JP2010221502A - Method for manufacturing frp-coated structure and frp-coated structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an FRP-coated structure which prevents the impregnation of the inside of a core formed of an expanded resin material with a liquid resin when the liquid resin is injected into a reinforcing fiber base material and is excellent in lightweight properties. <P>SOLUTION: The core 2 having a high density skin layer and a low density internal layer is manufactured by mold molding which molds the expanded resin material by expanding a reactive composition in a mold. The core 2 is coated with the reinforcing fiber base material, and the liquid resin is injected into the reinforcing fiber base material and heated and cured to form an FRP membrane 4. When the liquid resin is injected into the reinforcing fiber base material, the impregnation of the low density internal layer with the liquid resin is prevented by the high density skin layer. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for manufacturing an FRP coating structure and an FRP coating structure suitably used for aircraft parts, automobile parts, and the like.

  FRP (fiber reinforced plastic) is a lightweight, high-rigidity, high-strength material that has attracted attention as a substitute for metal materials and is widely used in aircraft, automobiles, ships, golf clubs, and the like.

  For example, when forming on a relatively large member such as a body frame of an automobile, as shown in FIG. 3, the FRP coating structure 100 in which the lightweight core 101 is coated with the FRP film 102 is used. However, the FRP coating structure 100 is obtained which is light and has the necessary strength and rigidity.

  For the core 101, a honeycomb material made of a metal material such as an aluminum alloy or a plastic resin foam is used. In particular, the resin foam is lightweight, excellent in corrosion resistance, and easily processed into various shapes. Therefore, it is preferably used.

  Conventionally, the FRP coating 102 is produced by preparing an intermediate in which a reinforced fiber base material is impregnated with a liquid resin, which is an uncured matrix resin, a so-called prepreg, and laminating the prepreg on the core 101, followed by heat curing. The method of making it widely used. However, prepregs require a large amount of labor, thermal energy, and capital investment required for production, and are difficult to manage due to complicated management and storage.

  On the other hand, liquid resin injection molding methods such as the RTM method have been developed, in which a thermosetting or thermoplastic liquid resin is injected into a reinforcing fiber base and thermoformed. However, in the case of the liquid resin injection molding method, if the injection pressure of the liquid resin is high, the liquid resin penetrates not only into the reinforcing fiber base material but also into the cells of the core 101, and the weight of the FRP coating structure 100 increases. In addition, there is a problem that the injection amount of the liquid resin is increased and the cost is increased.

  For such a problem, a method of preventing the liquid resin from being impregnated with a liquid resin by adhering an impervious shielding film to the core, interposing between the core and the FRP coating, and integrally molding the core (FRP coating). (See Patent Document 1).

JP 2006-175867 A

  However, as shown in Patent Document 1, in the case of a method in which an impermeable shielding film is adhered to a core and interposed between the core and the FRP coating, a process of adhering and interposing the shielding film is necessary. There is a possibility that the number of processes increases, the productivity is low, and the cost is increased.

  In addition, the shielding film has a problem that wrinkles are generated when it is bonded to the core and covers its surface, the outer shape of the FRP coating is deformed, and it is difficult to make the dimensional shape of the FRP coating structure uniform. is there.

  The present invention has been made in view of the above points, and the object of the present invention is to prevent a liquid resin from entering the core and to manufacture an FRP-coated structure excellent in lightness and a method for manufacturing the same. It is an object of the present invention to provide an FRP-covered structure manufactured by the above method.

  In the method for producing an FRP-coated structure of the present invention that solves the above-mentioned problems, a high-density skin layer and a low-density inner layer are formed by mold molding in which a reactive composition is foamed in a mold to mold a resin foam. To produce a core having

  Then, the core is covered with a reinforcing fiber base material, and a liquid resin is injected into the reinforcing fiber base material and cured by heating to form an FRP film. Therefore, the high density skin layer can prevent the liquid resin from being impregnated in the low density inner layer.

