JP2008238798A - Frp molded article having symmetrical surface pattern, and its molding process - Google Patents
Frp molded article having symmetrical surface pattern, and its molding process Download PDFInfo
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- 238000000465 moulding Methods 0.000 title claims abstract description 14
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- 239000002759 woven fabric Substances 0.000 claims abstract description 33
- 239000000463 material Substances 0.000 claims abstract description 29
- 238000001721 transfer moulding Methods 0.000 claims abstract description 13
- 239000011159 matrix material Substances 0.000 claims abstract description 7
- 239000000835 fiber Substances 0.000 claims description 27
- 239000002344 surface layer Substances 0.000 claims description 5
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- 238000009941 weaving Methods 0.000 abstract description 5
- 239000011152 fibreglass Substances 0.000 abstract 3
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- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 20
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- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- QLBRROYTTDFLDX-UHFFFAOYSA-N [3-(aminomethyl)cyclohexyl]methanamine Chemical compound NCC1CCCC(CN)C1 QLBRROYTTDFLDX-UHFFFAOYSA-N 0.000 description 1
- 238000011074 autoclave method Methods 0.000 description 1
- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
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- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
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Images
Abstract
Description
本発明は、繊維強化材料の織物とマトリックス樹脂とからなる、左右対称な表面模様を有するＦＲＰ成形品及びその成形方法に関する。 The present invention relates to an FRP molded article having a symmetrical surface pattern, which is made of a woven fabric of fiber reinforced material and a matrix resin, and a molding method thereof.
繊維強化プラスチック（ＦＲＰ）は、不飽和ポリエステル樹脂、エポキシ樹脂、ポリイミド樹脂等の熱硬化性樹脂や、ポリエチレン、ポリプロピレン、ポリアミド、ＰＰＳ、ＰＥＥＫ等の熱可塑性樹脂のマトリックス樹脂と、炭素繊維、ガラス繊維、アラミド繊維等の繊維強化材料とからなるものであり、軽量で且つ強度特性に優れるため、近年、航空宇宙産業から一般産業分野に至るまで、幅広い分野において利用されている。 Fiber reinforced plastic (FRP) is a thermosetting resin such as unsaturated polyester resin, epoxy resin and polyimide resin, matrix resin of thermoplastic resin such as polyethylene, polypropylene, polyamide, PPS, PEEK, carbon fiber, glass fiber In recent years, it is used in a wide range of fields from the aerospace industry to the general industrial field because it is made of a fiber reinforced material such as aramid fiber and is lightweight and excellent in strength characteristics.
様々なＦＲＰ成形品の中で、用途によっては、左右対称な表面模様を有するＦＲＰ成形品が望まれる場合がある。そして、かかる成形品は、従来、樹脂トランスファー（ＲＴＭ）成形法により、賦型性に優れた繊維強化材料の織物、例えば、綾織物を用いて成形するのが一般的であった。かかる方法において、表面の模様が左右対称になる成形品を得ようとした場合、対称模様となるよう綾織物基材を一旦対称軸で裁断し、残り半分は織物基材を裏返して織り目を反転させる必要があった。しかしこの方法では、中央部に基材の重なり部分が生じ、部分的な成形品厚みの変化、樹脂の部分的含浸性の違い、反転作業の非効率化等成形上色々な問題があった。 Among various FRP molded products, an FRP molded product having a symmetrical surface pattern may be desired depending on applications. And conventionally, such a molded article has been generally molded by a resin transfer (RTM) molding method using a fabric of a fiber reinforced material excellent in formability, for example, a twill fabric. In such a method, when trying to obtain a molded product having a symmetrical surface pattern, the twill fabric substrate is once cut along the axis of symmetry so that it becomes a symmetrical pattern, and the other half is turned over to reverse the texture. It was necessary to let them. However, in this method, an overlapping portion of the base material occurs in the central portion, and there are various problems in molding such as a partial change in the thickness of the molded product, a difference in partial impregnation of the resin, and inefficiency of the reversing operation.
