JP2008230020A - Preform, its manufacturing method, and method for manufacturing frp - Google Patents

Preform, its manufacturing method, and method for manufacturing frp Download PDF

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JP2008230020A
JP2008230020A JP2007072070A JP2007072070A JP2008230020A JP 2008230020 A JP2008230020 A JP 2008230020A JP 2007072070 A JP2007072070 A JP 2007072070A JP 2007072070 A JP2007072070 A JP 2007072070A JP 2008230020 A JP2008230020 A JP 2008230020A
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preform
frp
reinforcing fiber
resin
fiber base
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JP4965296B2 (en
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Shigeru Nishiyama
西山　　茂
Fumito Takeda
文人 武田
Konosuke Yamamoto
晃之助 山本
Tomoyuki Shinoda
知行 篠田
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Mitsubishi Heavy Industries Ltd
Toray Industries Inc
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Mitsubishi Heavy Industries Ltd
Toray Industries Inc
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<P>PROBLEM TO BE SOLVED: To provide a method for producing a preform which prevents the bridge of a reinforcing fiber substrate or a subsidiary material, maintains the thickness of the corner part to be a prescribed thickness, and prevents the occurrence of a resin-rich part or a void in the corner part when FRP having a corner part is molded, the preform produced by the method, and a method for producing the FRP. <P>SOLUTION: In the method for producing the preform, when the preform for molding the FRP having the corner part formed by using the reinforcing fiber substrate is produced, throughout at least the corner part and its both side parts, with the subordinate material integrated with the reinforcing fiber substrate, the preform is shaped. The preform produced by the method and the method for the FRP using the preform produced by the method are disclosed. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

本発明は、コーナー部を有するプリフォームの製造方法、その方法により製造されたプリフォーム、およびその方法により製造されたプリフォームを用いるＦＲＰ（繊維強化プラスチック）の製造方法に関する。   The present invention relates to a method for producing a preform having a corner portion, a preform produced by the method, and a method for producing FRP (fiber reinforced plastic) using the preform produced by the method.

ドライの強化繊維基材を成形型上に配置し、全体をバッグ材で覆って内部を減圧し、樹脂を注入して強化繊維基材に含浸させることによりＦＲＰを成形する真空ＲＴＭ（Resin Transfer Molding) 成形方法が知られている（例えば、特許文献１）。この真空ＲＴＭ成形方法においては、通常、強化繊維基材は予め所定の形状に賦形され、そのプリフォームが成形型上に配置される。また、ＦＲＰ成形の際の注入樹脂を均一に拡散させるための、樹脂拡散用の媒体や、該樹脂拡散媒体をＦＲＰ成形後にＦＲＰから剥離させるための剥離層（以下、ピールプライと呼ぶこともある。）等の副資材を用いる成形方法も知られている（同特許文献１）。   A vacuum RTM (Resin Transfer Molding) that molds FRP by placing a dry reinforcing fiber base on a mold, covering the whole with a bag material, depressurizing the inside, and injecting resin into the reinforcing fiber base. ) A molding method is known (for example, Patent Document 1). In this vacuum RTM molding method, the reinforcing fiber base is usually shaped in advance into a predetermined shape, and the preform is placed on a mold. Further, a resin diffusion medium for uniformly diffusing the injected resin at the time of FRP molding, or a release layer for peeling the resin diffusion medium from the FRP after FRP molding (hereinafter sometimes referred to as peel ply). A molding method using a secondary material such as) is also known (Patent Document 1).

