JP2009160879A - Method for manufacturing fiber reinforced resin structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber reinforced resin structure from fiber reinforced resin in a short time and at low cost. <P>SOLUTION: The method for manufacturing the structure 10 formed of fiber reinforced resin by arranging a reinforcing fiber base material 30 on the surface 22 of a shaping mold 20, shaping the reinforcing fiber base material 30 into solid shape with a plurality of ridge lines 32, and impregnating the reinforcing fiber base material 31 of solid shape with resin 42, includes at least processes for arranging resin 41 along at least the ridge lines 32 of the reinforcing fiber base material 31 of solid shape after arranging the reinforcing fiber base material 30 on the surface 22 of the shaping mold 20; juxtaposing heaters 12 at predetermined spaces at the respective ridge lines 32 of the reinforcing fiber base material 21 of solid shape and heating the resin 42 arranged at the ridge lines 32, by the heaters 12 to impregnate the ridge lines 32 of the reinforcing fiber base material 30 with the resin 42. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention is a method for producing a structure composed of a three-dimensional reinforcing fiber resin, and in particular, after the reinforcing fiber base is shaped into a three-dimensional shape, the shaped reinforcing fiber base is impregnated with the resin. It is related with the method of the reinforced fiber resin structure suitable for manufacturing.

  Conventionally, reinforced fiber resin consisting of reinforced fibers and matrix resin (resin) is lighter than metal materials, and has higher mechanical strength and elastic modulus than resin materials because it contains reinforced fibers, It is used in many fields such as aircraft, automobiles, railway vehicles, and ships, and is often used as a three-dimensional structural member (fiber reinforced resin structure).

  The fiber reinforced resin can be molded by an autoclave molding method or a resin transfer molding method (RTM method). In the case of the fiber reinforced resin structure, it is often molded by a resin transfer molding method. According to the resin transfer molding method, first, a reinforcing fiber base not impregnated with a resin is laminated on the surface of the shaping mold and shaped into a three-dimensional reinforcing fiber base. Then, after placing the three-dimensional reinforcing fiber base after shaping in the mold, a resin is injected into the mold and the reinforcing fiber base is impregnated with the resin to form a fiber reinforced resin structure. To do. In such a molding method, the reinforcing fiber base material can be shaped into a predetermined shape. Therefore, the reinforcing fiber base material is easily deformed and has a short occupation time in the mold, so that it is an effective molding method for mass production. is there.

  By the way, when molding by the resin transfer molding method, when the reinforcing fiber base shaped into a three-dimensional shape is arranged from the shaping mold to the molding die, the shaped three-dimensional reinforcing fiber base is a resin. Since it was not impregnated, the shape was easily deformed, and there were cases where it could not be placed well in the mold.

  In view of such points, the three-dimensional reinforcing fiber resin structure is manufactured, for example, by the method shown in FIG. Specifically, first, as shown in FIG. 3A, a three-dimensional shaping mold 20 having a plurality of ridge lines 21 and a sheet-like reinforcing fiber base 30 are prepared. Next, as shown in FIG. 3B, the sheet-like reinforcing fiber base 30 is deformed on the surface 22 of the shaping mold 20 so as to become a three-dimensional reinforcing fiber base 31 having a plurality of ridge lines 32. Laminated and arranged.

  After the step shown in FIG. 3B, as shown in FIG. 3C, for example, a powdery resin 41 is sprinkled (arranged) on the surface of the three-dimensional reinforcing fiber base 31 from above. In this state, as shown in FIG. 3 (d), the shaping mold 20 on which the reinforcing fiber base 31 is disposed is disposed in a heating furnace 60 using, for example, hot air as a heat source, and the resin 41 is disposed on the reinforcing fiber. Impregnating the base material 31 increases the strength of the reinforcing fiber base material. Thereafter, as shown in FIG. 3 (e), the shaping die 20 is taken out of the hot air heating furnace 60, and the reinforcing fiber base 31 is removed from the shaping die 20.

  Further, as shown in FIG. 3 (f), a three-dimensional reinforcing fiber base 31 is placed in a molding die 50 composed of an upper mold 51 and a lower mold 52, and a resin 42 is injected to the reinforcing fiber base 31. The resin 42 is impregnated, and then removed from the mold 50 to obtain the fiber reinforced resin structure 100.

  According to such a manufacturing method of the fiber reinforced resin structure 100, as shown in FIGS. 3C and 3D, the powdered resin 41 is reinforced as the binder resin of the sheet-like reinforcing fiber base 30. Since the fiber base material 31 is impregnated and temporarily fixed, the shape of the three-dimensional reinforcing fiber base material 31 is not easily collapsed, and the reinforcing fiber base material 31 can be easily removed from the shaping mold 20 and placed on the forming mold 50. Can do.

