assisted resin injection molding method: hereinafter abbreviated as VaRTM) molding method is known. In the VaRTM molding method, a reinforcing fiber substrate is placed in a mold, the inside of the mold cavity is decompressed, and the resin is injected into the cavity using the pressure difference between the decompressed cavity internal pressure and external pressure. Then, the impregnated resin is impregnated into the reinforcing fiber base, the resin is cured, and the mold is removed after curing to obtain FRP. The VaRTM method includes a molding method using a molding die set in an upper and lower set and a molding method in which a reinforcing fiber base is placed on a lower die and covered with a bag film to form a cavity. The present invention relates to an improvement of the VaRTM molding method using the latter bag film.

  In Patent Document 1, a reinforcing fiber base material and a pass medium are arranged on a mold, a resin inlet and a vacuum suction port communicating with the reinforcing fiber base material are installed, and the whole is covered with a bag film. A method of injecting and curing a resin while reducing the pressure is used.

  The performance required for the bag film is to easily follow the shape of the molded product while having airtightness. Generally, a film having low rigidity and good elongation is used. In addition, the pass media is a sheet made of a net or cloth having a large number of voids, and the resin diffuses rapidly along the surface while penetrating into the voids of the pass media. The resin can be uniformly permeated and impregnated easily. Therefore, it can be said that the higher the porosity of the pass media, the higher the resin diffusibility and the better the performance.

  On the other hand, in this method, the pass media and the bag film are sequentially arranged on the reinforcing fiber base material. However, the bag film is deformed by the differential pressure between the vacuum pressure in the cavity and the atmospheric pressure, and In order to decrease the volume of the void by entering the void portion, there is a problem that the porosity in the pass media is lowered and the diffusion rate of the resin is lowered. In addition to the problem that the production time of FRP becomes longer when the diffusion rate of the resin decreases, the resin fluidity is lost before the resin diffuses throughout the pass media, and an unimpregnated portion of the resin remains in the molded product. This problem was prominent particularly when a large FRP was produced.

  In this way, the bag film with lower rigidity has better followability to the shape of the molded product, and the pass media with higher resin diffusibility with higher porosity, instead of using the respective advantages, It has a relationship that results in inhibiting the diffusivity of. That is, when the gap of the pass media is increased in order to increase the resin diffusion rate, the span between the linear bodies forming the gap becomes longer, so the deformation amount (deflection) of the bag film becomes larger, rather the pass. On the other hand, if the volume of the voids in the media is reduced, it is necessary to use a bug film having high rigidity and low elongation, which causes a problem in conformity to the shape of the molded product. That is, there is a problem that there is a limit to the improvement of the diffusion speed of the pass media on the premise that the followability to the shape of the molded product, which is a premise of molding, is maintained.

  In Patent Document 2, in order to solve the problem of the surface property of the molded product, which is a problem different from the present invention, with respect to the pass media having a high porosity, a plurality of sheets having different porosity are provided on the reinforcing fiber substrate. A method of arranging pass media has been proposed. However, even in this case, the problem that the bag film enters the gap of the pass media has not been solved, and the impregnation efficiency is improved by the bag film because of the configuration in which the pass media having a high porosity is disposed on the bag film side. The problem of deteriorating arises. Even when a plurality of pass media are stacked, when the rigidity of the bag film is low, there is a problem that the bag film enters the gap in the lowermost medium. In the case of this method, since the pass media is removed and discarded after molding, there is a problem that wasteful resin in the pass media increases and costs increase, and waste increases.

In the method of Patent Document 3, a double bag having a bag film provided thereon is further provided by arranging a medium provided with unevenness to be a resin diffusion flow path on a normal bag film, and thereby forming both bags. By controlling the pressure between the materials, the diffusion rate of the resin is improved and the manufacturing time of FRP is shortened. According to this method, the resin diffusion rate can be increased, but since a process of forming a double bag is required, it cannot be said that the manufacturing time is shortened, and the pressure is required to be strictly controlled. There was a problem that control of conditions was necessary.
U.S. Pat. No. 4,902,215 JP 2004-188750 A JP 2004-130723 A

  The object of the present invention is to solve the above-mentioned problems in the FRP manufacturing method, improve the resin diffusion efficiency without reducing the waste of the resin and increase the amount of waste, and shorten the manufacturing time by a simple method. An object of the present invention is to provide a method for producing FRP having excellent surface quality.

