JP2009269283A - Device for manufacturing fiber-reinforced resin structure and manufacturing method using this device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a fiber-reinforced resin structure by which the generation of an impregnation defect can be hindered, as well as a manufacturing device using this method. <P>SOLUTION: This device is configured of a first mold 11 and a film-like second mold 12 covering the first mold 11, and also, for manufacturing the fiber-reinforced resin structure by impregnating a fibrous laminate 15 set inside the cavity, with a resin 16 under a decompression state. In addition, the device has a reticular resin flow medium 22 which is arranged on the second mold 12 side and increases the flow of the resin 16 with which the fibrous laminate 15 is impregnated and a curbing member 21 which is arranged on the first mold 11 side of the resin flow medium 22 and curbs the advance of the flow front of a fluid resin to be injected from a main resin supply part (a first resin supply part) 14-1. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to an apparatus and a method for manufacturing a fiber-reinforced resin structure that can be applied to large structures such as aircraft bodies, ships, railway vehicles, and windmill wings.

  The use of fiber reinforced resin (FRP) has been expanded to various fields. Carbon fiber rods are useful for fishing rods and golf putters. The multilayered fiber reinforced resin is usefully used for hull structures such as boats and yachts. Due to such light weight and high strength characteristics, in recent years, it is desired to use fiber reinforced resin for large structures such as aircraft bodies and windmill wings.

In order to guarantee the strength of this type of fiber reinforced structure or stabilize its physical properties, it is important that bubbles and cavities do not enter the fiber reinforced resin during the manufacturing process. In a construction method in which a fluid resin is poured into a fiber laminate laid in a mold and the fiber layer is impregnated with the fluid resin, a cavity may be formed in the resin layer. A vacuum forming method is known as a technique for preventing the voids from being formed in the layer (see, for example, Patent Document 1).
According to the above-mentioned Patent Document 1, the mold cavity closed by the inner surface of the mold and the vacuum film is evacuated on one side, and the fluid resin is injected from the other side, and the air is fluid resin in the cavity. Describes a technique for producing a fiber-reinforced resin structure that is replaced by the above and has few bubbles and cavities.

According to this technique, the vacuum forming technique needs to be improved so that the resin having fluidity is spatially uniformly distributed and distributed in the fiber layer. For example, Patent Document 2 and Patent Document 3 are known as such improved techniques.
A common feature of these known technologies is that, as abstracted and conceptually shown in FIG. 7, a structure having a lattice hole in a cavity formed between the mold 101 and the vacuum film 102, particularly a nylon net or the like. The resin flow media 103 is laid on the surface side of the resin laminate 106, and as shown in FIG. 8, the fluid resin 105 is injected from many holes formed in the resin injection hose 104, and from the end of the cavity. The vacuuming 107 is performed, and the lattice-like network of the resin flow media 103 is permeated to impregnate the resin into the base fiber laminate 106. Here, the resin flow media 103 is used to provide two-dimensional diffusion uniformity of the fluid resin.

  According to this technology, when manufacturing FRP products with a large plate thickness, the flow rate is difficult to be uniform, and as shown in FIG. 8, the flowable resin does not flow uniformly and the resin is impregnated into the fiber laminate. Unimpregnated sites 108 that are not formed are likely to occur, and impregnation defects are likely to occur.

  Thus, it is required to suppress the occurrence of impregnation defects by simultaneously improving the fluidity and diffusibility of the injected resin. As a result, it is desirable to shorten the manufacturing cycle by increasing the resin injection rate.

JP-A-60-83826 US Pat. No. 4,902,215 US Pat. No. 5,904,972

  By the way, when the resin flow media 103 is used, the flowability of the injected resin has a difference in the diffusibility between the vicinity of the resin flow media 103 and the mold 101 surface side. It is eagerly desired to suppress the occurrence of impregnation defects through improvement. In particular, when manufacturing a large structure having a large plate thickness or a long length, since there are many unimpregnated portions, it is required that no unimpregnated portions be generated.

  An object of this invention is to provide the manufacturing apparatus of the fiber reinforced resin structure which can eliminate generation | occurrence | production of an impregnation defect, and its manufacturing method in view of the said problem.

