JP2007237642A - Manufacturing method for fiber-reinforced plastic panel with opening - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a lightweight, high-strength and high-rigidity FRP panel with an opening, which can prevent a core material from being deteriorated by an environmental factor. <P>SOLUTION: In this manufacturing method for the fiber-reinforced panel, the opening is provided in the core material 31; a resin injection line 8 is arranged inside the opening; and grooves 2 are provided in the core materials in such a manner as to be radial from the resin injection line. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a method for producing a fiber-reinforced plastic (hereinafter sometimes abbreviated as FRP) panel having an opening and an FRP panel having an opening, and in particular, the resin is efficiently applied to the surface of the reinforcing fiber substrate and the core material. The present invention relates to a method for manufacturing an FRP panel having a lightweight, high-strength, high-rigidity opening that can be uniformly impregnated, and an FRP panel having an opening manufactured by the manufacturing method.

In the manufacturing method by the FRP sandwich panel RTM molding method, the reinforcing fiber base and the core material are arranged on the mold, the whole is covered with the bag base, the inside is evacuated, and the reinforcing fiber base in the bag base is formed. The FRP sandwich panel is formed by impregnating the material and the core material with resin. (For example, Patent Document 1)
When forming a FRP panel by placing a reinforcing fiber base material on the core material, injecting the resin and impregnating the reinforcing fiber base material, providing a groove or a through hole in the core material, or placing a resin diffusion medium, etc. In addition, a manufacturing method is used in which a resin is diffused through the grooves and through holes and a resin diffusion medium so that the reinforcing fiber base material is impregnated. When manufacturing an FRP panel having an opening using the above manufacturing method, means for manufacturing by providing an opening shape in the mold itself, or by placing a placement element or the like in the portion to be the opening. Has been taken. However, the cost is increased by providing an opening shape in the mold or producing a holder used for the opening. In addition, in order to prevent the core material from deteriorating due to environmental factors such as temperature and humidity in the opening, a method of pasting the end portions between the reinforcing fiber bases, or wrapping the reinforcing fiber base or the like in advance on the core material, etc. Then, a method of impregnating the resin is used. However, there arises a problem that peeling is likely to occur at the interface between the reinforcing fiber bases, and a problem of increase in weight and cost due to an increase in materials and work processes.
JP 2001-260238 A

  The subject of this invention pays attention to the above problems, and by efficiently impregnating the surface of the reinforcing fiber base and the core material with the resin, it is possible to prevent deterioration due to environmental factors of the core material, An object of the present invention is to provide a method for manufacturing an FRP panel having an opening with high strength and high rigidity, and an FRP panel having an opening produced by the manufacturing method.

  In order to solve the above-mentioned problem, the method for producing an FRP panel having an opening according to the present invention includes a core material having a groove on at least one side and a reinforcing fiber base material arranged in a mold, and the whole is covered with a bag base material. A method of manufacturing an FRP panel in which a resin is injected after the inside covered with a back base material is evacuated, and a reinforcing fiber base material is impregnated with the resin by using a groove of the core material as a resin flow path. An opening is provided, a resin injection line is disposed inside the opening, and a groove is provided in the core material radially from the resin injection line.

  In the manufacturing method of the FRP panel having the opening, since the resin is injected from the resin injection line provided inside the opening, the surface of the core material on which the reinforcing fiber base material is not disposed is also impregnated with the resin. Therefore, the core material is not deteriorated due to environmental factors, and there is no need for a mold having an opening shape or a laying element arranged in the opening, and an FRP panel having a light, high strength and high rigidity opening at low cost. Can be manufactured.

  The core material used above is preferably a foam from the viewpoint of weight reduction.

  In the case of a phenol resin used as an incombustible material in aircraft and railways, even if the viscosity of the resin is a little high, the resin can be efficiently impregnated on the surface of the reinforcing fiber base and the core material by using this production method. Can do. As the reinforcing fiber base, it is preferable to use carbon fibers that can exhibit high strength, rigidity, and lightness. In addition, since the FRP panel having an opening obtained by this manufacturing method is lightweight, high in strength and high in rigidity, and can be manufactured at low cost, it is preferably used for doors of aircraft, railways, automobiles and the like.