In order to achieve the above object, the present invention takes the following means. That is,
(1) A reinforcing fiber base material is disposed on a mold, the entire reinforcing fiber base material is covered with a bag film, and a cavity is formed by sealing between the mold and the inside of the cavity is decompressed. In the method for producing a fiber reinforced plastic in which a liquid resin is injected and the reinforcing fiber base material is impregnated with a resin, a pass media is disposed on the reinforcing fiber base material, and the Young's modulus of the bag film is set to E _b , thickness An auxiliary sheet having a Young's modulus E _S and a thickness T _S satisfying the following formula (I) when the thickness is T _b is disposed between the pass media and the bag film. Manufacturing method.

E _S T _S ³ > E _b T _b ³ (I)
(2) the path the media is a linear body sheet was set, the thickness T _P, the maximum value of the formed gap size between linear body when the L _P, the auxiliary sheet Satisfies the following formula (II): (1) The method for producing a fiber-reinforced plastic.

E _S T _S ³ > L _P ⁴ / (64 T _P ) (II)
(3) The method for producing a fiber-reinforced plastic according to any one of (1) and (2), wherein the auxiliary sheet satisfies the following formula (III).

E _S T _S ³ <4 N · m (III)
(4) the following equation resin distribution channel forming sheet material, characterized in that laminated and integrated imperforate sheet and pass medium having a Young's modulus E _s and the thickness T _s satisfying the (IV).

E _S T _S ³ > 0.0001 _N · m (IV)
(5) the path the media is a linear body sheet was set, the thickness T _P, the maximum value of the formed gap size between linear body when the L _P, the imperforate The sheet material for forming a resin diffusion channel according to (4), wherein the sheet satisfies the following formula (V).

E _S T _S ³ > L _P ⁴ / (64 T _P ) (V)
(6) The sheet material for forming a resin diffusion channel according to (4) or (5), wherein the non-porous sheet and the pass media are heat-sealed.
(7) A sheet for forming a resin diffusion channel, wherein a porous sheet is laminated and integrated on the side of the pass media surface of the sheet material for forming a resin diffusion channel according to any one of (4) to (6). Wood.

  According to the method for producing FRP according to the present invention, without increasing the waste of resin and the amount of waste, by preventing the reduction of the diffusion efficiency of the pass media by the bag film, in a simpler and cheaper method, It is possible to efficiently diffuse the resin into the pass media and shorten the FRP manufacturing time.

  Hereinafter, the best mode of the present invention will be described in the order of steps with reference to the drawings of one embodiment. For the sake of convenience, description will be made in the order of steps in one embodiment. However, the case where the order of each step is changed or the case where some steps are omitted is also included in the scope of the method for manufacturing FRP according to the present invention. .

  FIG. 1 is a cross-sectional view of a VaRTM molding apparatus for explaining an embodiment according to the manufacturing method of the present invention, and shows a state in which a resin in a resin pot 23 is injected while the bag film 14 is decompressed. Show. FIG. 3 is a cross-sectional view of a VaRTM molding apparatus for explaining another embodiment according to the manufacturing method of the present invention. FIG. 4 shows an example of one form of a reticulated path media according to the VaRTM molding method of the present invention.

1. Step of Setting Reinforcing Fiber Substrate In FIG. 1, first, a reinforcing fiber substrate 2 is placed on a flat plate-shaped mold 1 whose surface is coated with a release agent. Although it does not specifically limit as the reinforced fiber base material 2, For example, a carbon fiber, glass fiber, an aramid fiber etc. can be used. Further, the cross-sectional shape of the reinforcing fiber base 2 is not particularly limited, but may be a simple shape such as a rectangle, or a complicated shape having a curved surface or an acute angle. As will be described in detail later, the pass media 10 and the auxiliary sheet 12 according to the present invention can be molded to follow a complicated shape by providing flexibility.