ところが、成形すべきＦＲＰがコーナー部を有する場合、したがって、強化繊維基材のプリフォームがコーナー部を有する場合、以下のような問題を生じることがある。例えば図２に副資材を用いない場合の例を、図３に副資材を用いる場合の例を、それぞれ示す。図２に示す例においては、コーナー部を有する雌型１０１内に、対応するコーナー部を有する形状に賦形された強化繊維基材１０２が配置され、全体がバッグ材としてのバギングフィルム１０３（例えば、ナイロンフィルム）で覆われ、外部に対して内部がシール材１０４でシールされる（図２（Ａ））。この状態で、内部が真空吸引され、減圧された内部に樹脂が注入されて、樹脂が強化繊維基材１０２に含浸される（図２（Ｂ））。このとき、バギングフィルム１０３から強化繊維基材１０２には加圧力が作用するが、コーナー部においては強化繊維基材１０２がブリッジ状に突っ張るため、その部位における強化繊維基材１０２の厚みＡ（隙間が形成される場合にはその隙間込みの厚み）が他の部位よりも厚くなり、例えば型底部部位での強化繊維基材１０２の厚みＢ以上に厚くなる。この状態で樹脂を硬化させＦＲＰを成形すると、図２（Ｃ）に示すように、成形されたＦＲＰ１０５も同様に、対応する部位間に、Ａ’≧Ｂ’の関係が生じることになり、目標とする寸法精度が得られないおそれがある。また、厚みの厚い部位Ａ’では、強化繊維の体積含有率Ｖｆが小さくなったり、樹脂リッチ部が生じたり、場合によってはボイドが発生するおそれもある。   However, when the FRP to be molded has a corner portion, and accordingly, when the preform of the reinforcing fiber base has a corner portion, the following problems may occur. For example, FIG. 2 shows an example when no secondary material is used, and FIG. 3 shows an example when a secondary material is used. In the example shown in FIG. 2, a reinforcing fiber base material 102 shaped into a shape having a corresponding corner portion is disposed in a female mold 101 having a corner portion, and a bagging film 103 (for example, a bag material as a whole) , Nylon film), and the inside is sealed with a sealing material 104 with respect to the outside (FIG. 2A). In this state, the inside is evacuated and resin is injected into the decompressed interior, and the reinforcing fiber base material 102 is impregnated with the resin (FIG. 2B). At this time, a pressing force is applied from the bagging film 103 to the reinforcing fiber base 102, but the reinforcing fiber base 102 stretches in a bridge shape at the corner portion. Is formed, the thickness of the gap is thicker than other parts, for example, thicker than the thickness B of the reinforcing fiber base 102 at the bottom part of the mold. When the resin is cured in this state and the FRP is molded, as shown in FIG. 2C, the molded FRP 105 similarly has a relationship of A ′ ≧ B ′ between the corresponding portions. Dimensional accuracy may not be obtained. Further, in the thick portion A ′, the volume content Vf of the reinforcing fiber may be reduced, a resin rich portion may be generated, or a void may be generated in some cases.

また、図３に示す例においては、コーナー部を有する雌型１１１内に、対応するコーナー部を有する形状に賦形された強化繊維基材１１２が配置され、その上に、ピールプライ１１３、樹脂拡散媒体１１４（例えば、ポリプロピレン製のメディア）が順次配置され、これら全体がバッグ材としてのバギングフィルム１１５（例えば、ナイロンフィルム）で覆われ、外部に対して内部がシール材１１６でシールされる（図３（Ａ））。この状態で、内部が真空吸引され、減圧された内部に樹脂が注入されて、樹脂が樹脂拡散媒体１１４を介して拡散されつつ強化繊維基材１１２に含浸される（図３（Ｂ））。このとき、バギングフィルム１１５から強化繊維基材１１２には加圧力が作用するが、コーナー部においては強化繊維基材１１２やピールプライ１１３、樹脂拡散媒体１１４の副資材がブリッジ状に突っ張るため、その部位における強化繊維基材１１２の厚みＣが厚くなったり、隙間１１７が形成されたりし、例えば型底部部位での強化繊維基材１１２の厚みＢ以上に厚くなる。この状態で樹脂を硬化させＦＲＰを成形すると、図３（Ｃ）に示すように、成形されたＦＲＰ１１８も同様に、対応する部位間に、Ｃ’≧Ｂ’の関係が生じることになり、目標とする寸法制度が得られないおそれがある。また、厚みの厚い部位Ａ’では、強化繊維の体積含有率Ｖｆが小さくなったり、隙間１１７が形成された部位では、樹脂リッチ部分１１９が生じたり、場合によってはボイドが発生するおそれもある。
特開２００４−１３０５９９号公報 Further, in the example shown in FIG. 3, a reinforcing fiber substrate 112 shaped into a shape having a corresponding corner portion is disposed in a female mold 111 having a corner portion, and a peel ply 113 and a resin diffusion are formed thereon. A medium 114 (for example, a medium made of polypropylene) is sequentially arranged, and the whole is covered with a bagging film 115 (for example, a nylon film) as a bag material, and the inside is sealed with a sealing material 116 with respect to the outside (see FIG. 3 (A)). In this state, the inside is evacuated and resin is injected into the decompressed interior, and the reinforcing fiber base material 112 is impregnated while being diffused through the resin diffusion medium 114 (FIG. 3B). At this time, pressure is applied from the bagging film 115 to the reinforcing fiber base 112, but the auxiliary fiber base 112, the peel ply 113, and the auxiliary material of the resin diffusion medium 114 are stretched in a bridge shape at the corner portion. The thickness C of the reinforcing fiber base 112 becomes thicker or the gap 117 is formed, and becomes thicker than the thickness B of the reinforcing fiber base 112 at the bottom of the mold, for example. When the resin is cured and the FRP is molded in this state, as shown in FIG. 3C, the molded FRP 118 similarly has a relationship of C ′ ≧ B ′ between the corresponding portions. There is a risk that the dimensional system will not be obtained. Further, in the thick portion A ′, the volume content Vf of the reinforcing fiber is small, and in the portion where the gap 117 is formed, the resin rich portion 119 may be generated or a void may be generated in some cases.
JP 2004-130599 A