樹脂トランスファー成形法において、繊維強化材料として織物基材を用いることは良く知られている（例えば、特許文献１と２）。そして、左右対称な表面模様を有するＦＲＰ成形品を得るためには、前記のごとき面倒な織物基材の準備工程を経るのがこれまでのやり方であって、本発明者の知る限り、その方法を改善・改良する提案がなされたことはなかった。
本発明の課題は、従来のものよりも品質的に優れた左右対称な表面模様を有するＦＲＰ成形品と、それを効率良く成形するための従来よりも簡単な方法を提供することにある。 An object of the present invention is to provide an FRP molded product having a symmetrical surface pattern that is superior in quality to the conventional one, and a simpler method for efficiently molding the FRP molded product.
本発明者は、ＦＲＰ成形品を成形するに際し、織物基材の織り目を、任意の距離又はパターンで反転して製織したものを、少なくとも表面の織物基材として用いることにより、部分的な成形品厚みの変化や樹脂の部分的含浸性の違い、織物の裁断及び反転作業に伴う作業コストの増加、更には織物基材のハンドリング数増加による意匠性の低下等、多くの問題を一つの工程のみで解決できることを知見し、本発明に到達した。 The present inventor, when forming a FRP molded product, by using a woven fabric that is woven by inverting the weave of the woven fabric at an arbitrary distance or pattern, at least as a surface of the woven fabric substrate, Many problems, such as changes in thickness and differences in partial impregnation of resin, increase in work costs associated with cutting and reversing of fabrics, and deterioration in design properties due to increased handling of fabric substrates, can be handled in a single process. As a result, the present invention was reached.
本発明の請求項１に記載された発明は、一定間隔で織目の方向が逆になるようにして製織された織物を少なくとも表層に有する繊維強化材料と、マトリックス樹脂とからなる左右対称な表面模様を有するＦＲＰ成形品である。 The invention described in claim 1 of the present invention is a bilaterally symmetric surface comprising a fiber reinforced material having at least a surface layer of a woven fabric so that the direction of the weave is reversed at regular intervals, and a matrix resin. This is an FRP molded product having a pattern.
請求項２に記載された発明は、織物が綾織物である請求項１記載の左右対称な表面模様を有するＦＲＰ成形品である。 The invention described in claim 2 is the FRP molded article having a symmetrical surface pattern according to claim 1, wherein the fabric is a twill fabric.
請求項３に記載された発明は、樹脂トランスファー成形法により左右対称な表面模様を有するＦＲＰ成形品を成形するに際し、一定間隔で織目の方向が逆になるようにして製織された綾織物又はそれを用いたプリフォームを、織目の方向が変わる位置を成形品の対称軸に合わせて成形型に敷設し、その上に任意の繊維強化材料を積層配置し、次いで樹脂トランスファー成形法により成形することを特徴とする左右対称な表面模様を有するＦＲＰ成形品の成形方法である。 The invention described in claim 3 is a twill woven woven so that the direction of the weave is reversed at regular intervals when forming an FRP molded product having a symmetrical surface pattern by a resin transfer molding method. Preforms using it are laid on the mold so that the position where the direction of the weave changes is aligned with the axis of symmetry of the molded product, and an arbitrary fiber reinforced material is laminated on it, and then molded by the resin transfer molding method. This is a method for forming an FRP molded product having a symmetrical surface pattern.
そして、請求項４に記載された発明は、織物が綾織物である請求項３記載の左右対称な表面模様を有するＦＲＰ成形品の成形方法である。 The invention described in claim 4 is the method for forming an FRP molded product having a symmetrical surface pattern according to claim 3, wherein the fabric is a twill fabric.
織物基材、本発明においては織物、好ましくは綾織物を製織するに際し、任意の距離又はパターンで織り目を反転させることは製織段階で容易に行うことができる。そして、好ましくは、樹脂トランスファー成形法を採用して、得られた織物基材を少なくとも表面の織物基材として用いることにより、部分的な成形品厚みの変化や樹脂の部分的含浸性の違いのない、また、織物の裁断及び反転作業に伴う作業コストの増加もない、更には織物基材のハンドリング数増加による意匠性の低下等も起こらない等、多くのメリットを有するＦＲＰ成形品が得られる。 When weaving a woven substrate, in the present invention, a woven fabric, preferably a twill fabric, reversing the weave at any distance or pattern can be easily performed at the weaving stage. Preferably, by adopting a resin transfer molding method and using the obtained woven fabric base material as at least the surface woven fabric base material, there is a difference in partial molded product thickness and partial impregnation of the resin. FRP molded products having many merits such as no increase in work costs associated with cutting and reversing of the fabric, and no deterioration in design due to an increase in the number of handlings of the fabric base material can be obtained. .