2. Setting process of pass media 10 Pass media 10 is arranged on reinforcing fiber base 2 from the necessity of making resin flow in the in-plane direction (plane shape) of reinforcing fiber base 2 quickly. The pass media 10 is a net or cloth sheet having a large number of voids, and is interposed between the liquid resin supply portion and the reinforcing fiber base, and the resin penetrates into the voids of the pass media along the surface. The resin impregnates the reinforcing fiber base while diffusing rapidly. That is, uniform penetration and impregnation of the resin into the reinforcing fiber base can be performed easily and quickly. The pass media is not particularly limited as long as the resin flow resistance is lower than that of the reinforcing fiber base 2, and for example, a mesh sheet or a flat plate with a groove as a resin flow path can be used. It can be said that the higher the porosity of the pass media (the ratio of the voids in the volume of the pass media), the higher the resin diffusibility and the better the performance.

  It is preferable to arrange a peel ply 11 having releasability between the pass media 10 and the reinforcing fiber base 2. The peel ply 11 is not particularly limited in material as long as the pass media 10 can be easily released from the cured plate after curing. For example, a nylon woven fabric can be used.

3. Setting Step of Injection Port 22 and Suction Port 21 An injection port 22 for injecting resin into the reinforcing fiber base 2 and a suction port 21 for decompressing the reinforcing fiber base 2 are disposed. As shown in the drawing, a resin inlet 22 is disposed on the left side of the pass medium 10. The resin injection port 22 is preferably a mold material that is open so as to be easily diffused in the width direction of the reinforcing fiber base 2. The resin pot 23 is installed near the resin injection port 22 and communicated with the injection line 24. The injection line 24 is not particularly limited, but a larger inner diameter is preferable in order to reduce pressure loss.

  On the other hand, a breather 25 is arranged on the right side of the reinforcing fiber base 2 so that a part of the left side is in contact with the reinforcing fiber base 2 and the right side is communicated with the suction port 21 so as to be sucked under reduced pressure. The vacuum suction port 21 communicates with a vacuum trap 27 and a vacuum pump 28 through a vacuum suction line 26. The vacuum suction port 21 only needs to be open at the bottom as described above. The breather 25 is not particularly limited in form as long as the reinforcing fiber base 2 can be sucked under reduced pressure, and at least a part of the breather 25 may be in contact with the reinforcing fiber base 2. The material of the breather 25 is not particularly limited, and organic fiber cloth, inorganic fiber cloth, mesh material, and the like can be used. For example, glass fiber fabric or mat material, synthetic fiber non-woven fabric, the reinforcing fiber A part of the reinforcing fiber base 2 constituting the base 2 and a net-like sheet material can be used.

4). Auxiliary sheet 12 material setting step An auxiliary sheet 12 which is a feature of the present invention is arranged on the pass medium 10, a sealant 13 is arranged around the set molding portion, and then covered with a bag film 14. The gap between the periphery of the film 14 and the mold 1 is sealed and bagged.

  The bag film 14 is not particularly limited as long as it is an airtight and highly flexible material. However, since the bag film 14 is required to easily follow the shape of the molded product, a film having low rigidity and good elongation is used. It is preferable to do. For example, a nylon film material may be used.

The auxiliary sheet 12 disposed between the pass media 10 and the bag film 14 is a Young satisfying the following formula (I) when the Young's modulus of the bag film 14 is E _b and the thickness is T _b. It has a rate E _S and a thickness T _S.

E _S T _S ³ > E _b T _b ³ (I)
As the Young's modulus E of the bag film and the auxiliary sheet according to the present invention, the Young's modulus measured by the measuring method of ASTM D882 is used. The thickness T of the bag film and the auxiliary sheet is measured using a micrometer whose minimum unit is 10 μm or less, for example, a micrometer PMU manufactured by Mitutoyo.

