JP2008179149A - Rtm molding method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an RTM molding method which improves a quality in a design aspect of a molded article, and at the same time, can mold a thick article structure with a good resin impregnation property. <P>SOLUTION: The RTM molding method comprises a step of setting lower a resin flow resistance of a first resin distribution medium 5 arranged on a first surface of a reinforcing fiber substrate than the resin flow resistance of a second resin distribution medium arranged on a second surface in a shaping mold 1, and a step of impregnating the resin in the reinforcing fiber substrate by a suction through the second resin distribution medium while injecting the resin into the first resin distribution medium 5. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to an improved Resin Transfer Molding (hereinafter referred to as RTM) molding method for molding a structure made of fiber reinforced plastic (hereinafter referred to as FRP), and in particular, it is possible to mold a thick material. And it is related with the RTM shaping | molding method which can improve quality about surface property.

  Conventionally, FRP has been used in various fields. As a method for manufacturing an FRP structure, a preform having a shape of a structure to be molded in advance is formed by a prepreg, and this is then processed at a predetermined temperature and pressure. A so-called prepreg / autoclave molding method in which curing is performed in an autoclave set to conditions is common. However, in recent years, RTM molding methods have attracted attention for reducing manufacturing costs, and this molding method is gradually spreading.

  As a typical RTM molding method, a molding method described in Patent Document 1 is known. In the RTM molding method described in Patent Document 1, peel ply / resin dispersion media are arranged on both sides of a reinforcing fiber base made of a laminate of reinforcing fiber materials, and these are arranged on a molding die (tool) surface. The whole is covered with a bag material, and a resin injection gate and a suction gate for pressure reduction are provided in the interior sealed by the bag material. In this state, the resin is injected from the resin injection gate while reducing the pressure by sucking the inside of the bag through the suction gate at room temperature or in a heated atmosphere. The resin is impregnated into the reinforcing fiber base material by flowing from the lower surface side to the upper surface side. Then, after the impregnation is completed, the resin is cured at normal temperature or in a heated atmosphere, and after curing, the bag material is peeled off and the molded body is demolded.

However, this molding method has the following problems.
First, although resin dispersion media are arranged on both sides of the reinforcing fiber substrate, since the resin impregnation from one side is basically performed on the reinforcing fiber substrate, the distance that can be impregnated in the thickness direction of the substrate If the reinforcing fiber base becomes too thick, the predetermined impregnation becomes impossible.

  In order to impregnate the resin into the thick reinforcing fiber base, it is possible to impregnate the resin into the reinforcing fiber base from both of the resin dispersion media arranged on both sides of the reinforcing fiber base. Since resin dispersion media with substantially the same shape and characteristics are arranged on both sides, simply impregnating the resin from both sides will cause the resin to be impregnated in the same direction in the thickness direction of the substrate, and the void It becomes difficult to extrude to a direction etc., and a void becomes easy to be confine | sealed in a base material. If the void is confined, the target performance of the molded article cannot be obtained. In order to avoid such confinement of voids, resin impregnation is basically performed from one side.

  Another problem in the molding method is that it is difficult to obtain good smoothness on the design surface of the molded product. That is, the resin dispersion medium is configured as a member having a relatively large degree of unevenness with low airflow resistance in order to enhance the resin dispersion performance. Since it arrange | positions and shape | molds on both surfaces of a base material, the comparatively big unevenness | corrugation of the resin dispersion medium will be reflected also in the design surface which is one side of a molded article. As a result, the designability is impaired, and unevenness is formed on the surface of the molded product, which may cause a problem that aerodynamic characteristics and the like are deteriorated.

  In order to cope with such a problem, it is conceivable to use a resin dispersion medium having a small degree of unevenness. However, if it does so, the airflow resistance becomes too large and the target resin dispersion performance cannot be obtained. Moreover, since the ventilation from the inside of the reinforcing fiber base during suction is worsened, the degree of vacuum does not increase, and it becomes difficult to completely impregnate a thick base in the thickness direction.

  In this way, the size of the unevenness of the resin-dispersed media will affect the resin diffusion and ventilation performance, but the resin dispersion media unevenness (relatively large unevenness) and molding to improve the resin diffusion and ventilation performance The unevenness (relatively small unevenness) of the resin-dispersed media for improving the surface properties of the product has a contradictory relationship. Therefore, in the above-described conventional method in which substantially the same resin dispersion medium is disposed on both surfaces of the reinforcing fiber base, it is difficult to achieve both improvement of the resin impregnation property and improvement of the surface property of the molded product. This is particularly difficult in molding using a thick reinforcing fiber substrate.

Here, it is known that the impregnation property (permeability) of the resin to the reinforcing fiber base is generally expressed by the following formula.
I = (ε / (1-ε)) √ (αP / 2) × ∫ [dt / √ (μ (t) t)]
I: Permeability, ε: Resistance of base material, α: Constant, P: Vacuum pressure in base material μ (t): Viscosity, t: Elapsed time Here, the permeability is the distance that the resin impregnates the base material ( Thickness).

  In order to improve the quality of the surface properties of the molded product, it is conceivable not to provide a ventilation material on the tool surface side, but in that case, the ventilation in the base material deteriorates and the degree of vacuum does not increase. When molding an object (thick plate), it is difficult to impregnate completely. Therefore, in order to mold a thick material, it is necessary to arrange a medium for ventilation on the tool surface side, and as described above, while maintaining the resin diffusion performance on the opposite surface side, the tool surface side It becomes difficult to improve the surface properties of the.

In addition, regarding the resin impregnation into the reinforcing fiber base, the values, constants, and viscosities in the above formulas differ depending on the type of base and resin, but the impregnation distance converges as time passes, and the viscosity of the resin increases. In addition, since the resin gels before long, there is a limit to the distance that the resin can be impregnated, and when the reinforcing fiber substrate exceeds a certain thickness, it is no longer possible to impregnate completely with the conventional method described above. It was.
US Pat. No. 5,052,906 (Claim 1, FIG. 1)

  The object of the present invention is to solve the above-mentioned problems in the prior art, improve the quality of the design surface of a molded product, and provide an RTM molding method capable of molding a thick structure with good resin impregnation. There is to do.

  In order to solve the above-described problems, the RTM molding method according to the present invention includes a reinforcing fiber base disposed in a mold, and a resin flow resistance on both surfaces of the reinforcing fiber base is higher than that of the reinforcing fiber base. An RTM in which a low resin diffusion medium is placed, the inside of the mold is decompressed by suction, a resin is injected into the mold through the resin diffusion medium, and the reinforcing resin base material is impregnated with the injected resin In the molding method, the resin flow resistance of the first resin diffusion medium disposed on the first surface of the reinforcing fiber substrate is the resin flow resistance of the second resin diffusion medium disposed on the second surface. The reinforcing fiber base material is impregnated with the resin by suction through the second resin diffusion medium while injecting the resin into the first resin diffusion medium. It consists of a method (first method).