本発明において一定間隔で織目の方向が逆になるようにして製織された織物としては、斜文織、朱子織等があるが、賦型性に優れた斜文織物（綾織物）が好ましい。斜文組織は経糸・緯糸３本以上で作られ、連続的に浮いた組織点で斜めにうね状の線が現れるが、このうねが斜文線（本発明の織目）と呼ばれる。斜文線の角度は自由に変えることができる。また、組織としては、経糸と緯糸の交錯状態が表と裏で異なる片面斜文組織、表と裏で同じ両面斜文組織等があるが、本発明においてどのような綾織物でもかまわない。織物を形成する繊維ストランドは、繊維径４〜８μｍのモノフィラメントを一束あたり５００〜２４，０００本とすることが好ましい。 In the present invention, as the woven fabric woven so that the direction of the weave is reversed at regular intervals, there are a diagonal weave, a satin weave, etc., but an oblique fabric (twill fabric) excellent in formability is preferable. . The oblique structure is made up of three or more warps and wefts, and a ridge line appears diagonally at texture points that float continuously. This ridge is called the oblique line (texture of the present invention). The angle of the oblique line can be changed freely. In addition, examples of the structure include a single-sided oblique structure in which the crossing state of the warp and the weft is different between the front and the back, and a double-faced oblique structure in which the front and the back are the same. The fiber strand forming the woven fabric preferably has 500 to 24,000 monofilaments having a fiber diameter of 4 to 8 μm per bundle.
本発明の成形品は、左右対称な表面模様を有するものであるから、成形に際して、少なくともその表層（最外層）に前記の織物を用いる必要がある。表層以外の部分は、どのような形態の繊維強化材料であってもかまわない。 Since the molded product of the present invention has a symmetrical surface pattern, it is necessary to use the woven fabric at least on the surface layer (outermost layer) during molding. The portion other than the surface layer may be any form of fiber reinforced material.
本発明において用いられるマトリックス樹脂としては、熱硬化性樹脂と熱可塑性樹脂があるが、好ましいのは熱硬化性樹脂である。熱硬化性樹脂と熱可塑性樹脂を混合して用いることもできる。好ましい熱硬化性樹脂としては、エポキシ樹脂、不飽和ポリエステル樹脂、フェノール樹脂、メラミン樹脂、ポリウレタン樹脂、シリコン樹脂、マレイミド樹脂、ビニルエステル樹脂、シアン酸エステル樹脂、マレイミド樹脂とシアン酸エステル樹脂を予備重合した樹脂等があり、これらの熱硬化性樹脂を適宜量配合したものでも良い。これらの樹脂のうち、耐熱性、弾性率、耐薬品性に優れたエポキシ樹脂、ビニルエステル樹脂が好ましい。これらの熱硬化性樹脂には、硬化剤、硬化促進剤等が含まれていてもよい。 The matrix resin used in the present invention includes a thermosetting resin and a thermoplastic resin, and a thermosetting resin is preferable. A thermosetting resin and a thermoplastic resin can also be mixed and used. Preferred thermosetting resins include epoxy resin, unsaturated polyester resin, phenol resin, melamine resin, polyurethane resin, silicon resin, maleimide resin, vinyl ester resin, cyanate ester resin, maleimide resin and cyanate ester resin. Resins and the like may be used, and these thermosetting resins may be blended in appropriate amounts. Of these resins, epoxy resins and vinyl ester resins excellent in heat resistance, elastic modulus, and chemical resistance are preferable. These thermosetting resins may contain a curing agent, a curing accelerator and the like.