  Therefore, as compared with the prior art, the step of adhering the shielding film to the core and interposing between the core and the FRP film can be omitted, so that the productivity can be improved and the manufacturing cost can be reduced. And the deformation | transformation of the external shape resulting from the wrinkle of the conventional shielding film can also be prevented, and the dimensional accuracy of a FRP coating | coated structure can be improved.

  Moreover, in this invention, you may apply | coat the coating material which blocks | prevents passage of liquid resin to a resin foam. According to this, the coating film of the coating which prevents passage of liquid resin can be formed in the surface of a resin foam, and it can prevent reliably impregnating liquid resin with a low-density inner layer. .

  Further, in the present invention, after removing the resin foam from the mold, the resin foam is deburred, and a coating that prevents passage of the liquid resin is applied to the deburred portion of the resin foam. Also good. According to this, when a high-density skin layer is destroyed by deburring, it is possible to prevent the liquid resin from being impregnated into the low-density inner layer through such a portion.

  In the method for producing an FRP-coated structure according to the present invention, a coating material that prevents passage of a liquid resin is applied in advance to the molding surface of the mold, and then the reactive composition is foamed in the mold to mold the resin foam. In-core coating is performed to produce a core having a high-density skin layer and a low-density inner layer, and the outer surface of the skin layer is covered with a paint film.

  Then, the core is covered with a reinforcing fiber base material, and a liquid resin is injected into the reinforcing fiber base material and cured by heating to form an FRP film. Therefore, the liquid resin can be prevented from being impregnated in the low-density inner layer by the high-density skin layer and the coating film covering the outer surface of the skin layer.

  In particular, by performing in-mold coating, a so-called open cell is formed which prevents cell roughness peculiar to molding and communicates between a low-density inner layer and the outside through a high-density skin layer. And impregnation of the liquid resin into the inner layer can be effectively prevented.

  Moreover, the process of interposing a shielding film between the conventional core and the FRP film can be omitted, so that productivity can be improved and manufacturing cost can be reduced. And the deformation | transformation of the external shape resulting from the wrinkle of the conventional shielding film can also be prevented, and the dimensional accuracy of a FRP coating | coated structure can be improved.

Then, the foaming conditions of the reactive composition are set so that the compressive strength of the core is 0.1 MPa to 2.0 MPa, and the density of the inner layer of the core is 0.05 g / cm ³ to 0.5 g / cm. It is preferable to set the foaming conditions of the reactive composition to be ³ .

  The reactive composition preferably contains at least polyols, aromatic polyisocyanates, and auxiliaries, and the resin foam is preferably a hard urethane formed by reacting the reactive composition.

  According to the present invention, it is possible to prevent the liquid resin from being impregnated in the low-density inner layer when manufacturing the FRP-coated structure. Accordingly, it is possible to prevent an increase in weight due to the penetration of the liquid resin into the core and an increase in the injection amount of the liquid resin. Moreover, the process of interposing a shielding film between the conventional core and the FRP film can be omitted, so that productivity can be improved and manufacturing cost can be reduced. And the deformation | transformation of the external shape resulting from the wrinkle of the conventional shielding film can also be prevented, and the dimensional accuracy of a FRP coating | coated structure can be improved.

Sectional drawing explaining the structure of a FRP coating | coated structure. The figure which expanded the A section of FIG. Sectional drawing which shows a prior art.

  In the production method of the present invention, the reactive composition is foamed in a mold to form a resin foam, and a core having a high-density skin layer and a low-density inner layer is produced. Covering with a material, injecting a liquid resin into the reinforcing fiber base material, and heat-curing to form an FRP film.

  When the reactive composition is foamed in the mold, a resin foam having a high-density skin layer and a low-density inner layer can be formed. Therefore, in order to produce an FRP coated structure with this resin foam as the core, for example, when liquid resin is injected into the reinforcing fiber base by the RTM method or VARTM method, the infiltration of the liquid resin is blocked by the high-density skin layer. In addition, the liquid resin can be prevented from being impregnated in the low-density inner layer. Therefore, an increase in weight due to the impregnation of the liquid resin into the core can be prevented, and an increase in the material cost can be suppressed by setting the injection amount of the liquid resin to an appropriate amount.