そこで本発明の課題は、とくに上記のようなコーナー部における問題点に着目し、ＦＲＰ成形時における強化繊維基材や副資材のブリッジを防止し、コーナー部における厚みを所定の厚みに維持するとともに、コーナー部に樹脂リッチ部分やボイドを発生させないようにした、プリフォームの製造方法、およびその方法により製造されたプリフォーム、並びにその方法により製造されたプリフォームを用いるＦＲＰの製造方法を提供することにある。   Therefore, the object of the present invention is to pay particular attention to the above-described problems in the corner portion, prevent the reinforcing fiber base material and the auxiliary material from bridging during FRP molding, and maintain the thickness in the corner portion at a predetermined thickness. The present invention provides a preform manufacturing method, a preform manufactured by the method, and a FRP manufacturing method using the preform manufactured by the method, in which resin-rich portions and voids are not generated in the corner portion. There is.

上記課題を解決するために、本発明に係るプリフォームの製造方法は、強化繊維基材を用いて形成される、コーナー部を有するＦＲＰ成形用のプリフォームを製造する方法であって、少なくとも前記コーナー部およびその両側部分にわたって、前記強化繊維基材に副資材を一体化した状態に、プリフォームを賦形することを特徴とする方法からなる。   In order to solve the above-mentioned problems, a method for producing a preform according to the present invention is a method for producing a preform for FRP molding having a corner portion, which is formed by using a reinforcing fiber base material. The method is characterized in that the preform is shaped in a state in which the auxiliary material is integrated with the reinforcing fiber base material over the corner portion and both side portions thereof.

すなわち、本発明においては、コーナー部を有するプリフォームが、ＦＲＰ成形に使用される前に、予め、強化繊維基材に副資材を一体化した状態で所定形状のプリフォームとして賦形される。強化繊維基材と副資材が一体化されることにより、互いに所定形状に維持し合うことになるので、コーナー部におけるブリッジの発生が防止され、コーナー部で強化繊維基材の厚みが増加することが防止され、成形時にコーナー部で隙間が発生することが防止されて樹脂リッチ部やボイドの発生が防止される。   That is, in the present invention, a preform having a corner portion is shaped as a preform having a predetermined shape in a state in which the auxiliary material is integrated with the reinforcing fiber base before being used for FRP molding. Since the reinforcing fiber base material and the auxiliary material are integrated with each other, they maintain each other in a predetermined shape, so that the occurrence of a bridge at the corner portion is prevented and the thickness of the reinforcing fiber base material increases at the corner portion. Is prevented, and a gap is prevented from being generated at the corner portion during molding, thereby preventing the occurrence of a resin rich portion and a void.

より具体的には、例えば、上記プリフォームのコーナー部に対応するコーナー部を有する賦形治具上に、上記副資材と上記強化繊維基材を両者間に接着材料を介在させて配置し、その上にゴムシートを被せ内部を減圧することによりゴムシートによる加圧力を副資材および強化繊維基材に作用させ、該副資材および強化繊維基材を上記接着材料を介して一体化しつつ、該一体化材を上記賦形治具に沿わせて賦形する。この賦形時には、ゴムシートによる加圧に加え、一体化材を加熱することにより、賦形の容易化をはかるとともに、接着材料による一体化を促進することもできる。   More specifically, for example, on the shaping jig having a corner portion corresponding to the corner portion of the preform, the auxiliary material and the reinforcing fiber substrate are arranged with an adhesive material interposed therebetween, A pressure applied by the rubber sheet is applied to the auxiliary material and the reinforcing fiber base by covering the rubber sheet and reducing the inside, and the auxiliary material and the reinforcing fiber base are integrated via the adhesive material, The integrated material is shaped along the shaping jig. At the time of shaping, in addition to pressurization by a rubber sheet, heating of the integrated material can facilitate shaping and also promote integration by an adhesive material.

上記一体化材を上記賦形治具に沿わせて賦形した後、ゴムシートによる加圧は解除すればよく、加圧解除後に、所定形状に賦形されたプリフォームを賦形治具から脱型し、ＦＲＰの成形に供すればよい。   After shaping the integrated material along the shaping jig, the pressure applied by the rubber sheet may be released. After releasing the pressure, the preform shaped into a predetermined shape is removed from the shaping jig. The mold may be removed and used for FRP molding.

上記副資材としては、ＦＲＰ成形の際に樹脂を拡散させる樹脂拡散媒体、または該樹脂拡散媒体および該樹脂拡散媒体を成形後ＦＲＰから剥離させるための剥離層（つまり、前述のピールプライ）からなる構成のいずれも採用できる。ピールプライを使用しない場合には、用途によっては、樹脂拡散媒体をそのままＦＲＰ成形品内に残すことも可能である。   The auxiliary material includes a resin diffusion medium for diffusing a resin during FRP molding, or a release layer (that is, the above-described peel ply) for peeling the resin diffusion medium and the resin diffusion medium from the FRP after molding. Either of these can be adopted. When the peel ply is not used, the resin diffusion medium can be left in the FRP molded product as it is depending on the application.