本発明において用いられる繊維強化材料としては、炭素繊維、ガラス繊維、アラミド繊維、ボロン繊維、金属繊維等の、通常の繊維強化材に用いる材料が使用できる。中でも、炭素繊維、ガラス繊維、アラミド繊維が好ましい。表層以外に用いる繊維強化材料の形態としては特に制限されず、織物又は不織布等が利用できる。織物としては、平織物、綾織物、朱子織物等、あるいは一軸織物、多軸織物等を挙げることができる。織物を形成する強化繊維ストランドは、繊維径４〜８μｍのモノフィラメントを一束あたり５００〜２４，０００本とすることが好ましい。織物等の厚さは、成形品の用途により適宜選択するものであり、特に制限はない。 As the fiber reinforced material used in the present invention, materials used for ordinary fiber reinforcing materials such as carbon fiber, glass fiber, aramid fiber, boron fiber, and metal fiber can be used. Among these, carbon fiber, glass fiber, and aramid fiber are preferable. It does not restrict | limit especially as a form of the fiber reinforced material used except a surface layer, A woven fabric or a nonwoven fabric etc. can be utilized. Examples of the woven fabric include a plain woven fabric, a twill woven fabric, a satin woven fabric and the like, or a uniaxial woven fabric and a multiaxial woven fabric. The reinforcing fiber strands forming the woven fabric preferably have 500 to 24,000 monofilaments having a fiber diameter of 4 to 8 μm per bundle. The thickness of the woven fabric or the like is appropriately selected depending on the use of the molded product, and is not particularly limited.
本発明の左右対称な表面模様を有するＦＲＰ成形品の成形方法は特に限定されるものではないが、いったい成形が可能であるという点で、樹脂トランスファー成形法が好ましく採用される。 The method for molding an FRP molded product having a symmetrical surface pattern according to the present invention is not particularly limited, but a resin transfer molding method is preferably employed because it can be molded at all.
従って、本発明の他の態様は、樹脂トランスファー成形法により左右対称な表面模様を有するＦＲＰ成形品を成形するに際し、一定間隔で織目の方向が逆になるようにして製織された綾織物又はそれを用いたプリフォームを、織目の方向が変わる位置を成形品の対称軸に合わせて成形型に敷設し、その上に任意の繊維強化材料を積層配置して樹脂トランスファー成形法により成形することを特徴とする成形方法である。 Therefore, another aspect of the present invention is a twill woven woven so that the direction of the weave is reversed at regular intervals when forming an FRP molded product having a symmetrical surface pattern by a resin transfer molding method. A preform using the same is laid on a mold by aligning the position where the direction of the weave changes with the axis of symmetry of the molded product, and an arbitrary fiber reinforced material is laminated on it and molded by the resin transfer molding method. This is a molding method characterized by this.
樹脂トランスファー成形法は、長繊維や短繊維からなる繊維強化材料を、成形品形状に賦形したプリフォームあるいはシート状で、上型下型からなる金型内部に配置し、金型を型締めした後、樹脂注入孔から樹脂を減圧下に注入して繊維強化材料に含浸させ、加熱硬化の後、金型を開いて脱型する成形方法である。いわゆるプリプレグが必要でなく、オートクレーブ法やハンドレイアップ法に比べて生産性が良く、両面の仕上がりの良い、品質の優れた成形品が得られるという特徴がある。 In the resin transfer molding method, a fiber reinforced material composed of long fibers and short fibers is placed inside a mold composed of an upper mold and a lower mold in the form of a preform or sheet shaped into a molded product shape, and the mold is clamped After that, the resin is injected from the resin injection hole under a reduced pressure to impregnate the fiber reinforced material, and after heat curing, the mold is opened and demolded. A so-called prepreg is not required, and it is characterized in that a molded product with good productivity and good quality on both sides can be obtained compared to the autoclave method and the hand lay-up method.