  According to the method for manufacturing an FRP panel having an opening of the present invention, the resin is uniformly and efficiently impregnated on the surface of the reinforcing fiber base and the portion of the core material where the reinforcing fiber base is not disposed. , Light weight, high strength and high rigidity without deterioration of the core material without taking special measures to prevent the core material from deteriorating due to environmental factors. An FRP panel having a simple opening can be manufactured at low cost.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.

  First, the FRP panel having an opening as a target in the molding method of the present invention includes a core material, a resin impregnated on the surface of the core material, and an FRP plate disposed on the core material.

  The FRP plate is a composite material including a reinforcing fiber base and a resin.

  As the reinforcing fiber constituting the reinforcing fiber substrate, materials used for ordinary reinforcing fiber substrates such as carbon fiber, glass fiber, aramid fiber, and boron fiber can be used, and these can be used in combination. Among these, carbon fibers that can maximize the weight reduction effect are preferable. As the form of the reinforcing fiber base, it is preferable to use a woven fabric, a mat, a strand, or a roving alone or in combination.

  As the resin constituting the FRP plate, a thermosetting resin such as an epoxy resin, an unsaturated polyester resin, a phenol resin, or a vinyl ester resin is preferable in terms of moldability and cost. Moreover, it is preferable to use a phenol resin especially from a nonflammable viewpoint.

  A foam or wood can be used as the core material, but a foam is preferable in terms of weight reduction. As the material of the foam, foam core material made of vinyl chloride, acrylic, phenol, urethane, polystyrene, or the like can be used.

  Examples of the groove pattern of the core material used in the present invention are shown in FIGS. As shown in FIG. 1, the opening of the core material is such that the outer periphery of the opening 3 is entirely surrounded by the core material 1 and may be located at any position as long as the condition is satisfied. The shape of the opening 3 may be any shape such as a circle, an ellipse, a rectangle, or a polygon.

  In FIG. 1, radial grooves 2 are provided for resin injection line positions 4 in the openings 3 of the core material 1. In the present invention, the radial means the radial direction at a point on a semicircle centering on the end of the resin injection line and the direction perpendicular to the resin injection line from points other than the end of the resin injection line. To do. Further, even if there is a groove that is partially parallel to the resin injection line, it is said to be radial if it has at least the radial groove. As shown in FIG. 2, the groove pattern may be combined with a radial groove 2 and a groove 5 perpendicular and horizontal to the radial groove, and optimization of the groove pattern is appropriately performed according to the FRP panel to be manufactured. Just decide.

  3 and 4 show a schematic configuration of an apparatus for carrying out a method for manufacturing an FRP having an opening according to an embodiment of the present invention. FIG. 3 shows a so-called sandwich structure in which the reinforcing fiber base material 7 is arranged on both surfaces of the core material 31, and FIG. 4 shows a so-called canapé structure in which the reinforcing fiber base material 7 is arranged on one surface of the core material 41.

  3 and 4, reference numeral 6 denotes a mold, in which a core material 31 having grooves on both sides and a core material 41 having grooves on one side are arranged in the mold 6 and a reinforcing fiber base is formed on the surface of the core material. A material 7 is arranged. A plurality of reinforcing fiber substrates are appropriately laminated as necessary. In the core materials 31 and 41, the grooves shown in FIGS. 1 and 2 are provided on the surface on the side where the reinforcing fiber base material 7 is arranged. In a state where the core materials 31 and 41 and the reinforcing fiber base material 7 are arranged on the mold 6, the resin injection line 8 is arranged in the opening 3 of the core materials 31 and 41, and the whole is covered with the bug base material 9. . A sealing material 10 is disposed between the outer periphery of the bag base 9 and the mold 6 so that the inside can be evacuated. As the bag base material, for example, a nylon film or a polyolefin film can be used. In particular, when a phenol resin is used, it is preferable to use a polyolefin film because the curing agent is a strong acid. The inside is evacuated through the suction port 12 via the vacuum tube 13. Suction is performed by a vacuum pump (not shown). The position and number of the resin injection line 8 and the resin injection port 11 can be appropriately changed as long as they are within the range in the opening 3. The vacuum tube and the suction port can be similarly changed.