  The first invention of the present invention for solving the above-mentioned problem is that a cavity is formed from a first mold and a film-shaped second mold covering the first mold, and is installed in the cavity. An apparatus for manufacturing a fiber reinforced resin structure, in which a fiber laminate is impregnated with a resin in a reduced pressure state, and is disposed on the second mold side to increase the amount of resin impregnated in the fiber laminate. Progress of the flow front of the fluid resin injected from the main resin supply section, which is arranged on either or both of the mesh-shaped resin flow media and the first mold side or the second mold side of the resin flow media And a resin flow restraining member that restrains the fiber reinforced resin structure.

  According to a second invention, in the first invention, the resin flow suppressing member is in the vicinity of an inlet of a secondary resin supply unit that injects resin next to the main resin supply unit, and the resin flow from the main resin supply unit. An apparatus for manufacturing a fiber-reinforced resin structure, characterized in that the apparatus is arranged on a side to suppress a flow front of resin flowing through a medium.

  A third invention is the invention according to the first or second invention, wherein the resin suppressing member is any one of a soft material, a sponge, or a member that is crushed at atmospheric pressure during evacuation and closes the mesh of the resin flow media. In the manufacturing apparatus of the fiber reinforced resin structure characterized by these.

  4th invention arrange | positions a resin flow suppression member in the predetermined position of a resin flow media, and impregnates a fiber laminated body with resin, suppressing the flow of the resin flow front at the resin flow media side where the resin progresses quickly. In the manufacturing method of the fiber reinforced resin structure characterized by these.

  5th invention suppresses the flow of the flow front where the advance of the resin supplied from the main resin supply part to the resin flow media side is fast by the resin flow suppression member arranged in the predetermined position of the resin flow media which increases the resin flow rate And after the resin flow from the main resin supply unit is suppressed, the resin is continuously supplied from the sub resin supply unit and the fiber laminate is uniformly impregnated with the resin. It is in.

  A sixth invention is the invention according to the fourth or fifth invention, wherein the resin suppressing member is any one of a soft material, a sponge, or a member that is crushed at atmospheric pressure and closes the mesh of the resin flow media when evacuated. It is in the manufacturing method of the fiber reinforced resin structure characterized by the above-mentioned.

  A seventh invention is the method for producing a fiber reinforced resin structure according to any one of the fourth to sixth inventions, wherein the fiber reinforced structure is a large structure.

  According to the present invention, the flow of the flow front where the resin progresses fast can be suppressed by the fat flow suppressing member disposed at a predetermined position of the resin flow media that amplifies the fluidity of the resin, and the resin is uniformly impregnated into the fiber laminate. be able to.

  Hereinafter, the present invention will be described in detail with reference to the drawings. Note that the present invention is not limited to the embodiments. In addition, constituent elements in the following embodiments include those that can be easily assumed by those skilled in the art or those that are substantially the same.

An apparatus for manufacturing a fiber reinforced resin structure according to an embodiment of the present invention will be described with reference to the drawings.
1-1 and FIGS. 1-2 are conceptual diagrams illustrating a manufacturing apparatus for a fiber-reinforced resin structure according to an embodiment.
As shown to FIGS. 1-1, the embodiment of the manufacturing apparatus of the fiber reinforced resin structure which concerns on a present Example uses the sheet | seat for vacuum with a nondeformable shaping | molding die.
As illustrated in FIG. 1A, the fiber reinforced resin structure manufacturing apparatus 10-1 forms a cavity from a first mold 11 and a film-shaped second mold 12 that covers the first mold 11. The fiber laminate 15 installed in the cavity is impregnated with resin 16 in a reduced pressure state, and is a fiber reinforced resin structure manufacturing apparatus, disposed on the second mold 12 side, A mesh-like resin flow media 22 for increasing the flow rate of the resin 16 impregnated into the fiber laminate 15 and a first resin 11 on the first mold 11 side of the resin flow media 22 are arranged. And a resin flow suppression member 21 that suppresses the progress of the flow front of the fluid resin injected from the supply unit 14-1.

  Here, in this embodiment, a cavity is formed from the first mold 11 and the deformation mold 12 covering the first mold 11, and the inside of the cavity is decompressed by a vacuum pump (not shown). Reference numeral 13 denotes a seal band for maintaining airtightness.

  The second mold 12 is formed of, for example, a vacuum sheet such as a transparent resin film or a transparent resin sheet, is deformable in the direction of the normal line of each surface, and is transparent or translucent. The second mold 12 is light transmissive, and an operator can adjust the uniformity of diffusion by controlling the injection position and injection pressure while observing the state of resin diffusion.