The function ET ³ shown in the formula (I) is synonymous with the second moment of section in classical material dynamics, and is defined as so-called rigidity. That is, as ET ³ is larger, the rigidity is higher and the deformation is less likely (the deflection is smaller). Therefore, the problem of the prior art can be solved by making the rigidity of the auxiliary sheet according to the present invention higher than the rigidity of the bag film. That is, by disposing an auxiliary sheet having rigidity higher than that of the bag film, the bag film can be prevented from entering the gap of the pass media, and the diffusion efficiency of the resin into the pass media can be improved.

  In addition, when a plurality of pass media are stacked in the prior art, since the pass media is removed after molding and discarded, a large amount of resin remaining in the pass media becomes all waste, resulting in a low material yield. As a result, there is a problem that the cost increases and waste increases. Therefore, the auxiliary sheet according to the present invention is preferably in a form in which the resin hardly penetrates, that is, a sheet with few voids. More preferably, the non-porous sheet does not penetrate the resin, so that waste and cost can be reduced, and the auxiliary sheet itself can be reused, so that waste can be reduced. it can. For the auxiliary sheet, it is preferable to use a material excellent in releasability or to apply a release agent in advance from the viewpoint of easy removal of resin burrs and easy reuse.

  Further, in the FRP manufacturing method according to the present invention, since it is only necessary to arrange the auxiliary sheet material on the pass media, it is very simple and the manufacturing time is reduced by improving the diffusion efficiency of the pass media. Since it can be shortened, the entire manufacturing time of FRP can be shortened.

  Furthermore, in the conventional technique, when the gap of the pass media is increased in order to increase the resin diffusion rate, the span between the linear bodies forming the gap becomes long, and the deformation amount (deflection) of the bag film is large. On the contrary, there is a problem that the volume of voids in the pass media is reduced and there is a limit to the improvement of the diffusion rate of the pass media. However, according to the FRP manufacturing method according to the present invention, If the rigidity of the auxiliary sheet is increased according to the size of the gap, the diffusion efficiency of the pass media is maintained, so that the pass media diffusion rate can be improved more than in the prior art.

Further, as shown in FIG. 4, the pass medium 10 has a sheet shape in which linear bodies are gathered, the thickness is T _P , and the maximum value of the gap size formed between the linear bodies is L _P. The auxiliary sheet preferably satisfies the following formula (II).

E _S T _S ³ > L _P ⁴ / (64 T _P ) (II)
The thickness T of the pass media according to the present invention uses a micrometer whose minimum unit is 10 μm or less, for example, a micrometer PMU manufactured by Mitutoyo, and measures the thickest part (major axis) of the linear body. Size L _P of the voids of the path the media according to the present invention, as shown in FIG. 4, caliper and maximum span of the gap formed between the linear body, and the minimum unit of the following minimum unit 10 [mu] m, for example Mitutoyo calipers Measure using CD-C.

In Formula (II), the maximum value of the length of the gap formed between the linear bodies of the pass media is L _P, and the deflection caused when atmospheric pressure is applied to the auxiliary sheet with the linear body as a fulcrum is expressed as y. Is equivalent to satisfying the relationship of (flexure y of auxiliary sheet material) <(pass media thickness T _P ). In classical material dynamics, this is a formula calculated from a deflection calculation formula when a uniformly distributed load is applied to a two-point support beam (uniform cross section). That is, if the deflection of the auxiliary sheet material is larger than the thickness of the pass media, the gap of the pass media is completely blocked. Therefore, the deflection of the auxiliary sheet is preferably smaller than the thickness of the pass media.

  The auxiliary sheet preferably satisfies the following formula (III).

E _S T _S ³ <4 N · m (III)
In order to secure a large volume of the gap of the pass media, it can be said that the higher the rigidity of the auxiliary sheet, the better. However, when the rigidity of the auxiliary sheet is increased, if the molded product has a complicated shape, for example, an arc shape In the case of having a shape, the deformation of the sheet cannot follow the molded product only at atmospheric pressure. Therefore, it is preferable that the rigidity is less than or equal to following a complex shape, and if it has rigidity of the formula (III), it is preferable because it can follow the reinforcing fiber base 2 having a curved shape with a radius of 50 mm or more in calculation. . From the viewpoint of shape followability, the auxiliary sheet is preferably in the form of a film.