本発明は、このようなプリフォームの製造方法によって製造されたプリフォーム、つまり少なくともコーナー部において強化繊維基材と副資材が一体化されたプリフォームについても提供する。   The present invention also provides a preform manufactured by such a method for manufacturing a preform, that is, a preform in which a reinforcing fiber base material and an auxiliary material are integrated at least in a corner portion.

本発明に係るＦＲＰの製造方法は、上記のような方法により製造されたプリフォームを成形型上に配置し、該プリフォーム全体をバッグ材で覆って内部を減圧し、該プリフォームに対し樹脂を注入する方法からなる。   The FRP manufacturing method according to the present invention includes a preform manufactured by the above method placed on a molding die, the entire preform is covered with a bag material, the inside is decompressed, and a resin is applied to the preform. Consisting of a method of injecting.

また、本発明に係るＦＲＰの製造方法は、上記のような方法により製造されたプリフォームを、上記賦形治具の形状を反転した形状を有する雌型内に配置し、該プリフォーム全体をバッグ材で覆って内部を減圧し、該プリフォームに対し樹脂を注入する方法からなる。   The FRP manufacturing method according to the present invention includes a preform manufactured by the method as described above, which is disposed in a female mold having a shape obtained by inverting the shape of the shaping jig, and the entire preform is disposed. It consists of a method in which the interior is decompressed by covering with a bag material and a resin is injected into the preform.

このようなＦＲＰの製造方法においては、プリフォーム賦形段階での強化繊維体積含有率Ｖｐｆ（％）とＦＲＰ成形後の強化繊維体積含有率Ｖｆ（％）がＶｆ−５≦Ｖｐｆ≦Ｖｆ＋２の関係にあることが好ましい。この範囲への制御は、例えば、賦形温度と上記ゴムシート介した賦形圧力と保持時間の設定、制御によって行うことが可能である。このＶｆ（％）は、ＦＲＰの設計目標値である。Ｖｐｆ（％）がＶｆ−５（％）よりも低いと、図３に示したような従来と同様の問題が生じるおそれが高くなり、Ｖｐｆ（％）がＶｆ＋２（％）よりも高いと、ＦＲＰ成形時にＶｐｆがＶｆに戻されようとする際に、局部的にしわが発生しやすくなるおそれが高くなる。   In such an FRP manufacturing method, the relationship between the reinforcing fiber volume content Vpf (%) at the preform shaping stage and the reinforcing fiber volume content Vf (%) after FRP molding is Vf−5 ≦ Vpf ≦ Vf + 2. It is preferable that it exists in. Control within this range can be performed, for example, by setting and controlling the shaping temperature, the shaping pressure via the rubber sheet, and the holding time. This Vf (%) is the FRP design target value. When Vpf (%) is lower than Vf-5 (%), there is a high possibility that the same problem as shown in FIG. 3 will occur. When Vpf (%) is higher than Vf + 2 (%), FRP When Vpf is to be returned to Vf during molding, there is a high possibility that local wrinkles are likely to occur.

本発明によれば、強化繊維基材と副資材を一体化したプリフォームとすることにより、ＦＲＰ成形の際のコーナー部での強化繊維基材や副資材のブリッジの発生を防止でき、コーナー部で強化繊維基材の厚みが増加したり、コーナー部で隙間が発生したりすることを防止して、所定寸法への成形を確実に行うことができるとともに、樹脂リッチ部やボイドの発生を防止して均一なＦＲＰ物性を達成できる。   According to the present invention, by forming a preform in which the reinforcing fiber base material and the auxiliary material are integrated, it is possible to prevent occurrence of a bridge between the reinforcing fiber base material and the auxiliary material at the corner portion during FRP molding. Prevents the increase in the thickness of the reinforcing fiber base and the generation of gaps at the corners, ensuring molding to the specified dimensions and preventing the generation of resin rich parts and voids. Thus, uniform FRP physical properties can be achieved.

また、強化繊維基材と副資材の一体化により、ＦＲＰ成形時の副資材のずれを防止することもできる。さらに、ＦＲＰ成形時に副資材を個別に配置する必要がなくなるので、副資材を配置する際の、あるいは配置前の、異物の混入（コンタミ）がなくなり、ＦＲＰ成形品へのコンタミを防ぐこともできる。   Further, the integration of the reinforcing fiber base material and the secondary material can prevent the secondary material from shifting during FRP molding. Furthermore, since it is not necessary to separately arrange the auxiliary materials at the time of FRP molding, foreign matter contamination (contamination) at the time of arranging the auxiliary materials or before the arrangement is eliminated, and contamination to the FRP molded product can be prevented. .