In the present embodiment, as shown in FIG. 1-1, the second mold 12 is provided with first to third resin supply units 14-1 to 14-3 that are a plurality of resin injection ports.
In this embodiment, the first resin supply unit 14-1 is the main resin supply unit, and the second and third resin supply units 14-2 and 14-3 are the sub resin supply for supplying the resin following the main resin supply unit. As a part.
Here, in the resin supply parts 14-1 to 14-3, for example, in the formation of a long large structure, the supply pipe is disposed along the longitudinal direction, and the resin injection ports are formed at predetermined intervals. ing. Moreover, you may make it provide two or more sub resin supply parts according to manufacture of a large sized structure.

When the resin 16 is supplied, the pressure is reduced by a vacuum pump (not shown), and the second mold (vacuum sheet) 12 and the first to third resin supply units 14-1 to 14-3 are in close contact with each other. There is no air leakage between the second mold 12 and the first to third resin supply units 14-1 to 14-3. Note that FIG. 1 schematically shows a state before decompression, and the resin is actually supplied after decompression.
In the figure, reference numeral 15 denotes a fiber laminate, which is impregnated with resin 16.

In the present embodiment, the resin flow suppressing member 21 is disposed on the lower side of the resin flow medium 22 (the first mold 11 side) on the resin flow acquisition front side of the second resin supply unit 14-2 and the third resin supply unit 14-3. ).
Here, FIG. 1-1 is a cross-sectional view, and when the resin supply unit is provided in the longitudinal direction as described above, the resin flow suppressing member 21 is also provided along the longitudinal direction.
The resin flow restraining member 21 is disposed between a release sheet (not shown) and the resin flow media 22, and is separated from the resin flow media 22 by peeling the release sheet after molding. I have to.

  The resin flow media 22 amplifies the fluidity of the fluid resin. For example, a net or a sheet having continuous voids is used. The resin flow media 22 is disposed so as to cover the whole or part of the upper surface of the resin laminate 15.

  The fiber laminate 15 has a laminated structure in which a plurality of fiber layers and a plurality of foamed resin layers are combined to form a multilayer. As the fibers of the fiber layer, for example, glass fibers, carbon fibers, aramid fibers, and carbon fiber tubes are used. The fiber layer is usually multi-layered and reinforced. The fiber layer is formed from matrix fibers in which fiber groups extend in a lattice shape and are woven in a matrix shape. It is preferable that a sandwich foam is interposed between two fiber layers in a member that requires bending rigidity.

  By providing the resin flow restraining member 21 on the first mold 11 side of the resin flow media 22 disposed on the upper surface of the fiber laminate 15, the inside of the resin flow front formed by the resin flow flowing in from the main resin supply unit The flow of the flow front where the resin flow on the resin flow media 22 side is fast is suppressed. Thereby, the resin flow from the main resin supply part can be made to correspond on the resin flow front side and the base part side. Thereafter, by injecting the resin from the secondary resin supply unit (second resin supply unit or third resin supply unit), there is no occurrence of an unimpregnated portion where the resin is not impregnated in the fiber laminate 15, and as a result, Impregnation defects are eliminated.

  The material of the resin flow restraining member 21 is, for example, a soft material, a sponge tape, or the like that is crushed at atmospheric pressure and crushes the mesh of the resin flow media 22 and the cavity formed by the second mold. If it is not, any one may be used.

  In the fiber reinforced resin structure manufacturing apparatus 10-1 of FIG. 1-1, the resin flow suppressing member 21 is disposed on the lower side (first mold 11 side) of the resin flow medium 22, but the present invention. However, the present invention is not limited to this. As shown in the fiber-reinforced resin structure manufacturing apparatus 10-2 in FIG. 1-2, the resin flow suppressing member 21 is located above the resin flow medium 22 (on the second mold 12 side). You may make it arrange | position to. Further, the resin flow suppressing member 21 may be provided on both the first mold 11 and the second mold 12. In addition, although arrangement | positioning of the resin flow suppression member 21 is preferable in any arrangement, It is good to arrange | position to the 1st type | mold 11 side especially preferably.

Next, an injection process for injecting the fluid resin into the cavity so that there is no unimpregnated region will be described with reference to FIG. 2 (process 1) to FIG. 6 (process 5).
The resin 16 is supplied from the first resin supply unit 14-1, which is the main resin supply unit, to the resin passage, and impregnated in the resin flow media 22. Then, the resin 16 impregnated in the resin flow media 22 impregnates the fiber laminate 15.