  That is, in the RTM molding method according to the present invention, the resin flow resistance of the resin diffusion medium disposed on both surfaces of the reinforcing fiber base is intentionally given a magnitude relationship. In practice, the resin flow resistance can be grasped as a value corresponding to the measured ventilation resistance by measuring the ventilation resistance.

  In the present invention, the reinforcing fiber substrate may be a single layer or may be composed of a laminate of a plurality of reinforcing fiber materials, but the RTM molding method according to the present invention is particularly a thick article, that is, a thick reinforcing fiber. Since the present invention is suitable for molding in which a base material is impregnated with a resin, the present invention is mainly directed to the case where a reinforcing fiber base material composed of a laminate of a plurality of reinforcing fiber materials is used.

  In the RTM molding method according to the present invention, the resin flow resistance of the second resin diffusion medium is preferably set to 1/3 or less of the resin flow resistance of the reinforcing fiber base. As a result, the resin flow resistance (air flow resistance) of the second resin diffusion medium is higher than the resin flow resistance (air flow resistance) of the first resin diffusion medium, but the resin flow resistance (air flow resistance) of the reinforcing fiber base is increased. Compared to a sufficiently low level, the ventilation from the reinforcing fiber base is prevented from worsening and the degree of vacuum in the base is prevented from being lowered, and the resin impregnation property is impaired even for a thick reinforcing fiber base. Avoided.

  The resin flow resistance of the first resin diffusion medium is preferably 1/10 or less of the resin flow resistance of the reinforcing fiber substrate. This ensures that the resin injected into the first resin diffusion medium has a sufficiently high diffusibility in the surface direction of the reinforcing fiber base, and the resin injected into the first resin diffusion medium is not deposited on the surface. It is rapidly impregnated in the direction along the direction and rapidly impregnated in the thickness direction of the reinforcing fiber substrate. After satisfying the resin flow resistance of the first resin diffusion medium and the resin flow resistance of the second resin diffusion medium, the resin flow resistance of the first resin diffusion medium and the resin of the second resin diffusion medium are satisfied. A magnitude relationship is given to flow resistance.

  Moreover, in the RTM molding method according to the present invention, it is particularly preferable to start the injection of the resin from the second resin diffusion medium before the resin reaches the second surface. That is, resin impregnation from both sides substantially starts from this point.

  In the RTM molding method according to the present invention, it is preferable to interpose a peel ply that can be peeled integrally with the resin diffusion medium after molding between at least one of the resin diffusion medium and the reinforcing fiber substrate. As a result, the resin diffusion medium can be easily peeled off. However, after demolding the molded product, at least one of the resin diffusion media can be left in the molded product without peeling from the molded product. In this case, no peel ply is required for the side on which the resin diffusion medium remains.

  Moreover, in the RTM molding method according to the present invention, a porous sheet can be interposed between at least one of the resin diffusion media and the reinforcing fiber substrate. This porous sheet has a function different from that of the peel ply, and is a sheet for suppressing transfer of unevenness of the resin diffusion medium to the reinforcing fiber substrate side while maintaining the resin diffusion function of the resin diffusion medium. Therefore, the arrangement of the molded product on the design surface side is preferable.

  Furthermore, in the RTM molding method according to the present invention, at least one of the resin diffusion media can be configured by providing grooves as resin channels on the inner surface of the molding die. In this case, the inner surface of the mold itself can be used as the resin diffusion medium without separately preparing a resin diffusion medium.

  The present invention also provides the following RTM molding method from the viewpoint of molding a particularly excellent design surface. That is, in the RTM molding method according to the present invention, a reinforcing fiber base is disposed in a molding die, and a resin flow resistance is lower than that of the base on the surface of the reinforcing fiber base opposite to the molding die. A diffusion medium is disposed, a deaeration medium comprising a gas permeable membrane and a breathable base material is provided between the reinforcing fiber base and the mold surface, and the mold is decompressed by suction, and then the molding is performed. The resin is injected into the mold through the resin diffusion medium, and the injected resin is sucked from the deaeration space formed between the gas permeable membrane and the mold, so that the resin is injected into the reinforcing fiber base. It comprises a method characterized by impregnation (second method).

  In the second method, the reinforcing fiber base is made of, for example, a laminate of reinforcing fibers.

  Moreover, in the said 2nd method, it is preferable to use what has the release property which can peel from a molded article after shaping | molding as said gas permeable film.

  In the second method, when a molded product having a large area is formed, at least two or more resin injection gates are arranged above the resin diffusion medium and at least adjacent to the resin injection. It is preferable to inject the resin simultaneously from two matching resin injection gates or from all the resin injection gates.

  Furthermore, in the second method, when molding a molded product having a large area, in addition to the suction path from the deaeration space formed between the gas permeable membrane and the molding die, Preferably at least one additional suction path is provided.

  In the RTM molding method (first method) according to the present invention as described above, the resin is injected into the first resin diffusion medium having a lower resin flow resistance, and the injected resin is the reinforcing fiber base material. While being diffused quickly and sufficiently widely in the direction along the first surface, it is rapidly impregnated in the thickness direction in the reinforcing fiber substrate. Basically, the inside of the mold is depressurized by suction through the second resin diffusion medium having a higher resin flow resistance, and the injected resin is impregnated into the reinforcing fiber base in the suction / depressurized state. Go. At this time, the resin flow resistance (air flow resistance) of the second resin diffusion medium is higher than the resin flow resistance (air flow resistance) of the first resin diffusion medium, but the resin flow resistance (air flow resistance) of the reinforcing fiber base material. Since it is suppressed sufficiently low, the ventilation from the reinforcing fiber base material is prevented from being deteriorated and the degree of vacuum in the base material is prevented from being lowered, and the rapid impregnation of the resin is ensured. Therefore, a sufficiently good resin impregnation property is ensured even for a thick reinforcing fiber substrate. Since the second resin diffusion medium has its resin flow resistance (air flow resistance) set higher than that of the first resin diffusion medium, the second resin diffusion medium is compared with the first resin diffusion medium, Even when the surface of the second resin diffusion medium can be transferred onto the surface of the molded product, the degree of unevenness on the surface of the molded product due to the transfer can be kept small. Therefore, by setting this surface side as the design surface side, it is possible to obtain a design surface of a desired molded product with small unevenness.

