JP2009023163A - Fiber-reinforced resin surface material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fiber-reinforced resin surface material which can effectively inhibits the occurrence of burrs in drilling holes. <P>SOLUTION: The fiber-reinforced resin surface material 10A is composed at least of a first fiber bundle group in which a plurality of carbon fiber bundles comprising sheaved carbon fibers are laid in the same direction, presenting a flat surface and a second fiber bundle group in which a plurality of carbon fiber bundles comprising sheaved carbon fibers are laid in a direction different from the first fiber bundle, presenting a flat surface. At least the first and second fiber bundles are united in a laminated manner with a curable resin to form a carbon fiber-reinforced resin base material (CFRP sheet 1). A glass fiber-reinforced surface material (GFRP sheet 2) formed of a glass fiber cloth and a curable resin united together is adhered to the surface of the carbon fiber-reinforced resin base material. Preferably the GFRP sheet 2 is made of warp-knitted or weft-knitted glass fibers. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a resin face material reinforced with carbon fibers.

  Fiber reinforced plastic (FRP) in which a reinforcing fiber material is mixed in a resin is lightweight and has high strength, and is therefore used in a wide range of industries such as the automobile industry, construction industry, and aviation industry.

  The above-mentioned FRP is formed by laminating a plurality of fiber bundles arranged in a planar shape while changing the orientation direction, and is impregnated with resin in this posture to form a face material. The disclosed fiber mat can be cited as a prior art.

  By the way, in the above FRP, those using carbon fibers as reinforcing fibers are generally known as CFRP (carbon fiber reinforced plastic). This CFRP sheet (face material) is a bundle of a large number of carbon fibers integrated in a matrix resin in the same orientation posture, and preparing a plurality of them and laminating the fiber orientations of each CFRP sheet differently, A so-called multiaxial substrate is produced by stitching.

  As shown in FIG. 6, a machining hole b (for example, a bolt hole) for fastening with another member is machined at an appropriate location of the multiaxial substrate, but the CFRP sheet a on the surface layer is unidirectional as described above. Therefore, there is a problem that the fiber is caught on the drill during machining, and as a result, burr c tends to occur. This burr is a big obstacle for precise bolt fastening, and further, the bolt is tightened in the state where the burr is generated, and thus the strength of the fastening portion is reduced. In addition, when a so-called opening occurs in the surface layer of the sheet at the time of machining, it cannot be used as a product. Therefore, in the conventional multiaxial substrate made of CFRP, the manufacturing yield is increased by the final drilling process. There has also been a problem of decline.

  Accordingly, there has been a strong demand for the development of a fiber-reinforced resin face material that can effectively suppress the generation of burrs when drilling is performed by machining with a drill or the like.

JP 2005-324473 A

  The present invention has been made in view of the above-described problems, and an object of the present invention is to provide a fiber-reinforced resin face material that can effectively suppress the generation of burrs during drilling.

  In order to achieve the above object, the fiber reinforced resin face material according to the present invention includes a first fiber bundle group in which a plurality of carbon fiber bundles formed by bundling carbon fibers are arranged in a posture having the same orientation, and exhibit a planar shape, A plurality of carbon fiber bundles oriented in different directions from the first fiber bundle group are arranged in a posture having the same orientation, and at least a second fiber bundle group having a planar shape, at least the first, A carbon fiber reinforced resin base material is formed by integrally forming with a cured resin in a posture in which the second fiber bundle group is laminated, and a glass fiber cloth material is formed on the surface of the carbon fiber reinforced resin base material. And a glass fiber reinforced resin surface material integrally formed with a cured resin.