樹脂トランスファー成形法おいて用いられる型としては、特に制限はないが、剛性の高い金属の金型やＦＲＰ型等の金型が用いられる。下型には、シリコーンワックス等の公知の離型剤を用いて離型処理した後、繊維強化材料を敷設・積層しても良い。また、成形品を取出す際の離型性を高める目的で、繊維強化材料上にはピールクロス等を重ねても良い。以下、実施例により本発明を詳述する。 The mold used in the resin transfer molding method is not particularly limited, but a highly rigid metal mold or a mold such as an FRP mold is used. The lower mold may be subjected to a release treatment using a known release agent such as silicone wax, and then a fiber reinforced material may be laid and laminated. Moreover, a peel cloth or the like may be stacked on the fiber reinforced material for the purpose of improving the releasability when taking out the molded product. Hereinafter, the present invention will be described in detail by way of examples.
以下、図面により、一定間隔で織目の方向が逆になるようにして製織された織物を、織目の方向が変わる位置を、成形品の対称軸に合わせて成形型に敷設する方法について説明する。 Hereinafter, a method of laying a woven fabric woven in such a manner that the direction of the weave is reversed at regular intervals according to the drawing in accordance with the axis of symmetry of the molded product and the position where the direction of the weave changes will be explained. To do.
図１は、綾織物（織目が斜線で示されている）を繊維強化材料として、先ず、綾織物基材を一旦対称軸で裁断し、次いで、残り半分は織物基材を裏返して織り目を反転させ、その後、対称軸で対称模様となるように、織物基材の両端をオーバーラップさせて貼り付ける様子を示している。
この方法では、中央部に織物基材の重なり部分が生じ、部分的な成形品厚みの変化、樹脂の部分的含浸性の違い、反転作業の非効率化等成形上色々な問題がある。
FIG. 1 shows a twill woven fabric (weave is shown by diagonal lines) as a fiber reinforced material. First, a twill woven substrate is cut once with a symmetry axis, and then the other half is turned over and the woven substrate is turned over. It shows a state in which both ends of the textile base material are overlapped and pasted so as to have a symmetrical pattern with the symmetry axis.
In this method, an overlap portion of the fabric base material is generated in the central portion, and there are various problems in molding such as a partial change in the thickness of the molded product, a difference in partial impregnation of the resin, and inefficiency of the reversing operation.
図２は、綾織物を一定間隔で織目が逆になるようにジグザグに織ったものを示している。かかるジグザク織は、製織時に、一定間隔で緯糸の挿入タイミングを一段ずらし、織目の方向を逆（右下がり→右上がり）にすることで製織することができる。あるいは、織物組織図を示すことによって、例えば、電子ドビー付織機で自由に且つ容易に製織することができる。 FIG. 2 shows a twill woven zigzag so that the texture is reversed at regular intervals. Such a zigzag weave can be woven by shifting the weft insertion timing one step at regular intervals and reversing the direction of the weave (downward to right). Alternatively, by showing a fabric structure diagram, it is possible to weave freely and easily, for example, with an electronic dobby loom.
図２の方法によると、織物基材の準備の工数削減ができ、また、合わせ目でオーバーラップさせる必要がなく、設計の自由度の向上も見込まれる。ジクザク織の間隔は自由に調節できるし、表面の模様（柄）にも色々と変化を持たすことができる。 According to the method shown in FIG. 2, man-hours for preparing the textile base material can be reduced, and it is not necessary to overlap at the joint, so that the degree of freedom in design can be improved. The spacing of the zigzag weave can be freely adjusted, and the surface pattern (pattern) can be varied.
［製織］
炭素繊維ＵＴ−５００ Ｓ１２Ｋ（東邦テナックス社製）を用いて、２／２綾織物を基本とし、図２に示したようなジグザグ織（東邦テナックス社製、Ｗ−７Ｕ６１）を製織した。このものの目付は３８０ｇ／ｍ２であった。織目の方向は、図２に示したように１２５０ｍｍごとに変えた。
[Weaving]
Using a carbon fiber UT-500 S12K (manufactured by Toho Tenax Co., Ltd.), a zigzag weave (manufactured by Toho Tenax Co., Ltd., W-7U61) as shown in FIG. The basis weight of this product was 380 g / m 2 . The direction of the weave was changed every 1250 mm as shown in FIG.