  And in the molding which requires resin impregnation to a thicker reinforcing fiber base material, the reinforcing fiber base material can be obtained only by impregnating the reinforcing fiber base material from the first resin diffusion medium side as described above. When it is difficult to sufficiently impregnate the resin up to the surface of the second resin diffusion medium (when the conventional resin impregnation limit is exceeded), the reinforcing fiber base material from the first resin diffusion medium side is impregnated. Before the resin that has been reached reaches the second surface of the reinforcing fiber substrate, the injection of the resin can also be started from the second resin diffusion medium. By the resin injection from the second resin diffusion medium side, the resin impregnation is also compensated for the portion in which the resin in the reinforcing fiber base is not sufficiently impregnated, that is, the second surface side portion. Thus, the resin can be sufficiently impregnated throughout the thickness direction of the reinforcing fiber base. That is, in this process, the resin impregnation in the thickness direction of the reinforcing fiber base is mainly due to the impregnation from the first resin diffusion medium side, and the shortage of impregnation is from the second resin diffusion medium side. It will be compensated by impregnation. In addition, since the first resin diffusion medium and the second resin diffusion medium have a magnitude relationship in ventilation resistance (resin flow resistance), the first resin diffusion medium is rapidly impregnated with resin. On the other hand, on the second resin diffusion medium side, the resin impregnation is supplemented, and the void pushed out by the resin impregnated from the first resin diffusion medium side is impregnated from the second resin diffusion medium side. Instead of being confined within the reinforcing fiber substrate by the coming resin, it will be extruded at a relatively slow rate to the side, ie, along the second surface of the reinforcing fiber substrate. As a result, it is avoided that the void is confined in the reinforcing fiber base material despite the resin impregnation from both sides, and the resin impregnation on the second surface side is supplemented. It becomes possible to form a thick article well without enclosing problems. In addition, at this time, as described above, the design surface of the molded product is the second resin diffusion medium side, so that an excellent design surface with small unevenness can be obtained at the same time. That is, thick molding and surface quality improvement are achieved at the same time.

  Further, the RTM molding method (second method) according to the present invention is effective in the following cases. That is, in the case where the smoothness of the molding surface (design surface) on the mold side is required more strongly, or in the molding that requires resin impregnation into a thicker and larger area reinforcing fiber base material, As a means for making the degassing path from any place on the surface always effective, a degassing medium comprising a gas permeable membrane and a breathable substrate can be provided between the reinforcing fiber substrate and the mold surface. As a result, even when there is a difference in the time for the resin to reach the lower surface side (design surface molding side) of the reinforcing fiber base during resin injection and a slow part of the impregnated part is generated, the gas permeable membrane and the mold By suction from the formed deaeration space, it is finally possible to completely impregnate the resin over all parts of the surface. As a result, a design surface with good smoothness along the mold surface can be obtained.

  In addition, when resin is injected from at least adjacent resin injection gates, and also from all resin injection gates at the same time, there is usually a region where the resin flows overlap and an area that cannot be completely sucked is generated, which is not impregnated. However, according to the above method, since the deaeration path is always secured, it is possible to finally completely impregnate all surfaces.

  Further, the gas permeable membrane preferably has, for example, very fine holes on the surface and forms a smooth surface. However, when such a mode is used, the gas-permeable membrane is thin on the breathable substrate. Combined with the use of a substrate with less unevenness, the surface quality of the molded product can be improved.

  As described above, according to the RTM molding method of the present invention, the reinforcing fiber base material can be sufficiently satisfactorily impregnated while sufficiently ensuring the air permeability required for resin impregnation. In addition, it is possible to obtain a molded article having excellent surface properties by suppressing the unevenness formed on the design surface of the molded article to be small. In particular, in thick molding, even if it is impossible to impregnate the resin throughout the thickness direction of the base material without causing problems in the conventional method, the target and It is possible to perform molding.

  Therefore, the present invention is particularly suitable for RTM molding of thick molded articles. When the present invention is applied, a structure (for example, a wing member of an aircraft member) that requires a thickness of 10 mm or more is molded. It is possible to easily carry out without causing a problem.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 is a schematic longitudinal sectional view of a molding apparatus used in the RTM molding method according to the first embodiment of the present invention. The molding die 1 as a base is made of, for example, stainless steel and is configured in a flat plate shape.

In this embodiment, a breather 2 as a second resin diffusion medium is disposed on the mold 1. Here, the breather has a resin flow resistance that is not as low as that of the conventional resin diffusion media described above, but is much lower than the flow resistance of the resin flowing through the reinforcing fiber substrate. Quantitatively, it is preferable that the resin flow resistance of the breather 2 is 1/3 or less of the resin flow resistance of the reinforcing fiber base. Furthermore, the surface irregularities (surface roughness) of the breather 2 are preferably 1.3 times or less of the surface irregularities (surface roughness) of the reinforcing fiber substrate. Specifically, the breather 2 is a surface mat, a plain fabric, a mesh fabric, or a thick denier (200 denier) made of glass fiber or carbon fiber, which is a reinforcing fiber, with a low basis weight (100 g / m ² or less). The woven fabrics and knitted fabrics described above are preferable.

  A peel ply 3 a is disposed on the breather 2. The peel ply 3a is laid in order to easily remove media and the like from the molded body. As the peel ply 3a, for example, a woven fabric having a releasing function such as a nylon taffeta is used.

  A reinforcing fiber base 4 is disposed on the peel ply 3a. In this embodiment, the reinforcing fiber base 4 is formed by laminating a plurality of reinforcing fiber materials, particularly a plurality of reinforcing fiber fabrics. The present invention is particularly suitable for molding using a thick reinforcing fiber substrate 4 in which a plurality of such reinforcing fiber materials are laminated. However, even when a reinforcing fiber base made of a single reinforcing fiber material is used, the present invention can of course be applied. In this case, the present invention is a molding using a particularly thick reinforcing fiber base. It is suitable for.

  A first resin diffusion medium 5 is disposed on the reinforcing fiber base 4 via a peel ply 3b. The first resin diffusion medium 5 is a medium having irregularities on the surface and having a resin flow resistance of 1/10 or less of the resin flow resistance of the reinforcing fiber substrate 4 (a laminate of reinforcing fiber materials). The first resin diffusion medium 5 and the breather 2 as the second resin diffusion medium are given a magnitude relationship in the resin flow resistance, and the resin flow resistance of the breather 2 is greater than that of the first resin diffusion medium 5. It is set higher than the resin flow resistance. Specifically, the first resin diffusion medium 5 is preferably a mesh fabric made of polyethylene or polypropylene resin and having an opening of # 400 or less. As a result of this arrangement, the first resin diffusion medium 5 is arranged on the first surface of the reinforcing fiber base 4 and the second resin diffusion medium is arranged on the opposite second surface. The breather 2 is arranged.

  In this way, the entire material disposed on the mold 1 is covered with the bag material 8. The bag material 8 is an airtight material for forming a decompression cavity, but it is preferable to use, for example, a nylon film for the bag material 8 in consideration of heat resistance and the like. In the interior covered with the bag material 8, a resin injection gate 6c is provided for the first resin diffusion medium 5, and a suction gate 6a for decompressing the interior by suction with respect to the breather 2 as the second resin diffusion medium. , 6b are provided. These gates 6a, 6b, and 6c are configured using, for example, an aluminum C-channel material or the like, and these channel materials are connected to an external member via a plastic tube. A highly adhesive synthetic rubber sealant 7 is interposed between the edge of the bag material 8 and the mold 1, and the space between the sealant 7 is sealed to keep the bag material 8 in a reduced pressure state from the outside. Inflow of air is prevented. A thermosetting resin 10 as an FRP matrix resin to be impregnated is stored in the plastic pot 12, and the resin is injected through the resin injection gate 6c by opening the valve 9 at an appropriate timing. . The inside of the cavity covered with the bag material 8 is held in a reduced pressure state by the vacuum pump 11 through the suction gates 6a and 6b. In addition, as the bag material 8, the first bag material is further covered with the second bag material to form a double bag, thereby preventing air leakage. As a result, the volume content (Vf) of the reinforcing fiber is reduced. Can be improved.