  And since the process which adhere | attaches a shielding film on a core and interposes between a core and a FRP film | membrane can be abbreviate | omitted compared with the past, productivity can be improved and manufacturing cost can be reduced. And the deformation | transformation of the external shape resulting from the wrinkle of the conventional shielding film can also be prevented, and the dimensional accuracy of a FRP coating | coated structure can be improved.

  The reactive composition includes at least a polyol, an aromatic polyisocyanate, and an auxiliary agent, and the resin foam is made of a hard urethane obtained by reacting and foaming the reactive composition in a mold. The auxiliary agent includes a catalyst, a foam stabilizer, water as a foaming agent, and the like.

(Polyols)
The polyether polyol is obtained by adding an alkylene oxide to a polyhydric alcohol, saccharide, phenol, phenol derivative, aromatic amine, etc., for example, glycerin, propylene glycol, dipropylene glycol, ethylene glycol, diethylene glycol, It is obtained by adding alkylene oxide to one or more of trimethylolpropane, pentaerythritol, sucrose, sorbitol, novolak, nonylphenol, bisphenol A, bisphenol F, trelindiamine, diphenylmethanediamine and the like.

(Isocyanates)
A compound having a plurality of isocyanate groups, specifically, tolylene diisocyanate (TDI), 4,4-diphenylmethane diisocyanate (MDI), 1,5-naphthalene diisocyanate (NDI), triphenylmethane triisocyanate, xylene diisocyanate Aromatic polyisocyanates such as (XDI), alicyclic polyisocyanates such as isophorone diisocyanate (IPDI) and dicyclohexylmethane diisocyanate, aliphatic polyisocyanates such as hexamethylene diisocyanate (HDI), or reaction of these with polyols Free isocyanate prepolymers, modified polyisocyanates such as carbodiimide-modified polyisocyanates, and mixed polyisocyanates of these It is needed. Of these, tolylene diisocyanate and derivatives thereof, and 4,4-diphenylmethane diisocyanate and derivatives thereof are preferable, and these can also be mixed and used.

(catalyst)
A well-known nurating catalyst can be used. For example, potassium acetate, potassium octylate, carboxylic acid metal salts such as lead naphthenate and lead octylate, alcoholate compounds such as sodium ethoxide, phenolate compounds such as potassium phenoxide, metal complex compounds such as acetylacetone metal salt, 1, Triazines such as 3,5-tris (dimethylaminopropyl) hexahydro-S-triazine, quaternary ammonium compounds such as tertiary amine carboxylates, aziridines such as 2-ethylaziridine and 2,4,6-tris Examples thereof include amine compounds such as aminomethylphenol, 1,5-diaza-bicyclo [4.3.0] nonene-5, 1,8-diazabicyclo [5.4.0] -undecene-7. An amine catalyst can be used in combination, and examples thereof include triethylamine, triethylenediamine, tetramethylethylenediamine, pentamethyldiethylenetriamine, dimethylmethylenediamine, and dimethylaminoethanol.

(Foam stabilizer)
Linear or branched polyether-siloxane copolymers can be used, and examples include polyoxyalkylene copolymers such as polyoxyalkylene alkyl ethers.

  Reinforcing fiber base materials are woven fabrics, nonwoven fabrics, knitted fabrics made of carbon fiber or glass fibers, or sheets with reinforcing fibers oriented in parallel and laminated together so that the orientation directions are different from each other. A multi-axis stitch base material or the like is used.

  As the liquid resin, a general thermosetting resin as a matrix resin such as an epoxy resin, an unsaturated polyester resin, a vinyl ester resin, or a phenol resin is used. Moreover, you may use a thermoplastic resin instead of a thermosetting resin.

  And in this invention, you may apply | coat the coating material which blocks | prevents passage of liquid resin to a resin foam. Thereby, the coating film of the coating which blocks | prevents passage of liquid resin can be formed in the surface of a resin foam, and it can prevent reliably impregnating liquid resin with a low-density internal layer.

  For example, polyurethane resin or epoxy resin is used as the paint, and the resin foam is applied by a spray method in which the paint is sprayed or a dipping method in which the resin foam is immersed in the paint stored in the paint bath. Done.