［成形］
本実施例では、金型の成形キャビティに配置した繊維強化材料層に、マトリックス樹脂を含浸させ加熱硬化させる、樹脂トランスファー成形法を用いて成形した。製品面になる型面に、前記ジグザグ織物を敷設・配置した。この際、敷設・配置の仕方は、織目の方向が変わる位置を製品の対称軸に合わせるようにした。その後、製品の表面にならない裏面にかけて、ジグザグ織ではない一方向の織目を持った２／２綾織物を３枚金型内に積層・配置させた。
[Molding]
In this example, the fiber reinforced material layer disposed in the molding cavity of the mold was molded using a resin transfer molding method in which a matrix resin was impregnated and heated and cured. The zigzag woven fabric was laid and arranged on the mold surface to be the product surface. At this time, the laying / arranging method is such that the position where the direction of the weave changes is aligned with the symmetry axis of the product. Thereafter, a 2/2 twill fabric having a unidirectional texture that is not a zigzag weave was laminated and arranged in a mold on the back surface that does not become the surface of the product.
金型の下型パーティングライン面上の外周には、型内キャビティを真空状態に保ち、更に注入される樹脂が外部に漏れるのを防ぐため、Ｏリングを配した。前記繊維強化織物と真空用Ｏリングを金型に配した後、金型を型締めした。 On the outer periphery on the lower parting line surface of the mold, an O-ring was disposed in order to keep the cavity in the mold in a vacuum state and prevent the injected resin from leaking outside. The fiber reinforced fabric and the vacuum O-ring were placed in a mold, and then the mold was clamped.
次に、樹脂注入口及び排出口にウレタン製中空ホース（外径Φ１０×内径Φ８）を差し込み、樹脂注入口側のホースをクランプ等で閉じ、樹脂排出側のホース端は真空ポンプにつないだ。そして、真空ポンプを動作させ、型内を真空状態とし、その後、樹脂注入ホースの先端を樹脂タンクの中に差し込み、クランプを開放し、真空圧力を利用し、樹脂タンクから型内に樹脂を注入した。樹脂としては、エポキシ樹脂であるアデカレジンＥＰ−４９０１（アデカ社製）を１００質量部と１，３−ＢＡＣ（三菱ガス化学社製）を２０質量部混合した混合液を用いた。型内に樹脂が十分充填された後、樹脂注入側及び排出側のホースをクランプ等で閉じた。型内は密閉状態となり、型内部に注入された樹脂はその後硬化し、ＦＲＰ成形品が型内で出来上がった。 Next, a urethane hollow hose (outside diameter Φ10 × inside diameter Φ8) was inserted into the resin inlet and outlet, the hose on the resin inlet side was closed with a clamp or the like, and the hose end on the resin outlet side was connected to a vacuum pump. Then, the vacuum pump is operated and the inside of the mold is evacuated. Then, the tip of the resin injection hose is inserted into the resin tank, the clamp is opened, and the resin is injected from the resin tank into the mold using the vacuum pressure. did. As the resin, a mixed solution in which 100 parts by mass of Adeka Resin EP-4901 (manufactured by Adeka), which is an epoxy resin, and 20 parts by mass of 1,3-BAC (manufactured by Mitsubishi Gas Chemical Company) was mixed was used. After the resin was sufficiently filled in the mold, the resin injection side and discharge side hoses were closed with clamps or the like. The inside of the mold was sealed, and the resin injected into the mold was then cured, and an FRP molded product was completed in the mold.
［脱型］
樹脂が十分硬化した後金型を開放し脱型を行った。得られたＦＲＰ成形品は、その表面が、中心軸から左右対称の模様のものであった。
[Demolding]
After the resin was fully cured, the mold was opened and demolded. The obtained FRP molded product had a surface with a symmetrical pattern from the central axis.
Claims (4)
The method for forming an FRP molded product having a symmetrical surface pattern according to claim 3, wherein the woven fabric is a twill woven fabric.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2018047666A (en) * | 2016-09-23 | 2018-03-29 | 有限会社北鉄工所 | Molding method |
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| Publication number | Priority date | Publication date | Assignee | Title |
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| JP2018047666A (en) * | 2016-09-23 | 2018-03-29 | 有限会社北鉄工所 | Molding method |
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