  As another method for producing a fiber reinforced resin structure, when a reinforcing fiber base material is placed in a shaping mold, a reinforcing plate such as a water-resistant veneer is placed on the reinforcing fiber base material so that the reinforcing fiber base material is three-dimensional. A method of manufacturing a fiber-reinforced resin structure by forming a shape and impregnating a three-dimensional reinforcing fiber base with a resin has been proposed.

JP 2003-268126 A

  However, when a fiber-reinforced resin structure is manufactured by the method shown in FIG. 3, the heating time of the resin serving as the binder is increased because each shaping mold is placed in a heating furnace and heated to the shaping mold. It took a long time and the manufacturing cost tended to be high.

  Therefore, when the heating time is set to a short time, the reinforcing fiber base material is not sufficiently impregnated with the resin and the reinforcement may not be sufficient. For example, as described in Patent Document 1, a reinforcing fiber is used to reinforce the reinforcing fiber. It is considered that shaping the substrate is an effective means. However, even when manufactured in this way, it is difficult to avoid an increase in manufacturing cost due to the use of the reinforcing plate. Further, since the manufactured fiber-reinforced resin structure includes the reinforcing plate, a desired plate is obtained. It was sometimes difficult to obtain mechanical strength and physical properties.

  The present invention has been made in view of the above problems, and an object of the present invention is to provide a method for producing a fiber-reinforced resin structure made of a fiber-reinforced resin in a short time and at a low cost.

  In order to solve the above problems, a method for producing a fiber reinforced resin structure according to the present invention includes a reinforcing fiber base disposed on a surface of a shaping mold, and the reinforcing fiber base is formed into a three-dimensional shape having a plurality of ridge lines. A manufacturing method for manufacturing a structure made of a fiber reinforced resin by shaping and impregnating a resin into the three-dimensional reinforcing fiber base, the manufacturing method comprising the surface of the shaping mold After arranging the reinforcing fiber base material, the step of arranging the resin along at least the ridge line of the reinforcing fiber base material, and a heater arranged in parallel at a predetermined interval with respect to each ridge line of the reinforcing fiber base material And heating the resin disposed on the ridge line by the heater to impregnate the ridge line of the reinforcing fiber base with the resin.

  According to the method for manufacturing a fiber reinforced resin structure according to the present invention, it is only necessary to partially heat only the resin disposed on the ridge line of the three-dimensional reinforced fiber base material. Compared to the heating method, the fiber-reinforced resin structure can be manufactured at a lower cost and in a shorter time. Further, since the resin is reinforced by being impregnated with the resin along the ridge line of the reinforcing fiber base material, it is removed from the shaping mold without destroying the shaping shape of the three-dimensional reinforcing fiber base material which is an intermediate product. be able to. As a result, a fiber reinforced resin structure can be manufactured efficiently.

  In addition, the “heater” referred to in the present invention is not particularly limited as long as it is a heating device capable of adjusting the temperature at which the resin disposed on the ridge line is heated. For example, a heating device using a heating wire, A heating source using far-infrared rays can be used.

  In addition, when the heater is disposed with a predetermined interval with respect to each ridge line of the reinforcing fiber base, a certain interval is set along the ridge line of the reinforcing fiber base so as to be substantially parallel to the ridge line. It is more preferable that a bar-shaped heater is opened and arranged (arranged) side by side with respect to the ridgeline, and the heating is performed using this bar-shaped heater. As a result, the resin disposed on the ridge line can be heated more uniformly, and the manufacturing process can be shortened.

  In the method for manufacturing a fiber reinforced resin structure according to the present invention, the heater is disposed on a frame having a shape along a ridge line of the three-dimensional reinforced fiber base material, and heating by the heater is applied to the reinforced resin structure. More preferably, the reinforcing fiber substrate on the mold is covered with the frame.

  According to the method for manufacturing a fiber-reinforced resin structure according to the present invention, the frame has a shape along the ridge line of the three-dimensional reinforcing fiber base, and a heater is attached to the frame of this shape. The resin disposed on the ridge line of the reinforcing fiber base can be impregnated.

  Furthermore, in the method for manufacturing a fiber reinforced resin structure according to the present invention, it is more preferable to use a powdery resin as the resin disposed on the ridgeline. According to the method for manufacturing a fiber reinforced resin structure according to the present invention, by using a powdered resin, at least the resin can be easily arranged on the ridge line of the three-dimensional reinforcing fiber base, and the manufacturing time can be reduced. Shortening can be achieved.