  Moreover, even if the bag material 8 is a single bag, air leakage can be prevented by arranging the sealants 7 in parallel on the outer periphery of the bag material 8, and the same effect as the double bag can be obtained. In this case, there is an advantage that the usage amount and the attachment time of the auxiliary material can be reduced and the molding can be performed at a lower cost than the double bag.

  In the molding apparatus shown in FIG. 1, the peel ply 3b / resin dispersion medium 5 is disposed on the upper surface of the reinforcing fiber substrate 4 as in the conventional manner, and the peel ply 3a / breather is disposed on the lower surface side of the reinforcing fiber substrate 4. However, the breather 2 may be left as it is in the molded body after molding without arranging the peel ply 3a.

Molding in this embodiment is performed as follows.
The laminated body having the structure shown in FIG. 1 is disposed on the mold 1 (tool) surface at room temperature or in a heated atmosphere, and includes a resin injection gate 6c disposed on the upper side and suction gates 6a and 6b disposed on the lower side. Cover with bag material. In this state, when the resin is injected from the resin injection gate 6c while the bag material 8 is depressurized by suction through the suction gates 6a and 6b, the matrix resin 10 passes through the first resin diffusion medium 5 in the reinforcing fiber substrate 4. The reinforcing fiber base material 4 flows from the upper surface to the lower surface while rapidly diffusing in the direction along the upper surface of the reinforcing fiber base material 4 and is impregnated into the reinforcing fiber base material 4. After the impregnation is completed, the resin is cured at room temperature or in a heated atmosphere, and then the bag material 8 is peeled off to remove the molded body. Thereafter, the peel plies 3a and 3b, the resin dispersion medium 5 and the breather 2 are peeled off and removed from the product. However, the breather 2 may be left as it is in the molded product as one form.

  In this molding, since the resin flow resistance of the first resin diffusion medium 5 is set low, the resin injected into the first resin diffusion medium 5 is along the first surface of the reinforcing fiber base 4. While being diffused quickly and sufficiently widely in the direction, the reinforcing fiber substrate 4 is rapidly impregnated in the thickness direction. At this time, in order to depressurize the inside of the bag material 8, it is sucked from the inside of the bag material 8 through the breather 2 as the second resin diffusion medium, but the resin flow resistance (breathing resistance) of the breather 2 is the first resin. Although it is higher than the resin flow resistance (breathing resistance) of the diffusion medium 5, it is sufficiently low compared to the resin flow resistance (breathing resistance) of the reinforcing fiber base 4, so that the ventilation from the reinforcing fiber base is poor. Thus, the lowering of the degree of vacuum in the substrate is suppressed, and rapid impregnation of the resin is ensured. Therefore, a sufficiently good resin impregnation property from the first resin diffusion medium 5 side is ensured even for the thick reinforcing fiber base 4. Since the resin flow resistance (breathing resistance) of the breather 2 is set higher than that of the first resin diffusion medium 5, the breather 2 is a medium with less irregularities than the first resin diffusion medium 5. Can be formed. Therefore, even if such a surface form of the breather 2 is transferred to the surface of the molded product, the degree of unevenness on the surface of the molded product due to the transfer can be kept small. That is, the unevenness on the surface of the molded product on the second resin diffusion medium side can be kept small while ensuring good resin impregnation. By setting the surface side of the molded product having small irregularities as the design surface side, a molded product having a desirable surface property can be obtained. That is, it is possible to eliminate the trace of the media that has occurred on the tool surface side of the molded product due to the curing of the resin in the conventional method.

  FIG. 2 is a schematic longitudinal sectional view of a molding apparatus according to a second embodiment of the present invention, in which a second resin diffusion medium 5a and a porous sheet 20 are arranged on one side of a reinforcing fiber base instead of a breather. Show. FIG. 3 is a schematic longitudinal sectional view of a molding apparatus according to a third embodiment of the present invention, and a mold is formed by processing grooves in the mold instead of the resin diffusion medium arranged on the mold surface in FIG. The surface itself is configured as a resin diffusion medium on the resin injection side. Only differences from the apparatus of FIG. 1 will be described below.

  Reference numeral 20 denotes a perforated sheet. The material of the perforated sheet 20 is a metal thin plate material (aluminum or stainless steel), steel punching metal with a thickness of 0.1 mm or more, or a resin film (nylon, polyester, polyethylene). , Polypropylene, polyimide), and 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 is preferably used. The hole is preferably a round shape, 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 20 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 20 is that the smoothness is equal to or greater than the surface roughness required for the final product, and the rigidity is a rigidity that does not reflect the influence of the unevenness of the resin dispersion medium. A large number of holes are opened so that the resin can pass therethrough. Reference numeral 30 denotes a groove processed into a mold, and the groove 30 preferably has a width of 0.5 mm to 5 mm, a depth of 1 mm to 6 mm, a pitch of 2 mm to 25 mm, and a cross-sectional shape of a rectangle, inverted trapezoid or triangle. More preferably, a groove having a rectangular cross section with a width of about 1 mm and a depth of about 3 mm and a pitch of about 8 mm is desirable.

  2, the peel ply 3a / the porous sheet 20 / the second resin dispersion medium 5a are disposed on the lower surface of the reinforcing fiber base 4 from the side in contact with the reinforcing fiber base 4. However, the arrangement of the porous sheet 20 and the peel ply 3a may be reversed. As an embodiment of the present invention, in the molding apparatus of FIG. 2, a groove for resin injection (illustrated example) or vacuum suction is provided on the tool surface (molding surface) as shown in FIG. 3 without using the resin dispersion medium 5a. In this case, since the resin injection or vacuum suction can be made more uniform over the entire surface than in the case of using the resin dispersion medium, the generation of voids and undercuts can be further reduced and a good product can be stably produced. It becomes easy to obtain. Then, on the upper surface of the reinforcing fiber base 4, the conventional peel ply 3b / resin dispersion medium 5 (the peel ply is arranged on the reinforcing fiber base 4 side) or the same as the lower side of the reinforcing fiber base 4 is arranged. Thereafter, molding is performed in the same manner as in FIG.

  FIG. 4 is a schematic longitudinal sectional view of a molding apparatus according to a fourth embodiment of the present invention. Two suction gates 6d and 6e for decompression are installed on the upper part of the reinforcing fiber base of FIG. The gate 6d is switched to the resin injection port, and the resin is injected from both sides of the reinforcing fiber base. Only differences from the apparatus of FIGS. 1 to 3 will be described below.