Further, as shown in FIG. 3, instead of the pass medium 10 and the auxiliary sheet 12, a non-porous sheet having a Young's modulus E _S and a thickness T _S satisfying the following formula (IV) and a pass medium are laminated and integrated. It can also be set as the sheet material 15 for resin diffusion flow path formation.

E _S T _S ³ > 0.0001 _N · m (IV)
As described above, in addition to being able to solve the problems of the prior art, by integrating the non-porous sheet and the pass media, it is possible to stack two layers at one time. Time can be shortened.

Further, in the sheet material 15 for forming the resin diffusion channel, the path media is a sheet shape in which linear bodies are gathered, and the thickness is T _P , and the maximum value of the size of the gap formed between the linear bodies the when the L _P, that non-porous sheet satisfies the following formula (V), preferred by equivalent reasons and the formula (II).

E _s T _s ³ > L _P ⁴ / (64 T _P ) (V)
Moreover, it is preferable that the said non-porous sheet and the said pass media are heat-seal | fusing the said sheet material 15 for resin diffusion flow path formation. By manufacturing the sheet material by heat fusion, an inexpensive and simple sheet material can be obtained.

  Further, as shown in FIG. 6, the resin diffusion flow path forming sheet material is in the form of a resin diffusion flow path forming sheet material 15 ′ in which the porous sheet 16 is laminated and integrated on the surface of the pass medium 10. Also good. The porous sheet 16 is a sheet-like member having a finite number of holes (resin flow paths) 17, and the unevenness of the pass medium 10 is transferred to the reinforcing fiber substrate side while maintaining the resin diffusion function of the pass medium 10. It is a sheet | seat for suppressing. Therefore, it is preferable to arrange the porous sheet 16 on the surface of the pass media 10 (design surface of the molded product). Since the porous sheet 16 is integrated, in addition to the effect of improving the surface property of the molded product, it is possible to stack a plurality of times in one time, so that the time for stacking can be shortened. The material of the porous sheet 16 is, for example, a metal thin plate material (steel, stainless steel, aluminum, etc.) such as a net or punching metal, or a thickness of 0.1 mm or more, or a resin film (nylon, polyester, polyethylene, polypropylene, polyimide) It is preferable to use a sheet material having a thickness of 0.2 mm or more and an FRP sheet having a thickness of 0.2 mm or more. The means for integrating the non-porous sheet 12 ′, the pass media 10, and the porous sheet 16 is not particularly limited, but it is more preferable to manufacture by heat fusion because it can be manufactured inexpensively and easily. The hole 17 is preferably a round shape in terms of processing, but the shape is not particularly limited. In order to leave almost no trace on the surface of the molded body after peeling the porous sheet from the molded body, the hole diameter is desirably 3 mm or less, more desirably 1.5 mm or less. The arrangement of the holes may be random or regular. A preferable hole pitch varies depending on the specification of the reinforcing fiber base to be used, but it is 15 mm or less, preferably 10 mm or less. The required function for the porous sheet is that the smoothness is equal to or higher than the surface roughness required for the final product, and the rigidity is that the unevenness of the resin diffusion medium is not transferred to the reinforcing fiber substrate side.

5. Bagging and Depressurization Step of Entire Molding Portion Next, the suction side valve 29b is opened, and the inside of the bag film 14 is depressurized from the depressurization suction port 21. In order not to leave air in the molded body, the pressure is preferably reduced to 10 torr or less. In order to prevent air leakage into the bag film 14, a sealant is further arranged on the outer periphery of the bag film 14, covered with a second bagging film, communicated with a vacuum pump, and then the inside is depressurized. May be.

6). Resin impregnation / curing step Next, the injection side valve 29a is opened, and the resin in the resin pot 23 flows in from the resin injection port 22 due to the pressure difference from the atmospheric pressure. The resin is first filled in the full length direction of the injection port 22 (the width direction of the reinforcing fiber base 2), and then diffuses in the pass medium 10. According to the manufacturing method according to the present invention, the voids in the pass media 10 are sufficiently secured, so that the resin mainly impregnates the reinforcing fiber base 2 after quickly diffusing in the pass media 10.