  Moreover, when arrange | positioning powdery resin, it is more preferable to spray powdery resin on a reinforced fiber base material by spray etc. By such spraying, the resin can be reliably and uniformly arranged on the ridge line of the three-dimensional reinforcing fiber base.

  Moreover, the manufacturing method of the fiber reinforced resin structure which concerns on this invention uses a thermosetting resin as said resin, and it is more preferable to perform the heating by the said heater below the thermosetting start temperature of the said resin.

  According to the method for manufacturing a fiber reinforced resin structure according to the present invention, an uncured thermosetting resin starts thermosetting using an uncured thermosetting resin as a resin disposed on the ridge line of the reinforcing fiber base. The thermosetting resin can be heated and temporarily softened within a temperature range below the temperature at which the reinforcing fiber substrate is softened, and the reinforced fiber base material can be impregnated with the softened resin on the ridge line of the reinforcing fiber base material. As a result, when the fiber reinforced resin structure is molded in the mold, the resin constituting the fiber reinforced resin structure and the resin impregnated in the ridge line of the reinforcing fiber base are uniformly impregnated in the reinforcing fiber base. Therefore, a fiber reinforced resin structure with higher quality can be obtained.

  More preferably, in the method for producing a fiber-reinforced resin structure according to the present invention, a resin disposed on the ridge line of the reinforcing fiber base and a resin impregnated in the mold for the three-dimensional reinforcing fiber base For example, it is more preferable to use the same type of thermosetting resin such as an epoxy resin. Thus, by using the same kind of thermosetting resin, the fiber reinforced resin structure is composed of a more homogeneous fiber reinforced resin, and the mechanical strength of the manufactured fiber reinforced resin structure can be further stabilized.

  According to the method for producing a fiber reinforced resin structure according to the present invention, a fiber reinforced resin structure can be produced in a short time and at a low cost, and the produced fiber reinforced resin structure is composed of only a fiber reinforced resin. Desired mechanical strength and physical properties can be obtained.

  Below, with reference to drawings, it explains based on one embodiment of the manufacturing method of the fiber reinforced resin structure concerning the present invention.

  FIG. 1 shows an overall process diagram of a method for producing a fiber-reinforced resin structure according to this embodiment, and FIG. 2 is a diagram for explaining the details of the process shown in FIG.

  The method for producing a fiber reinforced resin structure according to the present embodiment includes at least the steps shown in FIGS. 1A to 1H, and in particular, a method for producing a fiber reinforced resin structure suitable for the resin transfer molding method. is there.

  Specifically, first, as shown in FIG. 1A, a shaping mold 20 and a sheet-like reinforcing fiber base 30 are prepared. The shaping mold 20 has a three-dimensional shape having a plurality of ridge lines 21, and is a mold for shaping the reinforcing fiber base 30 into a three-dimensional reinforcing fiber base 31A described later. The shaping mold 20 has substantially the same shape as the fiber reinforced resin structure to be manufactured, and has substantially the same size as the inner surface of the fiber reinforced resin structure.

  As will be described later, the shaping die 20 can be provided with the reinforcing fiber substrate 30 on the surface 22 of the shaping die 20 and is not thermally deformed by heating of the heater 12 described later. For example, the material such as metal or resin is not particularly limited.

  Further, the sheet-like reinforcing fiber substrate 30 is made of resin reinforcing fibers for reinforcing the mechanical strength of the fiber reinforced resin. Therefore, the reinforced fiber base material 30 can maintain a desired strength when the fiber reinforced resin structure is molded, and has a desired shape in a process described later (base material placement process in FIG. 1B). A material that is easily deformed and easily laminated on the surface 22 of the shaping mold 20 is preferable.

  For example, examples of the fibers constituting the reinforcing fiber base 30 include fibers such as glass fibers, carbon fibers, aramid fibers, alumina fibers, boron fibers, steel fibers, PBO fibers, or high-strength polyethylene fibers.

  The reinforcing fiber substrate 30 may be a woven fabric or a non-woven fabric made of the above fibers. In the case of a woven fabric, the weaving method is a woven structure such as plain weave, twill weave, satin weave or the like. A base material having a multi-axial fiber structure in which a plurality of layers in which reinforcing fibers are aligned in one direction may be cross-laminated so that the fiber axes of adjacent layers are shifted by about 30 ° to 90 °. It may be.