  The suction gate 6d is switched to a resin inlet during molding. When used as a suction gate, the valve 42 is closed and then the valve 41 is opened. When switching to the resin injection gate, the valve 41 is closed and the valve 42 is opened.

  In the molding apparatus of FIG. 4, the reinforcing fiber substrate 4 is disposed on the surface of the mold (tool) in which the groove 30 is processed at room temperature or in a heated atmosphere via the porous sheet 20 and the peel ply 3a. The bag includes the suction gates 6d and 6e for decompression and the resin injection gate (groove 30) disposed on the lower surface side. In this state, when the valve 41 is opened, the valve 42 and the valve 9 are closed, and the bag material 8 is sucked from the suction gate and decompressed, the valve 9 is opened and the resin is injected into the groove 30 as the resin injection gate. The matrix resin 10 flows and impregnates from the lower surface to the upper surface of the reinforcing fiber base 4. However, when the plate thickness of the reinforcing fiber base 4 is 10 mm or more, depending on the combination of the resin and the reinforcing fiber base, it may be difficult to completely impregnate the resin up to the upper surface. Therefore, when the upper surface cannot be satisfactorily impregnated, before the resin reaches the upper surface of the reinforcing fiber base 4, at least one of the suction gates on the upper surface side (6d in FIG. 4) is closed and the valve 41 is closed. Can be switched to the resin injection gate. In the case of switching to the resin injection gate, the resin is also injected from the upper surface side, and the insufficient resin impregnation is compensated. At the same time, since the resin flows from the gate 6d side to the suction gate 6e side, a void is pushed out in the direction of the suction gate 6e as the resin flows. That is, while the resin 30 is rapidly impregnated from the groove 30 side of the mold as the first resin diffusion medium, the shortage of resin impregnation is compensated for the upper surface side of the thick reinforcing fiber base 4 and at the same time the voids are laterally formed. To be trapped in the reinforcing fiber substrate 4. As a result, even when a thick reinforcing fiber base 4 that cannot be sufficiently impregnated due to the presence of the impregnation limit thickness in the conventional method can be molded, and at the same time, voids are confined during the molding. By avoiding this, it is possible to ensure good quality of the molded product.

  After the impregnation is completed, the resin is cured at room temperature or in a heated atmosphere. However, the porous sheet 20 having an appropriate rigidity is affected by the uneven shape of the medium itself and the effect of the resin sink marks accumulated in the medium during the curing. Cut off. Therefore, as the surface properties on the tool surface side of the molded product taken out by peeling off the porous sheet 20 / peel ply 3a, 3b / resin dispersion medium 5 after demolding, the surface properties almost reflecting the smoothness of the tool surface can be obtained.

  FIG. 5 is a schematic cross-sectional view of a molding apparatus used for carrying out the RTM molding method according to the fifth embodiment of the present invention. 50, a deaeration medium 54 including a gas permeable substrate 51 and a seal tape 52 is provided, and can be sucked through a deaeration hole 53 from a deaeration space formed between the gas permeable membrane 50 and the mold 1. The point is different. Hereinafter, only the points different from the above-described embodiment will be described for the molding method according to this embodiment.

  First, the laminated body 4 of the reinforcing fiber base material is disposed on the mold 1 (tool) surface at room temperature or in a heated atmosphere, and the resin injection gate 6f disposed on the upper side is interposed between the mold 1 and the laminated body 4. The gas permeable membrane 50 and the breathable base material 51 disposed are covered with the bag material 8. In this case, the entire outer periphery of the gas permeable membrane 50 is sealed with a sealing tape 52 attached to the mold surface. In this state, when the resin is injected from the resin injection gate 6 f while sucking with the vacuum pump 11 and reducing the pressure in the bag 8 through the gas passage film 50 and the deaeration space, the matrix resin 10 becomes the first resin diffusion medium 5. While rapidly diffusing in the direction along the upper surface (planar direction) of the reinforcing fiber base 4, it flows from the upper surface to the lower surface of the reinforcing fiber base 4 and impregnates the reinforcing fiber base 4. After the impregnation is completed, the resin is cured at room temperature or in a heated atmosphere, and then the bag material 8 is removed to remove the molded body.

  Here, the gas permeable membrane 50 can be any porous material such as a microporous sheet, a resin film, or a base material in which paper or cloth is coated with the microporous membrane, as long as it allows gas to pass but does not pass resin or liquid. Such a thing may be used. Moreover, the surface with smoothness can improve the surface quality of the molded product. In addition, the gas permeable membrane 50 desirably has releasability, but may be integrated with a molded product depending on circumstances.

  The breathable substrate 51 preferably has good breathability in order to improve the impregnation property, and preferably has as little as possible unevenness in order to improve the smoothness of the molded product.

  In this RTM molding method, the inside of the mold 1 is decompressed by suction, and then the injected resin is injected into the mold 1 via the resin diffusion medium 8, and the injected resin is injected into the gas permeable membrane 50 and the mold 1. Since the injected resin can be impregnated into the reinforcing fiber base material 4 while being sucked from the deaeration space formed between the resin and the resin, the resin can be quickly squeezed on the molding surface on the mold side which is the design surface. In addition, it can be sufficiently expanded, and an excellent quality design surface can be formed. In addition, by using the gas permeable membrane 50 having a high smoothness of micropores, a design surface with extremely small unevenness and high smoothness can be formed. Therefore, even for a thick laminate of reinforcing fiber bases 4, the entire laminate can be satisfactorily impregnated with the resin, and the design surface having a very smooth surface with extremely small irregularities as described above. can get.

  FIG. 6 shows a sixth embodiment, which is an application example of the fifth embodiment shown in FIG. This is a method of simultaneously injecting resin from at least two adjacent resin injection gates among a plurality of resin injection gates 6g and 6h, and is effective for a large molded article having a large area. In the figure, the laminate 4 has a flat plate shape, but it is possible to spread the resin throughout the entire laminate even if it is difficult to control the flow of the resin, such as a molded product with projections or changes in plate thickness, or a curved plate. Become.

  Further, a plurality of suction paths (suction holes 53) from the deaeration space formed between the gas permeable membrane 50 and the mold 1 are provided, and a large molded product can be sufficiently sucked. It is like that. Further, if necessary, in addition to the suction path from the deaeration space, it is possible to provide a suction gate 6a (suction path) separately from this, thereby controlling the impregnation direction during resin injection, It can be used for suctioning excess resin after resin impregnation.