  Further, in the present invention, after removing the resin foam from the mold, the resin foam is deburred, and a coating that prevents passage of the liquid resin is applied to the deburred portion of the resin foam. Also good. When the resin foam is molded, burrs may be formed in the resin foam along the split mold joints. And when removing this burr | flash, there exists a possibility of destroying a high-density skin layer, and there exists a concern that a liquid resin may impregnate a low-density internal layer through this site | part.

  Therefore, a paint is applied as a repair material to the deburred portion of the resin foam to form a coating film. Thereby, the part destroyed by the deburring can be repaired by filling with the paint, and the liquid resin can be prevented from entering the low-density inner layer through the part.

  Further, in the present invention, a coating for preventing the passage of the liquid resin is applied in advance to the molding surface of the mold, and then an in-mold coating is performed in which the reactive composition is foamed in the mold to mold the resin foam. A core having a high-density skin layer and a low-density inner layer, the outer surface of the skin layer being covered with a paint film, and coating the core with a reinforcing fiber base, It is good also as forming a FRP film | membrane by inject | pouring liquid resin into this and making it heat-harden.

  According to this, a skin layer and a coating film can be formed by simultaneous treatment, a high-functional core can be obtained with a smaller number of steps, and a high-density skin layer and a coating covering the outer surface of the skin layer can be obtained. Both of the membranes can prevent the liquid resin from being impregnated in the low density inner layer.

  Also, the in-mold coating prevents the cell roughness peculiar to molding, and the so-called open cell that penetrates the high-density skin layer and communicates between the low-density inner layer and the outside is formed on the outer surface of the resin foam. It can be prevented from being formed, and impregnation of the liquid resin into the inner layer can be effectively prevented. Further, by performing in-mold coating, the joint of the mold can be filled with a paint, and the amount of burrs generated in the resin foam can be reduced.

  Therefore, according to the method for producing an FRP-covered structure of the present invention, it is possible to prevent the liquid resin from entering the core and obtain an FRP-covered structure excellent in lightness.

[Example]
Examples of the present invention will be described below.
FIG. 1 is a cross-sectional view illustrating the configuration of the FRP-covered structure 1, and FIG. 2 is an enlarged view of part A in FIG. An FRP covering structure 1 manufactured by the manufacturing method of the present invention is a relatively large member such as a body frame of an automobile, for example. As shown in FIG. 1, a core 2 made of a resin foam has an FRP coating 4. It has a structure coated with.

  The core 2 is made of a hard urethane resin foam obtained by foaming a reactive composition in a mold, and has a high-density skin layer 12 and a low-density inner layer 11 as shown in FIG. The high density skin layer 12 covers the outside so as to isolate the low density inner layer 11 from the outside. And the outer surface of the core 2 is covered with the coating film 3 of the paint which prevents passage of liquid resin.

  The FRP film 4 is composed of a reinforcing fiber base material and a matrix resin, and is formed by impregnating the reinforcing fiber base material with a liquid matrix resin and curing by heating. The matrix resin is injected into the reinforcing fiber base material in the liquid state by the RTM method.

  Table 1 shows details of the materials used in the manufacture of the FRP coated structure 1.

  In order to manufacture the FRP coating structure 1 having the above-described configuration, first, a release material 23 is applied to a molding surface of a mold (not shown) heated in advance from 45 ° C. to 50 ° C., and then a paint for in-mold coating 24 is applied. Then, after clamping, 100 parts of the raw material 21 and 240 parts of the raw material 22 are injected into the mold using a dedicated injection machine, and reacted as a reactive composition in the mold to cause foaming. The mold is heated by a heating means and the temperature is maintained at 45 ° C. to 50 ° C., and is set so that the reaction of the reactive composition is suitably performed.

  Then, after a predetermined curing time has elapsed, the mold is opened, the resin foam is removed from the mold, and the resin foam is deburred. And the repair material 25 is apply | coated to the site | part deburred and the coating film 3 is repaired. By the above operation, the core 2 having the high-density skin layer 12 and the low-density inner layer 11 and having the outer surface of the skin layer 12 covered with the coating film 3 of the paint 24 is manufactured.