  The fiber-reinforced resin face material of the present invention includes a first fiber bundle group in which a plurality of carbon fiber bundles are arranged in a posture having the same orientation and exhibit a planar shape (sheet shape), and a carbon fiber bundle having a different orientation. A plurality of second fiber bundles that are arranged side by side are stitched together with a sewing thread such as polyester, and a matrix resin is impregnated and cured to form a carbon fiber reinforced resin base material. This carbon fiber reinforced For example, a glass fiber reinforced resin surface material in which a glass fiber cloth material and a cured resin are integrally formed on both surfaces of a resin base material is fixed. Of course, the carbon fiber reinforced resin base material may be formed from a laminate of three or more layers having the third or fourth fiber bundle group.

  For example, the carbon fiber reinforced resin base material may be a known CFRP (carbon fiber reinforced plastic) multiaxial base material, and the glass fiber reinforced resin surface material may be a known GFRP (glass fiber reinforced plastic). Here, the orientation of the fiber bundle is a normal plain weave 0/90 ° orientation, and in a multiaxial base material, the laminated sheets are laminated in the ± 45 ° direction.

  Conventionally, the CFRP sheet and the GFRP sheet were generally used alone, but in the present invention, for example, by fixing the GFRP sheet to the surface of the multiaxial substrate composed of a plurality of CFRP sheets, It is intended to effectively suppress the above-described conventional problem, that is, the generation of burrs when drilling by machining.

  This eliminates the process of removing burrs in the case of conventional multi-axis substrates, and also completely eliminates the problem of reduced strength of the fastening part when bolted with other members while allowing burrs. Can be resolved.

  Furthermore, in a preferred embodiment of the fiber-reinforced resin face material according to the present invention, the glass fiber cloth material has either a warp knitted structure or a weft knitted structure. It is a feature.

  As described above, for example, the occurrence of burrs during drilling can be suppressed by using the fiber reinforced resin face material of the present invention in which a GFRP sheet is attached to the surface of a multiaxial base material of CFRP. Here, when a GFRP sheet is stuck on the surface of a CFRP multiaxial substrate, when the fiber orientation of the CFRP constituting the multiaxial substrate is ± 45 °, the glass fiber has a normal plain weave 0/90 ° orientation. When attempting to apply the GFRP sheet to be presented in this direction, the ease of elongation to the fiber orientation (± 45 °) inherent to CFRP is constrained by the GFRP sheets having different orientations, and the desired elongation required for the fiber-reinforced resin face material Will not be able to demonstrate.

  Therefore, there is a method of attaching the GFRP sheet to the multiaxial substrate in the direction of ± 45 ° as in the case of the CFRP multiaxial substrate. In this case, a plurality of CFRP multiaxial substrates are provided side by side. Further, it is necessary to apply a GFRP sheet cut into a predetermined shape on this with the glass fiber orientation set to be ± 45 ° (in the same direction as the CFRP fiber orientation), and the work process is greatly increased. A GFRP sheet is pasted on both sides of a CFRP multiaxial substrate, then cut with a desired cut pattern to create a fiber reinforced resin face piece, and this is bonded to a desired shape to produce a vehicle body and the like. Will do.

  In this embodiment, in order to solve the problem of increasing the number of work steps described above, by using a glass fiber having a warp knitted structure or a weft knitted structure, these are used. Since the GFRP sheet in the knitted form can exhibit the same elongation in various directions other than the ± 45 ° direction and the 0,90 ° direction, the GFRP sheet is stuck on both sides of the CFRP multiaxial substrate without considering the directionality. It becomes possible. That is, even if the fiber orientation of the GFRP sheet is different from the fiber orientation of CFRP, the intended elongation of the CFRP multiaxial substrate is not hindered. Moreover, since it becomes possible to affix without considering directionality, work efficiency will be improved significantly.

  As described above, according to the fiber-reinforced resin face material of the present invention, the generation of burrs during machining can be effectively suppressed, and thus the production yield is not reduced, and further, it is required for a CFRP multiaxial substrate. The production efficiency can be increased while securing the expected growth.