以下に、本発明の望ましい実施の形態について、図面を参照しながら説明する。
図１は、本発明の一実施態様に係るプリフォームの製造方法、および、その方法により製造されたプリフォームを用いてＦＲＰを成形するまでの一連の工程を示している。図１（Ａ）、（Ｂ）は本発明の一実施態様に係るプリフォームの製造方法を示している。図１（Ａ）に示すように、ベースツール１上に、コーナー部を有する賦形治具としての雄型２が設けられており、本実施態様では、雄型２内に加熱のための温水用配管３が埋設されている。この賦形治具としての雄型２上に、副資材としての、樹脂拡散媒体４（例えば、ポリプロピレン製樹脂拡散媒体）と剥離層としてのピールプライ５（例えば、ナイロン製ピールプライ）がこの順に配置され、その上に、副資材側の表面に接着材料６（例えば、熱可塑性樹脂）が散布された強化繊維基材７（例えば、複数の基材の積層体からなる強化繊維基材）が配置される。その上にゴムシート８が被せられ、周囲がシール材９でシールされる。 Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
FIG. 1 shows a preform manufacturing method according to an embodiment of the present invention, and a series of steps until FRP is molded using the preform manufactured by the method. 1A and 1B show a preform manufacturing method according to an embodiment of the present invention. As shown in FIG. 1A, a male mold 2 as a shaping jig having a corner portion is provided on a base tool 1, and in this embodiment, hot water for heating is provided in the male mold 2. A piping 3 is buried. On the male mold 2 as the shaping jig, a resin diffusion medium 4 (for example, a polypropylene resin diffusion medium) as a secondary material and a peel ply 5 (for example, a nylon peel ply) as a release layer are arranged in this order. Further, a reinforcing fiber base material 7 (for example, a reinforcing fiber base material made of a laminate of a plurality of base materials) in which an adhesive material 6 (for example, a thermoplastic resin) is dispersed is disposed on the surface of the secondary material. The A rubber sheet 8 is placed thereon and the periphery is sealed with a sealing material 9.

この状態で、図１（Ｂ）に示すように、真空ポンプ（図示略）等による真空吸引によりゴムシート８で覆われた内部が減圧され、それによってゴムシート８による加圧力が作用されて、強化繊維基材７と上記副資材が雄型２の外面に沿うように密着されるように賦形されるとともに、強化繊維基材７と副資材との間に介在された接着材料６によって強化繊維基材７と副資材が一体化されたプリフォーム１０として賦形される。本実施態様では、この賦形時に、ゴムシート８上に断熱カバー１１が配置され、温水用配管３に温水が通水されて、加熱も行われ、それによってプリフォーム１０の賦形と接着材料６による強化繊維基材７と副資材の一体化が促進されるようになっている。所定の賦形が終了したら、コーナー部を有するプリフォーム１０が雄型２から脱型され、本発明に係るプリフォーム１０が得られる。   In this state, as shown in FIG. 1 (B), the inside covered with the rubber sheet 8 is depressurized by vacuum suction by a vacuum pump (not shown) or the like, whereby the pressing force by the rubber sheet 8 is applied, The reinforcing fiber base 7 and the auxiliary material are shaped so as to be in close contact with the outer surface of the male mold 2 and are reinforced by the adhesive material 6 interposed between the reinforcing fiber base 7 and the auxiliary material. It is shaped as a preform 10 in which the fiber base material 7 and the auxiliary material are integrated. In this embodiment, at the time of shaping, the heat insulating cover 11 is disposed on the rubber sheet 8, warm water is passed through the hot water pipe 3, and heating is also performed, whereby the shaping of the preform 10 and the adhesive material are performed. The integration of the reinforcing fiber base 7 and the auxiliary material by 6 is promoted. When the predetermined shaping is completed, the preform 10 having the corner portion is removed from the male mold 2 to obtain the preform 10 according to the present invention.