  First, in FIG. 2, the resin 16 supplied to the supply port of the first resin supply unit 14-1 is uniformly supplied to the resin flow media 22 side by the negative pressure in the cavity.

  As described above, the cavity is in a reduced pressure state, and the fluid resin 16 smoothly enters the cavity under the atmospheric pressure. Then, the double flow of the fluid resin diffuses and mixes, and further penetrates to the deep layer so as to soak into the fiber laminate 15.

  During the permeation, the resin 16 that has flowed in is guided to the resin flow media 22, and the resin flow front 16 a advances closer to the resin flow media 22 side due to the fluidity amplification of the resin 16. Will be promoted.

  Thereafter, as shown in step 1 of FIG. 2, when the resin flow front 16 a advances to the place where the resin flow suppressing member 21 is present, the resin flow suppressing action of the resin flow suppressing member 21 causes steps 2 to 2 in FIGS. 4, the resin flow front 16a is gradually brought into an upright state by the suppressing action.

  Then, in the vicinity of the entrance of the second resin supply unit 14-2 as the sub resin supply unit, the flow front 16a passes uniformly as shown in Step 5 of FIG. Is supplied from the second resin supply unit 14-2, thereby eliminating the occurrence of an unimpregnated portion of resin. Note that the injection timing of the resin from the second resin supply unit 14-2 and the third resin supply unit 14-3, which are sub resin supply units, differs depending on the state of the resin flow at that time. .

  The fiber reinforced resin formed in this manner is cured at room temperature or in an active heating environment while being pressed to atmospheric pressure through the second mold (vacuum sheet) 12 and transformed into a hard fiber reinforced resin structure. To do. After the fiber reinforced resin structure is manufactured, the second mold (vacuum sheet) 12 is removed, and the first to third resin supply units 14-1 to 14-3, the resin flow suppressing member 21, and the resin flow. The medium 22 is removed and the fiber reinforced resin structure is taken out from the first mold 11.

In the above embodiment, the resin flow media 22 is removed after the fiber reinforced resin structure is manufactured. However, the fiber reinforced resin structure is formed by molding the fiber layer with the same quality glass fiber or carbon fiber mat (felt). Therefore, it is not necessary to remove the resin flow media 22 after the manufacture. In this case, the resin flow media 22 is completely integrated with the fiber reinforced resin structure and constitutes a part of the reinforcing material.
As a result, the number of manufacturing steps can be reduced, and the work efficiency can be improved.

  In order to secure the resin passage, it is desirable that the resin flow medium 22 has a large void ratio and is thick. However, if the resin flow medium 22 is too thick, the material physical properties of the fiber reinforced resin itself may be deteriorated. It only has to be selected.

  In addition, according to the embodiment, the resin flow media 22 is arranged on the surface of the fiber laminate 15 during the production of the fiber reinforced resin structure, and is supplied from the first resin supply unit 14-1 as the main resin supply unit. Since the resin flow restraining member 21 is disposed so as to crush the mesh of the resin flow media 22 on the resin flow acquisition front side of the next resin supply units 14-2 and 14-3 disposed in the resin flow direction, The flow of the flowable resin flowing in the flow front 16a can be suppressed, and the flowable resin can be uniformly impregnated into the resin laminate, and as a result, a fiber-reinforced resin structure free from unimpregnated defects can be produced. .

  In the injection process of the present invention, the diffusion state of the resin supplied from the main resin supply unit is monitored, the degree of opening and closing of the sub resin supply unit is controlled, and the flow amount is made uniform even in the absence of unimpregnated parts. can do. It is desirable that the control is determined while an operator observes the flow situation from the outside of the transparent sheet 1.

  Furthermore, although the FRP structure of the present embodiment is described as a flat plate, as a general feature of the resin molding technology, particularly the insert injection molding technology, a complex large-sized FRP structure having variously curved inner and outer curved surfaces. The body can be molded. Such an FRP molding method is beneficially used for curved surface forming structures such as boats, yachts, ships, vehicle bodies, aircraft fuselage, ship rotor blades, wind turbine blades that require hardness and elasticity (flexibility) at the same time. Can be done.