  As can be understood from the above description, according to the fiber-reinforced resin face material of the present invention, the occurrence of burrs during drilling machining can be completely suppressed, and thus the production yield can be improved, and the multiaxial substrate has The production efficiency can be increased while satisfying the elongation of the period.

  Embodiments of the present invention will be described below with reference to the drawings. It is the figure explaining the outline | summary of the manufacturing process of one Embodiment of the fiber reinforced resin face material of this invention in order of FIG. 1a, b and FIG. 2a, b. FIG. 3 is a diagram illustrating a state in which the processing holes are processed in the fiber reinforced resin face material. FIG. 4 is a diagram for explaining the outline of the manufacturing process of another embodiment of the fiber-reinforced resin face material of the present invention in the order of FIGS. 4a to 4c. FIG. 5a is an enlarged view of a form in which glass fibers are warp knitted, and FIG. 5b is an enlarged view of a form in which glass fibers are weft knitted.

The manufacturing process of one embodiment of the fiber-reinforced resin face material of the present invention will be described based on FIGS.
First, as shown in FIG. 1a, two face materials on which fiber bundle groups plainly woven at 0/90 ° are arranged and stitched in a direction of ± 45 °, and a thermosetting matrix resin is put in these fibers. A plurality of CFRP sheets 1 formed by impregnating and curing are prepared and arranged side by side.

  Next, as shown in FIG. 1b, a GFRP sheet 2 in the same direction (± 45 ° direction) as the fiber orientation direction of the CFRP sheet 1 is prepared, and the CFRP sheets 1,... Arranged side by side as shown in FIG. Affix to both sides. In the illustrated example, the GFRP sheet 2 is affixed to one side, but the GFRP sheet 2 is similarly affixed to the back side.

  At the stage of FIG. 2a, the fiber orientation constituting the CFRP sheet 1 and the fiber orientation constituting the GFRP sheet 2 are both the same orientation, whereby the desired elongation of the CFRP sheet 1 can be ensured. .

  This is cut out along the shape of the GFRP sheet 2 to produce a fiber-reinforced resin face material 10 as shown in FIG. 2b. Actually, the area where the GFRP sheet 2 is pasted on the CFRP sheet 1 forms the fiber reinforced resin face material 10 next to FIG. 2a without cutting out as shown in FIG. 2b. Therefore, a desired cut pattern is cut within this range, and a cut pattern having an appropriate shape is bonded to form a final product, for example, a vehicle body.

  FIG. 3 shows a state in which the machined hole b (bolt hole) is machined on the manufactured fiber-reinforced resin face material 10 by machining with a drill. As shown in the figure, when the GFRP sheet 2 is formed on the surface layer of the CFRP sheet 1, it is possible to prevent the drill from pulling the CFRP fiber with respect to the CFRP fiber when the drill is pushed in or pulled out. No burr is generated in the processed hole b.

  Next, a manufacturing process of another embodiment of the fiber-reinforced resin face material of the present invention will be described based on FIG.

  First, as shown in FIG. 4a, a CFRP sheet formed by laminating two face materials in which fiber bundle groups plainly woven at 0/90 ° are arranged in a direction of ± 45 ° and impregnating and hardening these matrix fibers with a matrix resin. Prepare 1

  Next, a GFRP sheet 2A having a knitting form different from the plain weave form shown in FIG. 1b is prepared (see FIG. 4b).

  Here, the GFRP sheet 2A is composed of either a warp knitted glass fiber as shown in FIG. 5a or a weft knitted glass fiber as shown in FIG. 5b.

  The GFRP sheet 2A in the warp knitting mode or the weft knitting mode has an effect that the loop region in which the fibers are knitted to each other increases the flexibility of the sheet. Therefore, no matter which GFRP sheet is used, As shown by the arrows in FIGS. 5a and 5b, the film can extend in any direction of 360 °.

  By affixing the GFRP sheet 2A to both surfaces of the CFRP sheet 1, a fiber reinforced resin face material 10A as shown in FIG.