  Further, in the embodiment shown in the figure, the reinforcing fiber base 7 and the core materials 31 and 41 are directly covered with the bug base, respectively. A mold material (not shown) may be interposed. By using the resin diffusion medium, the reinforcing fiber base material can be more efficiently impregnated with the resin diffusion medium. As such a medium, for example, a polypropylene mesh or the like can be used.

In the said embodiment, the bug base material 9 itself is provided with the function of a mold release material. The release material provided as necessary is used for demolding. For example, a nylon taffeta woven sheet that can pass through the resin but is peeled off after being cured and removed from the FRP panel can be used.
Further, a rigid plate such as a metal plate may be disposed between the bag base material and the reinforcing fiber base material 7 in order to improve the smoothness of the FRP panel.

  The injected resin is diffused in the surface direction of the reinforcing fiber base 7 through the grooves 5 perpendicular and horizontal to the radial grooves 2 and 2 provided in the core materials 31 and 41, and also in the thickness direction. Impregnated. At that time, the surfaces of the core materials 31 and 41 where the reinforcing fiber base material is not disposed are also impregnated with the resin. The impregnated resin is cured at room temperature or by heating, and an FRP panel having an opening is formed in one shot.

  In the above molding, it is not necessary to provide an opening shape in the mold and to prepare a laying element or the like installed in the opening. In addition, since the surface of the portion of the core material where the reinforcing fiber base material is not disposed is impregnated with the resin, means for preventing deterioration of the core material due to environmental factors, such as wrapping the reinforcing fiber base material in advance on the core material, In addition, it is not necessary to bond the reinforcing fiber bases at the end portions, and an FRP panel having a lightweight, high-strength, high-rigidity opening can be obtained. Further, in the embodiment shown in FIG. 4, the resin is evenly impregnated into the surface of the portion of the core material 41 where the reinforcing fiber base is not disposed by the above manufacturing method, so that no uneven warping occurs after molding. There are advantages such as.

  The FRP panel having an opening obtained by the embodiment shown in FIG. 3 is light in weight, high strength and high rigidity without deterioration of the core due to environmental factors. You may use for the door which has window parts, such as an aircraft, a railroad, and a motor vehicle, by arrange | positioning the frame material which can be attached to other parts in an outer peripheral part. Similarly, an FRP panel having an opening obtained by the embodiment shown in FIG. 4 is used as a door by arranging windows, an outer frame, etc., and attaching a separately molded FRP plate to the core material side. Is possible.

It is a perspective view which shows an example of the groove pattern of a core material. It is a perspective view which shows an example of the groove pattern of a core material. It is a schematic block diagram which shows an example of the manufacturing method of the FRP panel which has an opening part which concerns on this invention. It is a schematic block diagram which shows an example of the manufacturing method of the FRP panel which has an opening part which concerns on this invention.

Explanation of symbols

1, 2, 31, 41 Core material 2 Radial groove 3 Opening 4 Resin injection line position 5 Parallel and perpendicular to radial groove 6 Mold 7 Reinforcing fiber substrate 8 Resin injection line 9 Bug substrate 10 Sealing material 11 Resin injection port 12 Suction port 13 Vacuum tube

Claims (5)

  A core material having a groove on at least one side and a reinforcing fiber base material are placed in a mold, the whole is covered with a bag base material, and the interior covered with the back base material is evacuated, and then a resin is injected to the core material. A fiber reinforced plastic panel manufacturing method in which a reinforcing fiber base material is impregnated with a resin using a groove as a resin flow path, wherein an opening is provided in the core material, a resin injection line is disposed inside the opening, and the core material A method for producing a fiber-reinforced plastic panel having an opening, wherein grooves are provided radially from the resin injection line.   The manufacturing method of the fiber reinforced plastic panel which has an opening part of Claim 1 using a foam as a core material.   The manufacturing method of the fiber reinforced plastic panel which has an opening part of Claim 1 or 2 using a phenol resin as resin.   The manufacturing method of the fiber reinforced plastic panel which has an opening part in any one of Claims 1-3 which uses a carbon fiber for a reinforced fiber base material.   A fiber-reinforced plastic door comprising a fiber-reinforced plastic panel having an opening manufactured according to any one of claims 1 to 4.

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