Hereinafter, the present invention will be described based on examples.
Example 1
In the RTM molding device of FIG. 1, a breather 2 (glass fiber surface mat, 80 g / m ² basis weight) is disposed on the molding surface of the mold 1, and suction gates 6a and 6b are disposed at both ends. The vacuum pump 11 was connected. Reinforced fiber base material in which a peel ply 3a is arranged on the breather 2, and a 120-ply laminated carbon fiber fabric (a plain fabric CO6343 using T300 carbon fiber, weight per unit: 200 g / m ² ) manufactured by Toray Industries, Inc. 4 was placed. At this time, the peel ply 3a between the breather 2 and the reinforcing fiber base 4 may be omitted, but this is based on the premise that the breather is left in the molded product, and a carbon fiber mesh is used as the breather at that time. Woven fabric is desirable.

  The peel ply 3b is disposed on the reinforcing fiber base 4, and the resin diffusion medium 5 ("Netron" TSX-400P, manufactured by Tokyo Polymer Co., Ltd.), which is a polypropylene mesh material, is disposed on the peel ply 3b. The resin injection gate 6c was disposed and connected to the resin pot 12 through the valve 9. The whole was covered with a bag material 8 (bag sheet) and the periphery was sealed with a sealant 7 (note that although not shown in this figure, a double bag was used). The valve 9 was closed, the inside of the cavity covered with the bag material 8 was sucked and depressurized with a vacuum pump 11, and the whole was heated to 70 ° C. in an oven and held for 1 hour. A thermosetting epoxy matrix resin 10 (an epoxy resin having a resin viscosity of 130 mPa · s at 70 ° C. (injection temperature) and a resin viscosity of 320 mPa · s after 1 hour at 70 ° C.) is accommodated in a resin pot 12 and valved. When 9 is opened, the matrix resin 10 is impregnated in the thickness direction of the reinforcing fiber base 4 from the top to the bottom while diffusing into the medium 5 from the resin injection line, and the base of about 25 mm thickness is completely removed without any unimpregnated portion. Resin impregnated. About 50 minutes after the resin impregnation, the valve 9 was closed to stop the supply of the resin, and the whole was heated to 130 ° C. at about 2 ° C./minute and held for 2 hours to cure the matrix resin. Thereafter, the temperature was lowered to about 2 ° C./min to room temperature, the whole was removed from the mold, and the bag material 8 was removed. By peeling off the peel ply from the cured product, the cured resin, medium and breather on the surface of the molded product were removed. The surface where the medium was in contact was uneven, whereas the surface where the breather was in contact was a surface with good surface smoothness.

Example 2
In the RTM molding device shown in FIG. 2, a medium 5a (made by Tokyo Polymer Co., Ltd., “Netron” TSX-400P) is disposed on the molding surface of the mold 1 and suction is applied to the periphery thereof. Gates 6 a and 6 b were placed and connected to the vacuum pump 11. A porous sheet 20 (a polyester film having a thickness of 0.2 mm and holes having a diameter of 1 mm arranged at a pitch of 10 mm) is placed on the medium 5a, a peel ply 3a is placed thereon, and a carbon fiber fabric (Toray ( Co., Ltd., a reinforced fiber substrate 4 in which 120 plies of plain fabric CO6343 using a T300 carbon fiber, basis weight: 200 g / m ² ) was laminated.

  A peel ply 3b is disposed on the reinforcing fiber substrate 4, a medium 5b is disposed thereon, a resin injection port 6c is disposed thereon, and this is used as a resin injection gate via the valve 9 and the resin pot 12 Connected. At this time, a porous sheet may be arranged instead of the peel ply 3b. The bag material 8 was covered twice over the whole, and the periphery was sealed with a sealant 7. The valve 9 was closed, the inside of the cavity covered with the bag material 8 was decompressed with a vacuum pump 11, and the whole was heated to 70 ° C. in an oven and held for 1 hour. A thermosetting epoxy matrix resin 10 (an epoxy resin having a resin viscosity of 130 mPa · s at 70 ° C. (injection temperature) and a resin viscosity of 320 mPa · s after 1 hour at 70 ° C.) is accommodated in a resin pot 12 and valved. When 9 is opened, the matrix resin 10 is impregnated in the thickness direction of the carbon fiber woven laminate 4 from the top to the bottom while diffusing into the medium 5b above the resin injection line, and the reinforcing fiber base 4 having a thickness of about 25 mm is not yet formed. The resin was completely impregnated without the impregnation part. After the resin impregnation, the valve 9 is closed to stop the supply of the resin, the whole is heated to 130 ° C. at about 2 ° C./minute and held for 2 hours to cure the matrix resin, and then to about 2 ° C./room temperature. The temperature was lowered in minutes, the whole was removed from the mold, and the bag material 8 was removed. As a result of removing the peel ply from the cured product and removing the cured resin, the medium, and the porous sheet, the surface on which the medium is in contact is uneven, whereas the surface on which the porous sheet is in contact is surface smooth. A good aspect was obtained.

Example 3
In the RTM molding device of FIG. 3, a valve 9 is formed in the groove by using a molding die in which a well 30 for resin diffusion is processed (a rectangular groove having a width of 1 mm and a depth of 3 mm and a pitch of 8 mm). The resin pot 12 was connected via A porous sheet 20 (a polyester film having a thickness of 0.2 mm and holes having a diameter of 1 mm arranged at a pitch of 10 mm) is placed on the molding surface, a peel ply 3a is placed thereon, and a carbon fiber fabric (Toray ( Co., Ltd., a reinforced fiber substrate 4 in which 120 plies of plain fabric CO6343 using a T300 carbon fiber, basis weight: 200 g / m ² ) was laminated. A peel ply 3b is disposed on the reinforcing fiber base 4, and a medium 5 (“Netron” TSX-400p, manufactured by Tokyo Polymer Co., Ltd.), which is a polypropylene mesh material, is disposed on the peel ply 3b. The gate 6 was placed and connected to the vacuum pump 11. The bag material 8 was covered twice on the whole, and the periphery was sealed with a sealant 7. The valve 9 was closed, the inside of the cavity covered with the bag material 8 was decompressed with a vacuum pump 11, and the whole was heated to 70 ° C. in an oven and held for 1 hour. A thermosetting epoxy matrix resin 10 (an epoxy resin having a resin viscosity of 130 mPa · s at 70 ° C. (injection temperature) and a resin viscosity of 320 mPa · s after 1 hour at 70 ° C.) is accommodated in a resin pot 12 and valved. When 9 is opened, the matrix resin 10 is impregnated from the resin injection line to the grooved molding surface, and is impregnated from the bottom to the top in the thickness direction of the carbon fiber woven laminate 4, and the 25 mm thick laminate is completely free from the unimpregnated portion. Was impregnated with resin. After the resin impregnation, the valve 9 is closed to stop the supply of the resin, the whole is heated to 130 ° C. at about 2 ° C./minute and held for 2 hours to cure the matrix resin, and then to about 2 ° C./room temperature. The temperature was lowered in minutes, the whole was removed from the mold, and the bag material 8 was removed. By peeling off the peel ply from the cured product, the cured resin and medium and the porous sheet on the surface of the molded product were removed, and the surface of the molded product appeared. Although the unevenness was observed, the surface with which the porous sheet was in contact had a surface with good surface smoothness.