  According to the fiber-reinforced resin face material 10A, the fiber orientation of the CFRP sheet 1 is taken into account when being applied to the CFRP sheet 1 by using the GFRP sheet 2A having extensibility in various directions ( Therefore, the production efficiency is significantly improved compared to the production of the fiber-reinforced resin face material 10.

  Note that the matrix resin of the CFRP sheet and the GFRP sheet is preferably a thermosetting resin of the same material from the viewpoint of adhesiveness, and examples of the thermosetting resin include epoxy resins, vinyl ester resins, and unsaturated polyesters. Resin or the like can be used.

[Experiments and results on saddle formability, machinability, and lamination time when the weight of the GFRP sheet affixed to the CFRP sheet is changed]
The inventors varied the basis weight of multi-axis CFRP materials with ± 45 ° orientation (matrix resin is epoxy resin, basis weight 330 gsm), plain weave glass cloth and warp GFRP (matrix resin is epoxy resin) In this case, the differences in shape, machinability, and lamination time were verified. The results are shown in Table 1 below. In the table, ◯ indicates good or the time is within the allowable range (short), and x indicates bad or the time does not satisfy the allowable range (long).

  From Table 1, warp knitting GFRP is good in all of its own formability, machinability and lamination time if it is 20 gsm or more, but it is 200 gsm or less from the viewpoint of weight reduction of the fiber-reinforced resin face material. Is preferred. On the other hand, when the GFRP is a plain weave cloth, when the fiber orientation is 0/90 °, which is different from the multiaxial CFRP material, the saddle shape is poor, and when the fiber orientation is ± 45 °, As described above, the lamination time with the multiaxial CFRP material becomes long, and the production efficiency is deteriorated.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

It is the figure explaining the outline | summary of the manufacturing process of one Embodiment of the fiber reinforced resin face material of this invention in order of (a) and (b). It is the figure explaining the outline | summary of the manufacturing process of one Embodiment of the fiber reinforced resin face material of this invention in order of (a) and (b) following FIG. It is the figure explaining the state by which the processing hole was processed in the fiber reinforced resin face material. It is the figure explaining the outline | summary of the manufacturing process of other embodiment of the fiber reinforced resin face material of this invention in order of (a)-(c). (A) is an enlarged view of the form in which the glass fiber was warp knitted, (b) is an enlarged view of the form in which the glass fiber was weft knitted. It is the figure explaining the state which the burr | flash has arisen in the case of the drilling machining to the conventional CFRP multiaxial base material.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 1 ... CFRP sheet (carbon fiber reinforced resin base material), 2, 2A ... GFRP sheet (glass fiber reinforced resin surface material) 10, 10A ... Fiber reinforced resin face material, b ... Processing hole

Claims (3)

A first fiber bundle group in which a plurality of carbon fiber bundles formed by bundling carbon fibers are arranged in a posture having the same orientation and have a planar shape;
A plurality of carbon fiber bundles oriented in different directions from the first fiber bundle group, and a plurality of second fiber bundle groups arranged in a posture having the same orientation and exhibiting a planar shape,
A carbon fiber reinforced resin base material is formed by being integrally formed with a cured resin in a posture in which at least the first and second fiber bundle groups are laminated,
A fiber-reinforced resin face material in which a glass fiber-reinforced resin surface material in which a glass fiber cloth material and a cured resin are integrally formed is fixed to a surface of the carbon fiber-reinforced resin base material.   2. The fiber-reinforced resin face material according to claim 1, wherein the glass fiber cloth material has either a warp knitted structure or a weft knitted structure of glass fibers.   The fiber reinforced resin according to claim 1 or 2, wherein the carbon fiber reinforced resin base material is made of CFRP (carbon fiber reinforced plastic), and the glass fiber reinforced resin surface material is made of GFRP (glass fiber reinforced plastic). Resin face material.

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