このプリフォーム１０を用いて、本発明に係るＦＲＰの製造方法は、図１（Ｃ）、（Ｄ）、（Ｅ）に示すように実施される。図１（Ｃ）に示すように、プリフォーム１０が、プリフォーム１０のコーナー部に対応するコーナー部を有する（つまり、上記賦形治具としての雄型２の形状を反転した形状を有する）、成形型としての雌型１２内に配置され、バッグ材としてのバギングフィルム１３で覆われて周囲がシール材１４でシールされる。この状態で、図１（Ｄ）に示すように、バギングフィルム１３で覆われた内部が真空ポンプ（図示略）等による真空吸引により減圧され、減圧された内部に、ＦＲＰのマトリックス樹脂となる液状の樹脂が注入され、いわゆる真空ＲＴＭ成形が行われる。この真空ＲＴＭ成形時においては、プリフォーム１０は、強化繊維基材７と副資材が予め一体化されたものからなるので、その形状、とくにコーナー部の形状は、所定の成形目標形状に相当する形状に維持され、コーナー部で強化繊維基材７や副資材がブリッジ状に突っ張ることが防止される。したがって、コーナー部における強化繊維基材７の厚みＥと、それ以外の部位の厚み、例えば雌型１２の底部における強化繊維基材７の平坦部の厚みＤとは実質的に等しい厚みに保たれる。また、成形品の表面性状を向上させるためにカールプレートをプリフォームの表面、または、前記副資材の上に配してもよい。   Using this preform 10, the FRP manufacturing method according to the present invention is carried out as shown in FIGS. 1 (C), (D), and (E). As shown in FIG. 1C, the preform 10 has a corner portion corresponding to the corner portion of the preform 10 (that is, has a shape obtained by inverting the shape of the male mold 2 as the shaping jig). These are placed in a female die 12 as a molding die, covered with a bagging film 13 as a bag material, and the periphery is sealed with a sealing material 14. In this state, as shown in FIG. 1D, the interior covered with the bagging film 13 is depressurized by vacuum suction using a vacuum pump (not shown) or the like, and the liquid that becomes the matrix resin of FRP is contained in the depressurized interior. The resin is injected and so-called vacuum RTM molding is performed. At the time of this vacuum RTM molding, the preform 10 is formed by integrating the reinforcing fiber base material 7 and the auxiliary material in advance, so that the shape, particularly the shape of the corner portion, corresponds to a predetermined molding target shape. The shape is maintained, and the reinforcing fiber base material 7 and the auxiliary material are prevented from stretching in a bridge shape at the corner portion. Therefore, the thickness E of the reinforcing fiber base 7 in the corner portion and the thickness of other portions, for example, the thickness D of the flat portion of the reinforcing fiber base 7 in the bottom of the female die 12 are kept substantially equal. It is. Further, in order to improve the surface property of the molded product, a curl plate may be arranged on the surface of the preform or on the auxiliary material.

上記真空ＲＴＭ成形において、樹脂の硬化が終了したら、バギングフィルム１３が取り外され、成形体が雌型１２から脱型され、さらに、ピールプライ５の剥離によりピールプライ５と樹脂拡散媒体４が除去されて、図１（Ｅ）に示すようなＦＲＰ１５（ＦＲＰ成形品）が得られる。上記の如く真空ＲＴＭ成形時の強化繊維基材７の厚みＥとＤとが等しく保たれているので、この成形後のＦＲＰ１５においても、コーナー部における厚みＥ’と底部平坦部における厚みＤ’も実質的に等しい厚みとなり、ＦＲＰ１５は全体にわたって目標とする形状、寸法に仕上げられる。   In the vacuum RTM molding, after the resin is cured, the bagging film 13 is removed, the molded body is removed from the female mold 12, and the peel ply 5 is peeled off to remove the peel ply 5 and the resin diffusion medium 4. An FRP 15 (FRP molded product) as shown in FIG. 1 (E) is obtained. As described above, since the thicknesses E and D of the reinforcing fiber base 7 at the time of vacuum RTM molding are kept equal, the thickness E ′ at the corner portion and the thickness D ′ at the bottom flat portion also in the FRP 15 after molding. The thickness is substantially equal, and the FRP 15 is finished to a target shape and size throughout.

なお、この真空ＲＴＭ成形においては、前述したように、プリフォーム１０の賦形段階における強化繊維基材７の強化繊維体積含有率Ｖｐｆ（％）とＦＲＰ成形後の強化繊維体積含有率Ｖｆ（％）がＶｆ−５≦Ｖｐｆ≦Ｖｆ＋２の関係にあることが好ましい。この範囲への制御は、上記温水の温度を制御して賦形温度を適切に設定、制御すること、上記真空吸引による減圧度を制御してゴムシート８による賦形加圧力を適切に設定、制御することによって容易に行うことが可能である。前述の如く、ＦＲＰ１５の設計目標値であるＶｆ（％）に対し、Ｖｐｆ（％）がＶｆ−５（％）よりも低いと、図３に示したような従来と同様の問題が生じるおそれが高くなり、Ｖｐｆ（％）がＶｆ＋２（％）よりも高いと、ＦＲＰ１５の成形時にＶｐｆがＶｆに戻されようとする際に、局部的にしわが発生しやすくなるおそれが高くなる。   In this vacuum RTM molding, as described above, the reinforcing fiber volume content Vpf (%) of the reinforcing fiber base 7 in the shaping stage of the preform 10 and the reinforcing fiber volume content Vf (%) after the FRP molding. ) Is preferably in a relationship of Vf−5 ≦ Vpf ≦ Vf + 2. Control to this range is to appropriately set and control the shaping temperature by controlling the temperature of the hot water, appropriately set the shaping pressure force by the rubber sheet 8 by controlling the degree of vacuum by the vacuum suction, It can be easily performed by controlling. As described above, when Vpf (%) is lower than Vf-5 (%) with respect to Vf (%) which is the design target value of FRP 15, there is a possibility that the same problem as the conventional one shown in FIG. 3 may occur. If Vpf (%) is higher than Vf + 2 (%), there is a high possibility that local wrinkles are likely to occur when Vpf is returned to Vf during molding of FRP 15.