[Test example]
First, as the fiber laminate 15, glass fiber (400 × 500 × 1.24 (mm) × 23 layers): impregnation coefficient 1.16 × 10 ⁻¹¹ (m ² ) was used.
Moreover, as the resin 16, a polyester resin (viscosity: 160 mPas, gelation time: 200 min) was used.
As the resin flow media 22, a nylon fish net (400 × 500 mm, impregnation coefficient 1.16 × 10 ⁻¹¹ (m ² )) was used.
As the resin flow suppressing member 21, sponge rubber (80 × 5 × 400 (mm)) was used.

  Resin 16 was injected into the cavity as shown in FIG. 1 at a pressure difference of 0.1 MPa to impregnate the laminate. At that time, the resin injected from the main resin supply unit was suppressed from flowing in the flow front by the resin flow suppressing member 21 and passed through the second resin supply unit, which is the sub resin supply unit, in a uniform flow. Then, the fiber reinforced resin structure without an unimpregnated part was able to be obtained by injecting resin from the 2nd resin supply part 14-2.

  As described above, according to the present invention, it is possible to eliminate the occurrence of impregnation defects. For example, large-sized fiber reinforced resin structures such as large structures such as aircraft bodies, ships, railway vehicles, windmill wings, etc. Suitable for use in manufacturing.

It is the schematic of the manufacturing apparatus of the fiber reinforced resin structure which concerns on the Example of this invention. It is the schematic of the manufacturing apparatus of the fiber reinforced resin structure which concerns on the other Example of this invention. It is a schematic diagram of the process 1 of the manufacturing process of the fiber reinforced resin structure which concerns on an Example. It is a schematic diagram of the process 2 of the manufacturing process of the fiber reinforced resin structure which concerns on an Example. It is a schematic diagram of the process 3 of the manufacturing process of the fiber reinforced resin structure which concerns on an Example. It is a schematic diagram of the process 4 of the manufacturing process of the fiber reinforced resin structure which concerns on an Example. It is a schematic diagram of the process 5 of the manufacturing process of the fiber reinforced resin structure which concerns on an Example. It is a conceptual diagram of the manufacturing apparatus of the fiber reinforced resin structure of a prior art. FIG. 8 is a plan view of FIG. 7.

Explanation of symbols

10-1, 10-2 Manufacturing apparatus for fiber reinforced resin structure 11 First type 12 Second type for deformation molding 13 Sealing band for pressure reduction 14-1 to 14-3 First to third resin supply unit 15 Fiber laminate 16 Resin

Claims (7)

A fiber formed by forming a cavity from a first mold and a film-shaped second mold covering the first mold, and impregnating a resin in a reduced pressure state in a fiber laminate placed in the cavity An apparatus for manufacturing a reinforced resin structure,
A mesh-like resin flow media that is disposed on the second mold side and increases the amount of resin impregnated in the fiber laminate;
A resin flow restraining member which is disposed on either or both of the first mold side and the second mold side of the resin flow media and suppresses the progress of the flow front of the fluid resin injected from the main resin supply unit; An apparatus for producing a fiber-reinforced resin structure, comprising: In claim 1,
The resin flow suppressing member is
Located near the injection port of the sub resin supply unit for injecting resin next to the main resin supply unit, on the side to suppress the flow front of the resin flowing from the main resin supply unit through the resin flow media An apparatus for manufacturing a fiber-reinforced resin structure, characterized in that. In claim 1 or 2,
The apparatus for producing a fiber reinforced resin structure, wherein the resin suppressing member is any one of a soft material, a sponge, and a member that is crushed at atmospheric pressure during evacuation and closes the mesh of the resin flow media.   Fiber reinforcement characterized by placing a resin flow restraining member at a predetermined position of the resin flow media and impregnating the fiber laminate with resin while suppressing the flow of the resin flow front where the resin flow is fast on the resin flow media side Manufacturing method of resin structure.   Resin flow control member placed at a predetermined position of the resin flow media that increases the resin flow rate suppresses the flow on the flow front where the resin supplied from the main resin supply unit is fast on the resin flow media side. A method for producing a fiber-reinforced resin structure, wherein after the resin flow from the resin is suppressed, the resin is continuously supplied from the sub-resin supply unit and the fiber laminate is uniformly impregnated with the resin. In claim 4 or 5,
The method for producing a fiber-reinforced resin structure, wherein the resin suppressing member is any one of a soft material, a sponge, or a member that is crushed at atmospheric pressure and closes the mesh of the resin flow media when evacuated. In any one of Claims 4 thru | or 6,
A method for producing a fiber reinforced resin structure, wherein the fiber reinforced structure is a large structure.

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