  When the resin impregnation to the reinforcing fiber base 2 is completed, the injection side valve 29a is closed. The valve 29b on the suction side may be left open to increase the fiber volume content of the molded body, but may be closed when surface smoothness is required. Next, if necessary, the temperature of the molded part is raised to the curing temperature to solidify the molded body.

  In addition, as resin to be used, thermosetting resins, such as an epoxy, unsaturated polyester, phenol, and vinyl ester, can be used preferably. Unsaturated polyester resin and vinyl ester resin are preferable in terms of moldability and cost, epoxy resin is preferable when mechanical properties and adhesiveness are required, and phenol resin is preferable when flame retardancy is required .

7). FRP Demolding Step After confirming that the molded body has solidified, the bag film 14 is peeled off, and the solidified molded body is demolded from the mold 1. By removing the pass media 10 and the auxiliary sheet 12 from the molded body, a desired FRP can be obtained. The removed auxiliary sheet 12 can be reused by removing resin burrs and the like. By reusing the auxiliary sheet 12, the manufacturing time of FRP can be shortened without increasing waste.

  Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

In the examples, the Young's modulus E of the bag film and the auxiliary sheet is determined by ASTM D882, and the thickness of the bag film, auxiliary sheet, and pass media (the thickest part (major axis) of the linear body) is made by Mitutoyo. Using the micrometer PMU, the size L _P of the gap of the pass media (maximum span portion of the gap formed between the linear bodies shown in FIG. 4) was measured using a caliper CD-C made by Mitutoyo. .
(Example 1, Comparative Example 1)
In FIG. 1, first, a carbon fiber woven fabric CO6343B ("Treka (registered trademark)" T300, 200 g / m ² basis weight, plain weave structure, size on an aluminum mold 1 having a release agent applied on its surface. A reinforcing fiber substrate 2 in which 10 ply of 1000 mm × 500 mm) was laminated was disposed. Next, a peelable ply 11 (nylon taffeta) having releasability on the reinforcing fiber base 2 and a mesh (span 3 mm) polyethylene network (thickness 0.5 mm, maximum gap size) as pass media 10 Value 3.2 mm).

  Next, on the left side of the pass medium 10, a resin inlet 22 with an aluminum C-channel material opening down was disposed. The resin pot 23 was installed near the resin injection port 22 and communicated with an injection tube made of nylon having an inner diameter of φ6 mm. On the other hand, a polyester non-woven fabric was arranged as a breather 25 on the right side, and a vacuum suction port 21 with an opening of an aluminum C channel material on the right side of the breather 25 was arranged. The vacuum suction port 21 communicated with a vacuum trap 27 and a vacuum pump 28 through a vacuum suction line 26 using a nylon tube having an inner diameter of φ6 mm.

  Two sets of Example 1 and Comparative Example 1 were prepared for the molded body that was implemented up to the setting step of the injection port 22 and the suction port 21. In the first set, as Example 1, a Toray Lumirror (polyester film, thickness 0.3 mm, Young's modulus 6 GPa) was placed on the pass media 10 as an auxiliary sheet 12. In the second set, as Comparative Example 1, the auxiliary sheet 12 was not arranged.

  Next, the sealant 13 is arranged around the molded part set up to the above steps, and the bag film 14 is entirely made of RICMOND VAC-PAK (nylon film, thickness 0.05 mm, Young's modulus 0.5 GPa). And the space between the mold 1 was sealed. The suction side valve 29b was opened, and the inside of the bag film 14 was depressurized from the reduced pressure suction port 21 to 1 torr.