Example 4
In the RTM molding apparatus of FIG. 4, a molding die obtained by processing a well 30 for resin diffusion (a rectangular groove having a width of 1 mm and a depth of 3 mm and a pitch of 8 mm) is inserted into the groove 30 via a valve 9. The resin pot 12 was connected. A porous sheet 20 (0.2 mm-thick stainless steel punched metal with holes with a diameter of 1 mm being processed at a pitch of 15 mm) is placed on the molding surface, a peel ply 3a is placed thereon, and a carbon fiber fabric ( A reinforced fiber substrate 4 in which 120 plies of a unidirectional woven fabric using T800S carbon fiber manufactured by Toray Industries, Inc., with a basis weight of 285 g / m ² ) was laminated was disposed. A peel ply 3b is disposed on the reinforcing fiber base 4, and a medium 5 (“Netron” TSX-400p, manufactured by Tokyo Polymer Co., Ltd.), which is a polypropylene mesh material, is disposed on the peel ply 3b. Gates 6d and 6e were placed and connected to the vacuum pump 11. The bag material 8 was covered twice on the whole, and the periphery was sealed with a sealant 7. The valve 9 was closed, the inside of the cavity covered with the bag material 8 was decompressed by the vacuum pump 11, and the whole was heated to 70 ° C. in an oven and held for 1 hour. A thermosetting epoxy matrix resin 10 (an epoxy resin having a resin viscosity of 130 mPa · s at 70 ° C. (injection temperature) and a resin viscosity of 320 mPa · s after 1 hour at 70 ° C.) is accommodated in a resin pot 12 and valved. When 9 was opened, the matrix resin 10 was impregnated from the bottom to the top in the thickness direction of the carbon fiber woven laminate 4 while diffusing from the resin injection line to the grooved molding surface. However, when this state is maintained, the impregnation of the resin converges when impregnating up to about 2/3 of the thickness of the reinforcing fiber base 4.

  Therefore, when the resin impregnated 1/2 or more of the thickness of the reinforcing fiber base 4, the valve 41 was closed, the valve 42 was opened, and the suction gate 6d was switched to the resin injection gate. The resin injected from the gate 6d diffused in the diffusion medium 5 in the direction of the suction gate 6e, and the resin was impregnated downward into the substrate through the medium 5. Eventually, the entire substrate was impregnated with resin. Then, the valves 9 and 42 were closed to stop the resin supply.

  The whole is heated to 130 ° C. at about 2 ° C./minute and held for 2 hours to cure the matrix resin, and then cooled to room temperature at about 2 ° C./minute, the whole is removed from the mold and the bag material 8 is removed. Removed. By peeling off the peel ply from the cured product, the cured resin and medium and the porous sheet on the surface of the molded product were removed, and the surface of the molded product appeared. Although the unevenness was observed, the surface with which the porous sheet was in contact had a surface with good surface smoothness.

Example 5
In the RTM molding device of FIG. 5, “Peel Ply # 60001” manufactured by RICHMOND of the United States is disposed as the breathable substrate 51 on the molding surface of the molding die 1, and further, a gas permeable membrane having releasability thereon. 50, Vapor Permeable Release Film “E3760” used in “TSB system” manufactured by RICHMOND of the United States was placed, and the entire periphery was sealed with heat-resistant nitroflon tape 52. The deaeration space surrounded by the gas permeable membrane 50 and the mold 1 was connected to the vacuum pump 11 through the deaeration holes 53 provided in the mold 1.

Subsequently, on the gas permeable membrane 50, a reinforced fiber base material 4 (laminated with 120 ply of carbon fiber fabric (manufactured by Toray Industries, Inc., plain fabric CO6343 using T300 carbon fiber fabric, basis weight; 200 g / m ² )). About 25 mm thick).

  Next, the peel ply 3b is arranged on the reinforcing fiber base 4, and the resin diffusion medium 5 (Tokyo Polymer, “Netron” TSX-400P), which is a polypropylene mesh material, is arranged on the reinforcing ply 3b. A resin injection gate 6 f was arranged and connected to the resin pot 12 through the valve 9. A bag material 8 was placed over the whole, and the periphery was sealed with a sealant 7. The valve 9 was closed, the inside of the cavity covered with the bag material 8 was sucked and depressurized with a vacuum pump 11, and the whole was heated to 70 ° C. in an oven and held for 1 hour. A thermosetting epoxy matrix resin 10 (an epoxy resin having a resin viscosity of 130 mPa · s at 70 ° C. (injection temperature) and a resin clay of 320 mPa · s after 1 hour at 70 ° C.) is contained in a resin pot, and a valve 9 The matrix resin 10 was impregnated from the top to the bottom in the thickness direction of the reinforcing fiber base 4 while diffusing into the medium 5 from the resin injection line. In this case, if the gas permeable membrane 50 is not present, the lower surface of the reinforcing fiber base material 4 is pressure-bonded to the surface of the molding die 1, and the gas existing in the vicinity of the lower surface of the base material is not completely removed. However, when the gas permeable membrane 50 is provided, a deaeration space is formed between the mold 1 and the membrane 50, and the gas is permeable from the entire lower surface of the reinforcing fiber base 4. Since it was completely deaerated through the base material 51, the base material was completely impregnated with a resin without an unimpregnated portion although the thickness was 25 mm, and the surface quality was particularly improved. After the resin impregnation, when a predetermined amount of resin is injected, the valve 9 is closed to stop the supply of the resin, and the whole is heated to 130 ° C. at about 2 ° C./minute and held for 2 hours to cure the matrix resin. I let you. Thereafter, the temperature was lowered to about 2 ° C./min to room temperature, the whole was removed from the mold, and the bag material 8 was removed. A surface having good surface smoothness was obtained on the lower surface of the cured molded article by peeling off the gas permeable membrane 50.

Example 6
In the RTM molding apparatus of FIG. 6, as in Example 5, “Peel Ply # 60001” manufactured by RICHMOND of the United States as a breathable base material 51 is disposed on the molding surface of the mold 1, and a mold release is further performed thereon. Vapor Permeable Release Film “E3760” used in “TSB system” manufactured by RICHMOND of the United States was placed as a gas permeable membrane 50 having a property, and the entire periphery was sealed with heat-resistant nitroflon tape 52. The deaeration space surrounded by the gas permeable membrane 50 and the mold 1 was connected to the vacuum pump 11 through the deaeration holes 53 provided in the mold 1.

Subsequently, a reinforced fiber base material 4 in which a carbon fiber fabric (a plain fabric CO6343 using a T300 carbon fiber fabric, weight per unit: 200 g / m ² ) 120 ply laminated on the gas permeable membrane 50 is laminated. Arranged. At that time, the suction gate 6a was also arranged on one side of the lower surface of the reinforcing fiber base.