  Next, as shown in FIG.1 (b), the prepared sheet-like reinforcing fiber base material 30 is deform | transformed, and is laminated | stacked and arrange | positioned on the surface 22 of the shaping die 20 (base material arrangement | positioning process). In this way, the sheet-like reinforcing fiber base material 30 follows the surface 22 of the shaping mold 20 by deforming and arranging the sheet-like reinforcing fiber base material 30 on the surface of the shaping mold 20. . Thereby, it can shape | mold from the sheet-like reinforcing fiber base material 30 to the three-dimensional reinforcing fiber base material 31 </ b> A, and the three-dimensional reinforcing fiber base material 31 </ b> A has a plurality along the ridge line 21 of the shaping die 20. The ridge line 32 is formed.

  Next, after arranging the reinforcing fiber base on the surface 22 of the shaping mold, as shown in FIG. 1C, the resin 41 is arranged along at least the ridge line 32 of the three-dimensional reinforcing fiber base 31A. . The resin 41 is a resin for reinforcing the reinforcing fiber base 31A so that the shape of the reinforcing fiber base 31A does not collapse when the three-dimensional reinforcing fiber base 31A is removed from the shaping mold 20.

  In addition, as long as the resin 41 can be disposed at least on the ridgeline 32, for example, a sheet-like resin, a powder-like resin, a rod-like resin having substantially the same length as the ridgeline 32 can be used. A more preferable resin is a powdery resin. By using the resin, the resin 41 can be easily disposed on the ridge line 32 of the three-dimensional reinforcing fiber base 31A, for example, by spraying with a spray.

  The resin 41 is preferably a resin constituting the reinforcing fiber resin of the fiber-reinforced resin structure, that is, the same type of resin as the resin 42 impregnated in the reinforcing fiber base 31A in the mold, and is uncured. Either a thermosetting resin or a thermoplastic resin may be used, but a thermosetting resin is more preferable.

  Examples of the thermosetting resin include epoxy resins, phenol resins, melamine resins, urea resins, silicone resins, maleimide resins, vinyl ester resins, unsaturated polyester resins, cyanate resins, and polyimides. A resin such as a resin may be used, and the type of the resin is not particularly limited as long as a predetermined strength can be maintained together with the reinforcing fiber. And the said kind of resin means the thermosetting resin with the same resin system illustrated above.

  Next, as shown in FIG. 1 (d), at least the powdery resin 41 disposed on the ridge line 32 is impregnated into the ridge line 32 of the reinforcing fiber base 31 </ b> A, and the resin 41 is formed along the ridge line 32 to strengthen the resin. The fiber base 31A is reinforced.

  Specifically, as shown in FIG. 2, a frame 10 having a shape along the ridge line 21 of the shaping mold 20, more preferably, a shape along the ridge line 32 of the three-dimensional reinforcing fiber base 31 </ b> A is prepared. The frame 10 has a rod-like portion 11 corresponding to at least each ridgeline 32, and each rod-like portion 11 has a rod-like shape having a length substantially equal to that of the ridgeline 32 so that the inner direction of the frame 10 can be heated. A heater 12 is arranged.

  Then, as shown in FIG. 2, the frame 10 is covered with a reinforcing fiber base 31 </ b> A on the shaping mold 20. Thereby, the heater 12 is juxtaposed with respect to the ridge line 32 at a predetermined interval with respect to each ridge line 32 of the reinforcing fiber base 31 </ b> A. In this state, the heater 41 is used to heat the resin 41 disposed on the ridge line 32 so that the resin 41 is impregnated into the ridge line 32 of the reinforcing fiber base 31A.

  Thereby, the ridgeline 32 impregnated with the resin 41 can improve the mechanical strength as compared with the other reinforcing fiber base 31A portion not impregnated. Further, the frame 10 has a shape along the ridge line 32 of the three-dimensional reinforcing fiber base 31 </ b> A by the rod-shaped portion 11, and the heater 12 is disposed in each rod-shaped portion 11 toward the inside of the frame 10. At the same time, the resin disposed on each ridge line 32 of the reinforcing fiber base 31A can be impregnated into the ridge line 32 of the reinforcing fiber base.

  Here, when a thermosetting resin is used for the powdery resin 41, the thermosetting resin is at least equal to or higher than the temperature at which the reinforcing fiber base material can be impregnated and less than the temperature at which thermosetting starts, that is, the uncured temperature. It is desirable to heat in the region and soften the thermosetting resin so that the reinforcing fiber substrate can be impregnated.