  Next, Showa High Polymer vinyl ester resin R-806 (initial viscosity 100 cPs at a temperature of 25 ° C., gelation time 50 minutes) was prepared and set in the resin pot 23. Then, the injection side valve 29 a was opened, and the resin in the resin pot 23 was injected from the resin injection port 22. The resin was instantaneously filled into the resin inlet 22 and then diffused in the pass media 10. In Example 1 and Comparative Example 1, FIG. 5 shows the results of measuring the distance at which the resin diffused in the pass media 10 with respect to the elapsed time after the start of injection. As shown in FIG. 5, in the case of Comparative Example 1, it took 45 minutes to diffuse 1000 mm in the pass medium 10, whereas in Example 1, the result was 1000 mm diffused in 15 minutes. In Example 1, the inside of the pass medium 10 was diffused in 1/3 of the time of Comparative Example 1. Finally, in Example 1, the outflow (arrival) of the resin from the suction port 21 was confirmed 16 minutes after the start of injection, but in Comparative Example 1, the resin was sucked into the suction port after diffusing in the pass medium 10. Since the resin solidified before reaching 21 and the fluidity was lost, an unfilled portion of the resin was generated.

Next, the injection side valve 29a was closed, and the suction side valve 29b was closed, and the resin in the reinforcing fiber base 2 was cured. After confirming the curing of the resin, the molded product was demolded. The auxiliary sheet 12 was removed from the molded product, and the resin burr was removed and reused. In addition, the molded product of Example 1 was a good product having no unimpregnated portion of the resin, and compared with Comparative Example 1, the production time of FRP could be shortened.
(Example 2)
In FIG. 3, first, Toray carbon fiber fabric CO6343B (“Treka (registered trademark)” T300, 200 g / m ² basis weight, plain weave structure, size on an aluminum mold 1 having a release agent applied on its surface. A reinforcing fiber substrate 2 in which 10 ply of 1000 mm × 500 mm) was laminated was disposed. Next, a peel ply 11 having a releasability (nylon taffeta) on the reinforcing fiber base 2 and a resin diffusion in which a non-porous sheet 12 ′, a pass medium 10 and a porous sheet 16 are laminated and integrated as shown in FIG. A flow path forming sheet material 15 ′ was disposed. A mesh medium (span 3 mm) -like polyethylene mesh (thickness 0.5 mm, maximum gap size 3.2 mm), non-porous sheet 12 ′ as a pass medium 10 constituting the resin diffusion flow path forming sheet material 15 ′ Toray Lumirror (polyester film, thickness 0.3 mm, Young's modulus 6 GPa) and Toray Lumirror with a large number of holes 17 (hole diameter 1 mm, hole pitch 10 mm) were used as the porous sheet 16. Next, on the left side of the resin diffusion flow path forming sheet material 15 ′, a resin injection port 22 with an aluminum C channel material opening down was disposed. The resin pot 23 was installed near the resin injection port 22 and communicated with an injection tube made of nylon having an inner diameter of φ6 mm. On the other hand, a polyester non-woven fabric was arranged as a breather 25 on the right side, and a vacuum suction port 21 with an opening of an aluminum C channel material on the right side of the breather 25 was arranged. The vacuum suction port 21 communicated with a vacuum trap 27 and a vacuum pump 28 through a vacuum suction line 26 using a nylon tube having an inner diameter of φ6 mm.

  Next, the sealant 13 is arranged around the molded part set up to the above steps, and the bag film 14 is entirely made of RICMOND VAC-PAK (nylon film, thickness 0.05 mm, Young's modulus 0.5 GPa). And the space between the mold 1 was sealed. The suction side valve 29b was opened, and the inside of the bag film 14 was depressurized from the reduced pressure suction port 21 to 1 torr.

Next, Showa High Polymer vinyl ester resin R-806 (initial viscosity 100 cPs at a temperature of 25 ° C., gelation time 50 minutes) was prepared and set in the resin pot 23. Then, the injection side valve 29 a was opened, and the resin in the resin pot 23 was injected from the resin injection port 22. After the resin is instantaneously filled into the resin injection port 22, the holes (resin flow) of the porous sheet 16 are diffused while diffusing the path media 10 in the resin diffusion flow path forming sheet material 15 'at a speed of 1000 mm / 15 minutes. Road) 17 and impregnated into the reinforcing fiber base 2. . Finally, the outflow (arrival) of the resin from the suction port 21 was confirmed 16 minutes after the start of injection. Next, the injection side valve 29a was closed, and the suction side valve 29b was closed, and the resin in the reinforcing fiber base 2 was cured. After confirming the curing of the resin, the molded product was demolded.
The resin diffusion flow path forming sheet material 15 ′ and the peel ply 11 were removed from the molded product, and the surface of the molded product was confirmed. As a result, an FRP having good surface properties with no unevenness of the pass media 10 could be obtained. . Further, in the setting step, it is only necessary to set one sheet material 15 ′ for forming the resin diffusion flow path, so that the entire manufacturing time can be shortened together with the effect of improving the diffusion rate of the resin.