  A peel ply 3b is arranged on the reinforcing fiber base 4, and a resin diffusion medium 5 (manufactured by Tokyo Polymer Co., Ltd., “Netron” TSX-400P) is arranged on the reinforcing ply base material 4 and on top thereof. The two resin injection gates 6g and 6h were arranged and connected to the resin pot 12 through the valve 9. A bag material 8 was placed over the whole, and the periphery was sealed with a sealant 7. The valve 9 was closed, the inside of the cavity covered with the bag material 8 was sucked and depressurized with a vacuum pump 11, and the whole was heated to 70 ° C. in an oven and held for 1 hour. A thermosetting epoxy matrix resin 10 (an epoxy resin having a resin viscosity of 130 mPa · s at 70 ° C. (injection temperature) and a resin clay of 320 mPa · s after 1 hour at 70 ° C.) is contained in a resin pot, and a valve 9 Is opened, the matrix resin 10 flows into the medium 5 simultaneously from the two resin injection lines 6g and 6h, and is impregnated from the top to the bottom in the thickness direction of the reinforcing fiber base 4 while diffusing on the surface, and is about 25 mm. The substrate was completely impregnated with resin without any unimpregnated part.

  At that time, the resin immediately reaches the lower surface of the reinforcing fiber base 4 in the region immediately below the injection gates 6g and 6h, that is, the resin reaches the lower surface of the reinforcing fiber base in the middle region between the two injection gates. Although it was slow to complete, finally, the resin was completely impregnated by suction through the degassing path of the gas permeable membrane 50.

  After the resin impregnation, when a predetermined amount of resin is injected, the valve 9 is closed to stop the supply of the resin, and the whole is heated to 130 ° C. at about 2 ° C./minute and held for 2 hours to cure the matrix resin. I let you. By sucking from the suction gate 8 as well, the resin impregnation time was faster than in Example 5.

  Thereafter, the temperature was lowered to about 2 ° C./min to room temperature, the whole was removed from the mold, and the bag material 8 was removed. A surface having good surface smoothness was obtained on the lower surface of the cured molded article by peeling off the gas permeable membrane 50.

  The RTM molding method of the present invention is particularly suitable for RTM molding of a thick article, and is suitable for molding a structure (for example, a wing member of an aircraft member) requiring a thickness of 10 mm or more.

It is a schematic longitudinal cross-sectional view of the shaping | molding apparatus used for the RTM shaping | molding method which concerns on the 1st embodiment of this invention. It is a schematic longitudinal cross-sectional view of the shaping | molding apparatus used for the RTM shaping | molding method which concerns on the 2nd embodiment of this invention. It is a schematic longitudinal cross-sectional view of the shaping | molding apparatus used for the RTM shaping | molding method which concerns on the 3rd embodiment of this invention. It is a schematic longitudinal cross-sectional view of the shaping | molding apparatus used for the RTM shaping | molding method which concerns on the 4th embodiment of this invention. It is a schematic longitudinal cross-sectional view of the shaping | molding apparatus used for the RTM shaping | molding method which concerns on the 5th embodiment of this invention. It is a schematic longitudinal cross-sectional view of the shaping | molding apparatus used for the RTM shaping | molding method which concerns on the 6th embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Mold 2 Breather as 2nd resin diffusion medium 3a, 3b Peel ply 4 Reinforcing fiber base material 5, 5a, 5b Resin diffusion medium 6, 6a, 6b, 6d, 6e Suction gate 6c, 6f, 6g, 6h Resin injection Gate 7 Sealant 8 Bag material 9, 41, 42 Valve 10 Matrix resin 11 Vacuum pump 12 Resin pot 20 Porous sheet 30 Resin diffusion mold groove 50 Gas permeable membrane 51 Breathable base material 52 Seal tape 53 Deaeration hole 54 Deaeration medium

Claims (14)

  A reinforcing fiber base is disposed in the mold, a resin diffusion medium having a resin flow resistance lower than that of the reinforcing fiber base is disposed on both sides of the reinforcing fiber base, and the inside of the mold is decompressed by suction. Thereafter, in the RTM molding method in which a resin is injected into the mold through the resin diffusion medium and the injected resin is impregnated into the reinforcing fiber base, the resin is disposed on the first surface of the reinforcing fiber base. The resin flow resistance of the first resin diffusion medium is set lower than the resin flow resistance of the second resin diffusion medium disposed on the second surface, and the resin is injected into the first resin diffusion medium However, the RTM molding method is characterized in that the reinforcing fiber base material is impregnated with the resin by suction through the second resin diffusion medium.   The RTM molding method according to claim 1, wherein the reinforcing fiber base is made of a laminate of reinforcing fiber materials.   The RTM molding method according to claim 1 or 2, wherein the resin flow resistance of the second resin diffusion medium is set to 1/3 or less of the resin flow resistance of the reinforcing fiber base.   The RTM molding method according to claim 1, wherein a resin flow resistance of the first resin diffusion medium is set to 1/10 or less of a resin flow resistance of the reinforcing fiber base.   The RTM molding method according to claim 1, wherein the injection of the resin is also started from the second resin diffusion medium before the resin reaches the second surface.   The RTM molding method according to claim 1, wherein a peel ply that can be peeled integrally with the resin diffusion medium after molding is interposed between at least one resin diffusion medium and the reinforcing fiber base.   The RTM molding method according to claim 1, wherein a porous sheet is interposed between at least one resin diffusion medium and the reinforcing fiber substrate.   The RTM molding method according to claim 1, wherein at least one of the resin diffusion media is configured by providing a groove as a resin flow path on the inner surface of the molding die.   The RTM molding method according to claim 1, wherein at least one of the resin diffusion media is left in the molded product without being peeled from the molded product after the molded product is removed from the mold.   A reinforcing fiber base is disposed in the mold, and a resin diffusion medium having a resin flow resistance lower than that of the base is disposed on the surface of the reinforcing fiber base opposite to the mold, and the reinforcing fiber base A degassing medium comprising a gas permeable membrane and a gas permeable substrate is provided between the material and the mold surface, and after the pressure inside the mold is reduced by suction, the resin is placed in the mold via the resin diffusion medium. The RTM molding method is characterized in that the reinforcing fiber base material is impregnated with the resin by sucking the injected resin from a deaeration space formed between the gas permeable membrane and the mold.   The RTM molding method according to claim 10, wherein the reinforcing fiber base is composed of a laminate of reinforcing fibers.   The RTM molding method according to claim 10 or 11, wherein the gas permeable membrane has a releasability capable of being peeled off from a molded product after molding.   At least two or more resin injection gates are disposed above the resin diffusion medium, and at the time of resin injection, resin injection is performed simultaneously from at least two adjacent resin injection gates or from all resin injection gates. The RTM molding method according to claim 10, wherein the RTM molding method is characterized.   14. In addition to the suction path from the deaeration space formed between the gas permeable membrane and the mold, at least one other suction path is provided in the mold. The described RTM molding method.

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