  Thus, when adjusting the heating temperature of resin 41 so that it may become the temperature range mentioned above, a temperature measuring device is installed in the vicinity of each ridgeline 32 of 31 A of reinforcing fiber bases, and the measurement temperature of this temperature measuring device is set. It is more preferable to adjust the heat generation temperature of the heater 12 so as to be in the temperature range. By heating in this temperature region, the resin 41 impregnated in the ridge 32 is also softened by the resin 42 injected into the molding die, which will be described later, and the injected resin 42 is reliably impregnated into the three-dimensional reinforcing fiber base 31. As a result, a homogeneous and high-quality fiber-reinforced resin structure 100 can be obtained.

  Then, as shown in FIG. 1 (e), the frame 10 is removed from the reinforcing fiber base 31A reinforced by impregnating the resin only in the ridge line portion. Further, as shown in FIG. 1 (f), the reinforcing fiber base 31 </ b> A is removed from the shaping mold 20. At this time, as shown in FIG. 1 (g), when moving the three-dimensional reinforcing fiber base 31A from the shaping mold 20 to the forming mold 50, the ridge line 32 of the reinforcing fiber base 31A is impregnated with the resin 41. Since it is reinforced, its shaped shape is hardly collapsed.

  Furthermore, as shown in FIG. 1 (h), the reinforcing fiber base 31 </ b> A shaped into a three-dimensional shape is placed on the lower mold 52 and clamped by the upper mold 51. And the heated resin 42 is inject | poured in the shaping | molding die 50, and a reinforced fiber base material is impregnated with resin. Furthermore, when an uncured thermosetting resin is used as the resin to be injected, the resin is heated at a temperature higher than the curing start temperature, and then cooled to obtain the fiber reinforced resin structure 40.

  According to the manufacturing method of the fiber reinforced resin structure according to the present embodiment, it is only necessary to partially heat only the resin 41 disposed on the ridgeline 32. Therefore, the fiber is cheaper and shorter in time than the conventional method. A reinforced resin structure can be manufactured. Moreover, since the ridgeline 32 of the reinforcing fiber base 31A is reinforced, it can be removed from the shaping mold 20 without breaking the shaped shape of the three-dimensional reinforcing fiber base 31A that is an intermediate product. A high-quality fiber reinforced resin structure 40 can be manufactured.

  Further, since the fiber reinforced resin structure is manufactured by using the same type of resin 41 for shaping and the resin 42 for molding without using a reinforcing plate or the like as in the prior art, it is made of a homogeneous fiber reinforced resin. A structure can be obtained.

  As mentioned above, although embodiment of this invention has been explained in full detail using drawing, a concrete structure is not limited to this embodiment, Even if there is a design change in the range which does not deviate from the gist of the present invention. These are included in the present invention.

The whole process figure of the manufacturing method of the fiber reinforced resin structure concerning this embodiment. The figure for demonstrating the detail of the process shown in FIG.1 (d). The whole process figure of the manufacturing method of the conventional fiber reinforced resin structure.

Explanation of symbols

  10: Frame, 11: Each rod-shaped part, 12: Heater, 20: Shaped mold, 21: Surface of shaped mold, 22: Ridge line of shaped mold, 30: Reinforced fiber base material in sheet form, 31A: Solid shape Reinforced fiber base material, 32: ridge line, 40: fiber reinforced resin structure, 41: resin disposed on the ridge line of the reinforced fiber base material, 42: resin, 50: molding die, 51: upper die, 52: lower die, 60: heating furnace

Claims (4)

A fiber is formed by arranging a reinforcing fiber base on the surface of a shaping mold, shaping the reinforcing fiber base into a three-dimensional shape having a plurality of ridge lines, and impregnating the three-dimensional reinforcing fiber base with a resin. A manufacturing method for manufacturing a structure made of reinforced resin,
The manufacturing method includes a step of disposing the resin along at least a ridge line of the reinforcing fiber substrate after disposing the reinforcing fiber substrate on the surface of the shaping mold;
A heater is arranged in parallel with each ridge line of the reinforcing fiber base, and the resin disposed on the ridge line is heated by the heater, and the resin is applied to the ridge line of the reinforcing fiber base. And a step of impregnating the fiber-reinforced resin structure.   The heater is disposed on a frame having a shape along the ridge line of the three-dimensional reinforcing fiber base, and heating by the heater is performed while covering the frame on the reinforcing fiber base on the shaping mold. The manufacturing method of the fiber reinforced resin structure of Claim 1 characterized by these.   The method for producing a fiber-reinforced resin structure according to claim 1 or 2, wherein a powdery resin is used as the resin disposed on the ridge line.   The production of a fiber reinforced resin structure according to any one of claims 1 to 3, wherein a thermosetting resin is used as the resin, and heating by the heater is performed at a temperature lower than a thermosetting start temperature of the resin. Method.

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