  INDUSTRIAL APPLICABILITY The present invention can be applied to a method for manufacturing FRP using a single-sided pass media and a bag film, and is used in various fields such as industrial uses such as vehicles, ships, aircraft, and building members, or sports uses. It can be applied to a wide range of FRP manufacturing methods.

It is sectional drawing of the VaRTM shaping | molding apparatus for demonstrating one Embodiment which concerns on the manufacturing method of this invention. It is sectional drawing of the VaRTM shaping | molding apparatus for demonstrating embodiment which concerns on the comparative example of this invention. It is sectional drawing of the VaRTM shaping | molding apparatus for demonstrating another embodiment which concerns on the manufacturing method of this invention. It is a fragmentary top view for demonstrating one form of the path media of the mesh body which concerns on the manufacturing method of this invention. It is a measurement result of the distance which the resin in the elapsed time after resin injection concerning Example 1 and comparative example 1 diffused in the pass media. It is a partial section and a top view for explaining one form of a sheet material for resin diffusion channel formation concerning the present invention.

Explanation of symbols

1: Mold 2: Reinforcing fiber substrate 10: Pass media 11: Peel ply 12: Auxiliary sheet 12 ': Non-porous sheet 13: Sealant 14: Bag film 15, 15': Sheet material 16 for forming resin diffusion channels 16: Porous Sheet 17: Hole (resin channel)
21: suction port 22: injection port 23: resin pot 24: injection line 25: breather 26: suction line 27: vacuum trap 28: vacuum pump 29a: valve (injection side)
29b: Valve (suction side)

Claims (7)

A reinforcing fiber base material is disposed on a mold, the entire reinforcing fiber base material is covered with a bag film, and a cavity is formed by sealing between the mold and the inside of the cavity is decompressed and a liquid resin is added. In the method for producing a fiber reinforced plastic that is injected and impregnated with a resin in the reinforcing fiber base, a pass medium is disposed on the reinforcing fiber base, the Young's modulus of the bag film is E _b , and the thickness is T An auxiliary sheet having a Young's modulus E _S and a thickness T _S satisfying the following formula (I) when _b is placed between the pass media and the bag film: .
E _S T _S ³ > E _b T _b ³ (I) The pass media is a linear body sheet was set, the thickness T _P, the maximum value of the formed gap size between linear body when the L _P, the auxiliary sheet, following Formula (II) is satisfied, The manufacturing method of the fiber reinforced plastics of Claim 1 characterized by the above-mentioned.
E _S T _S ³ > L _P ⁴ / (64 T _P ) (II) The said auxiliary sheet | seat satisfy | fills following formula (III), The manufacturing method of the fiber reinforced plastic in any one of Claim 1 or 2 characterized by the above-mentioned.
E _S T _S ³ <4 N · m (III) Formula resin distribution channel forming sheet material, characterized in that laminated and integrated imperforate sheet and pass medium having a Young's modulus E _s and the thickness T _s satisfying the (IV).
E _S T _S ³ > 0.0001 _N · m (IV) The pass media is a linear body sheet was set, the thickness T _P, the maximum value of the formed gap size between linear body when the L _P, the non-porous sheet, The sheet material for forming a resin diffusion channel according to claim 4, wherein the following formula (V) is satisfied.
E _S T _S ³ > L _P ⁴ / (64 T _P ) (V) The sheet material for forming a resin diffusion channel according to claim 4 or 5, wherein the non-porous sheet and the pass media are heat-sealed. A sheet material for forming a resin diffusion channel, wherein a porous sheet is laminated and integrated on the pass media surface side of the sheet material for forming a resin diffusion channel according to any one of claims 4 to 6.

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