  Next, the core 2 is covered with a reinforcing fiber substrate. The reinforcing fiber base material is formed by weaving carbon fibers, which are reinforcing fibers, and is wound around the core 2 by a brader machine (not shown) to cover the entire outer peripheral surface of the core 2.

  And liquid resin is inject | poured into a reinforced fiber base material, and it heat-hardens it. Here, the core 2 and the reinforcing fiber base material are housed in a cavity of a molding die in a state where the reinforcing fiber base material is wound around the outer peripheral surface of the core 2, and are clamped, and are liquid resin in the cavity. Epoxy resin is injected and impregnated into the reinforcing fiber substrate. Then, it is cured by heating in a mold with a heater. Thereby, the FRP film 4 is formed and the FRP coating structure 1 is obtained.

  As the liquid resin, a two-component mixed epoxy resin was used. And as a result of evaluating the resin impregnation property with respect to the core 2, the impregnation to the core 2 was not recognized and the result that the impregnation was prevented appropriately was obtained.

The strength of the core 2 is improved by covering the outer surface with the coating film 3. Therefore, the density of the inner layer 11 can be reduced as compared with the case where the coating layer 3 is not used. In this embodiment, inner layer 11 is set from 0.05 g / cm ³ to have a density of 0.5 g / cm ^3. The core 2 has a compressive strength of 0.1 MPa to 2.0 MPa.

  As mentioned above, although the Example of this invention was explained in full detail using the figure, this invention is not limited to the content of the above-mentioned Example, Even if there is a design change etc. in the range which does not deviate from the summary of this invention. These are included in the present invention.

DESCRIPTION OF SYMBOLS 1 FRP coating structure 2 Core 3 Coating film 4 FRP coating 11 Inner layer 12 Skin layer

Claims (8)

In a method for producing an FRP-coated structure in which a core made of a resin foam is coated with an FRP film,
Forming the resin foam by foaming a reactive composition in a mold, and manufacturing the core having a high-density skin layer and a low-density inner layer;
Coating the core with a reinforcing fiber substrate, injecting a liquid resin into the reinforcing fiber substrate and heat-curing to form the FRP film;
The manufacturing method of the FRP coating structure characterized by including this. In the core manufacturing process,
The method for producing an FRP-coated structure according to claim 1, further comprising a step of applying a coating material that prevents the liquid resin from passing through the resin foam. In the core manufacturing process,
3. The method according to claim 2, further comprising: deburring the resin foam after removing the resin foam from the mold and applying the paint to a deburred portion of the resin foam. The manufacturing method of the FRP coating | coated structure body of description. In a method for producing an FRP-coated structure in which a core made of a resin foam is coated with an FRP film,
Applying a paint that prevents the passage of liquid resin on the molding surface of the mold;
The resin foam is formed by foaming a reactive composition in the mold, and has a high-density skin layer and a low-density inner layer, and the outer surface of the skin layer is covered with the coating film of the paint. Manufacturing the core;
Coating the core with a reinforcing fiber substrate, injecting a liquid resin into the reinforcing fiber substrate and heat-curing to form the FRP film;
The manufacturing method of the FRP coating structure characterized by including this.   The method for producing an FRP-coated structure according to claim 4, wherein the foaming conditions of the reactive composition are set so that the compressive strength of the core is 0.1 MPa to 2.0 MPa. 5. The FRP according to claim 4, wherein the foaming conditions of the reactive composition are set so that the density of the inner layer of the core is 0.05 g / cm ³ to 0.5 g / cm ^3. A manufacturing method of a covering structure. The reactive composition includes at least polyols, aromatic polyisocyanates, and auxiliary agents,
The said resin foam is a hard urethane formed by making the said reactive composition react, The manufacturing method of the FRP coating | coated structure as described in any one of Claims 1-6 characterized by the above-mentioned.   An FRP coating structure manufactured by the method for manufacturing an FRP coating structure according to any one of claims 1 to 7.

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