このプリフォームにおける強化繊維体積含有率Ｖｐｆは、次のように算出することができる。
Ｖｐｆ＝Ｗ１／（ρ×Ｔ１）×１００（％）
ここで、
Ｗ１：プリフォーム１ｃｍ2当たりの強化繊維の重量（ｇ／ｃｍ2）
ρ：強化繊維の密度（ｇ／ｃｍ3）
Ｔ１：ＪＩＳＲ７６０２に準拠し、０．１ＭＰａの荷重下で測定したプリフォームの厚さ（ｃｍ）
である。 The reinforcing fiber volume content Vpf in this preform can be calculated as follows.
Vpf = W1 / (ρ × T1) × 100 (%)
here,
W1: Weight of reinforcing fiber per 1 cm 2 of preform (g / cm 2 )
ρ: Density of reinforcing fiber (g / cm 3 )
T1: Preform thickness measured in accordance with JIS R7602 under a load of 0.1 MPa (cm)
It is.

ＦＲＰ成形品における高Ｖｆを達成するためには、このプリフォームにおけるＶｐｆも高いことが好ましく、好ましいＶｐｆとして、例えば４５〜６０％の範囲が挙げられる。４５％未満であると、真空ＲＴＭ成形における樹脂の含浸性は良いが、繊維体積含有率の小さなＦＲＰとなり、その分ＦＲＰの機械的特性も低くなる。一方、６０％を越えると、強化繊維糸条間や繊維間の隙間が小さくなって、樹脂が流れ難くなり好ましくない。本成形品の強化繊維体積含有率Ｖｆの測定方法は、ＡＳＴＭ Ｄ３１７１−９９（２００４）に準拠し、厚みは、０．００１ｍｍまで表示可能なダブルボールマイクロメータ（ボール直径６ｍｍ）を用いて測定し、下記式により算出する。
Ｖｆ＝Ｗ２／（ρ×Ｔ２）×１００（％）
ここで、
Ｗ２：強化繊維基材１ｍ2当たりの質量
Ｔ２：厚さ（１０点箇所の平均値）
ρ：強化繊維密度（ｇ／ｃｍ3）
である。 In order to achieve a high Vf in the FRP molded product, it is preferable that the Vpf in this preform is also high, and examples of preferable Vpf include a range of 45 to 60%. If it is less than 45%, the resin impregnation property in vacuum RTM molding is good, but the FRP has a small fiber volume content, and the mechanical properties of the FRP are also lowered accordingly. On the other hand, if it exceeds 60%, the gaps between the reinforcing fiber yarns and the fibers become small, and the resin hardly flows, which is not preferable. The measurement method of the reinforcing fiber volume content Vf of this molded product is based on ASTM D3171-99 (2004), and the thickness is measured using a double ball micrometer (ball diameter 6 mm) that can display up to 0.001 mm. Calculated by the following formula.
Vf = W2 / (ρ × T2) × 100 (%)
here,
W2: Mass per 1 m 2 of reinforcing fiber base T2: Thickness (average value at 10 points)
ρ: Reinforcing fiber density (g / cm 3 )
It is.

本発明は、コーナー部を有するあらゆるプリフォーム、ＦＲＰに対して適用可能である。   The present invention is applicable to any preform and FRP having a corner portion.

本発明の一実施態様に係るコーナー部を有するプリフォームの製造方法、および、その方法により製造されたプリフォームを用いてＦＲＰを成形するまでの一連の工程を示す、概略断面図である。It is a schematic sectional drawing which shows a series of processes until shape | molding FRP using the manufacturing method of the preform which has a corner part which concerns on one embodiment of this invention, and the preform manufactured by the method. 従来のコーナー部を有するＦＲＰの製造方法における一連の工程を示す概略断面図である。It is a schematic sectional drawing which shows a series of processes in the manufacturing method of FRP which has the conventional corner part. 従来の別のコーナー部を有するＦＲＰの製造方法における一連の工程を示す概略断面図である。It is a schematic sectional drawing which shows a series of processes in the manufacturing method of FRP which has another conventional corner part.

符号の説明Explanation of symbols

１ ベースツール
２ 賦形治具としての雄型
３ 温水用配管
４ 樹脂拡散媒体
５ 剥離層としてのピールプライ
６ 接着材料
７ 強化繊維基材
８ ゴムシート
９ シール材
１０ プリフォーム
１１ 断熱カバー
１２ 成形型としての雌型
１３ バッグ材としてのバギングフィルム
１４ シール材
１５ ＦＲＰ DESCRIPTION OF SYMBOLS 1 Base tool 2 Male mold as shaping jig 3 Hot water piping 4 Resin diffusion medium 5 Peel ply 6 as peeling layer Adhesive material 7 Reinforced fiber base material 8 Rubber sheet 9 Sealing material 10 Preform 11 Insulation cover 12 As mold Female mold 13 Bagging film 14 as bag material Sealing material 15 FRP

Claims (8)

強化繊維基材を用いて形成される、コーナー部を有するＦＲＰ成形用のプリフォームを製造する方法であって、少なくとも前記コーナー部およびその両側部分にわたって、前記強化繊維基材に副資材を一体化した状態に、プリフォームを賦形することを特徴とするプリフォームの製造方法。   A method of manufacturing a preform for FRP molding having a corner portion, which is formed using a reinforcing fiber base material, and a subsidiary material is integrated with the reinforcing fiber base material at least over the corner portion and both side portions thereof. A preform manufacturing method, wherein the preform is shaped into a finished state. 前記プリフォームのコーナー部に対応するコーナー部を有する賦形治具上に、前記副資材と前記強化繊維基材を両者間に接着材料を介在させて配置し、その上にゴムシートを被せ内部を減圧することによりゴムシートによる加圧力を作用させ、前記副資材および前記強化繊維基材を前記接着材料を介して一体化しつつ、該一体化材を前記賦形治具に沿わせて賦形する、請求項１に記載のプリフォームの製造方法。   The auxiliary material and the reinforcing fiber base material are disposed on the shaping jig having a corner portion corresponding to the corner portion of the preform, with an adhesive material interposed therebetween, and a rubber sheet is put on the inside. The pressure applied by the rubber sheet is applied by reducing the pressure, and the auxiliary material and the reinforcing fiber base are integrated via the adhesive material, and the integrated material is shaped along the shaping jig. The method for producing a preform according to claim 1. 前記一体化材を前記賦形治具に沿わせて賦形した後、ゴムシートによる加圧を解除する、請求項２に記載のプリフォームの製造方法。   The preform manufacturing method according to claim 2, wherein the integrated material is shaped along the shaping jig, and then the pressure applied by the rubber sheet is released. 前記副資材が、ＦＲＰ成形の際に樹脂を拡散させる樹脂拡散媒体、または該樹脂拡散媒体および該樹脂拡散媒体を成形後ＦＲＰから剥離させるための剥離層からなる、請求項１〜３のいずれかに記載のプリフォームの製造方法。   The auxiliary material is composed of a resin diffusion medium for diffusing a resin during FRP molding, or a release layer for peeling the resin diffusion medium and the resin diffusion medium from the FRP after molding. A process for producing the preform as described in 1. 請求項１〜４のいずれかに記載の方法により製造されたプリフォーム。   The preform manufactured by the method in any one of Claims 1-4. 請求項１〜４のいずれかに記載の方法により製造されたプリフォームを成形型上に配置し、該プリフォーム全体をバッグ材で覆って内部を減圧し、該プリフォームに対し樹脂を注入する、ＦＲＰの製造方法。   The preform manufactured by the method according to any one of claims 1 to 4 is placed on a mold, the entire preform is covered with a bag material, the inside is decompressed, and a resin is injected into the preform. The manufacturing method of FRP. 請求項２〜４のいずれかに記載の方法により製造されたプリフォームを、前記賦形治具の形状を反転した形状を有する雌型内に配置し、該プリフォーム全体をバッグ材で覆って内部を減圧し、該プリフォームに対し樹脂を注入する、ＦＲＰの製造方法。   The preform manufactured by the method according to any one of claims 2 to 4 is placed in a female mold having a shape obtained by inverting the shape of the shaping jig, and the entire preform is covered with a bag material. A method for producing FRP, wherein the inside is decompressed and a resin is injected into the preform. プリフォーム賦形段階での強化繊維体積含有率Ｖｐｆ（％）とＦＲＰ成形後の強化繊維体積含有率Ｖｆ（％）がＶｆ−５≦Ｖｐｆ≦Ｖｆ＋２の関係にある、請求項６または７に記載のＦＲＰの製造方法。   The reinforcing fiber volume content Vpf (%) at the preform shaping stage and the reinforcing fiber volume content Vf (%) after FRP molding are in a relationship of Vf-5 ≦ Vpf ≦ Vf + 2. FRP manufacturing method.
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