JP2010221551A - Fiber-reinforced resin material and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a fiber-reinforced resin material which causes less or no disorder of the mesh of a cross material serving as a designed surface material for the front layer even when there are protrusions, recessed grooves, etc. in the wall surface of a cavity of a mold and a fiber-reinforced resin material having high designability. <P>SOLUTION: The manufacturing method of manufacturing a fiber-reinforced resin material comprises a first process of preparing, in a mold, a laminate 20 consisting of a fiber bundle layer unit 10 composed of two or more planar fiber bundle layers of different orientations laminated and intermediate layers 2 intervening between the fiber bundle layers and made of a second resin having an elastic modulus higher than that of a first resin injected and a surface layer 3 arranged on one side of the fiber bundle layer unit 10 and imparting designability and the second process of injecting the first resin into the mold to carry out impregnation hardening of the first resin on the surface layer 3 so as to form a front-surface fiber substrate 3A and to carry out impregnation hardening of the first resin in the fiber bundle layers so as to form reinforcing fiber base materials 11A, 12A, 13A and 14A. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a fiber reinforced resin material reinforced with a fiber material such as carbon fiber and a method for producing the same.

  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 FRP described above is formed by laminating a plurality of fiber bundles arranged in a planar shape while changing the orientation direction thereof, and a face material is formed by impregnating the resin in this posture.

  By the way, in the above FRP, those using carbon fibers as reinforcing fibers are generally known as CFRP (carbon fiber reinforced plastic). The CFRP member is a member in which a bundle of carbon fibers forms the same orientation posture to form a planar member, and other planar members having different fiber orientations are laminated to each other, and both are stitched. It is a member made of a multiaxial base material that is formed by impregnating and curing a matrix resin to form an integrally molded member. Note that the cardinal number of the planar members to be stacked varies depending on the desired rigidity and the like. For example, there is a base member made of a five-axis base material in which five planar members are stacked.

  By the way, at present, in the automobile industry, hybrid cars and electric cars are attracting attention as vehicles that are friendly to environmental impacts, etc., and development aimed at further miniaturization, weight reduction, and higher performance has been developed by automobile manufacturers and automobiles. It is being promoted every day by related manufacturers. Looking at these vehicles and other vehicles in general, CFRP (glass fiber) that uses the above-mentioned CFRP or carbon fiber as a reinforcing fiber as a member that satisfies both weight reduction and high rigidity of the vehicle. There is a growing need to apply reinforced plastics) to some or all of vehicle body panels.

  For example, when an embodiment of a method for producing CFRP is outlined, a first face material composed of a first fiber bundle group in which a plurality of carbon fiber bundles obtained by bundling carbon fibers are arranged in a posture having the same orientation. Is formed, and a second face material composed of a second fiber bundle group oriented in a different direction from the first fiber bundle group is formed. If necessary, a third face material, a fourth face material, Face materials are similarly formed, and these face materials are laminated in a mold, a matrix resin is injected, and pressure molding is performed to produce a CFRP member (fiber reinforced resin material). For example, Patent Document 1 discloses a method of manufacturing a fiber reinforced resin by applying an RTM molding method which is a kind of injection molding.

  When the fiber reinforced resin material including the CFRP member is applied to the vehicle body, in practice, a high-design surface material is generally disposed on both sides or one side of the fiber reinforced resin material. is there. For example, a cloth material made of carbon fiber or glass fiber is used, and a surface layer fiber material is formed by impregnating and curing a matrix resin in a cloth material in which these fibers are warp knitted or weft knitted. Appears to have an appearance design.

JP 2007-269015 A

  In actual in-mold molding, there are not a few deformed parts on the cavity wall surface of the mold (mold), for example, protrusions projecting from the cavity wall surface into the cavity, and concavities or grooves recessed in the cavity wall surface. Is present. For example, when there are protrusions on the lower surface of the cavity, a stack of fiber bundle groups before matrix resin injection is placed on the lower surface of the cavity, and a cloth material for design face material is stacked on the top layer In the molding in which the mold is closed and the matrix resin is injected, the fiber bundles constituting the laminate are meandered in the lamination direction by the protrusions on the lower surface, and the injected matrix resin is also laminated in the same manner so as to follow this. The fiber bundle group is impregnated while meandering in the direction. As a result, crossing of the cloth material of the surface layer occurs, and the problem that the appearance design, which is its original function and effect, is often lost, is an urgent solution in the technical field. ing.

  The present invention has been made in view of the above-described problems, and at least forms a design face material for the surface layer even when there is a shape deformation portion such as a protrusion or a groove on the cavity wall surface of the mold. A method of manufacturing a fiber-reinforced resin material that does not cause or hardly causes a cross-over of the cloth material, and a fiber-reinforced resin material that does not have a cross-over and has high design properties. The purpose is to provide.

  In order to achieve the above object, a method for producing a fiber reinforced resin material according to the present invention includes a first fiber bundle layer in which a plurality of fiber bundles obtained by bundling fibers are arranged in a posture having the same orientation and exhibit a planar shape, A plurality of fiber bundles oriented in different directions from the first fiber bundle layer are arranged in a posture having the same orientation, and at least a second fiber bundle layer having a planar shape is laminated, and further in the fiber bundle layer A fiber bundle layer unit having an intermediate layer formed of a second resin having a higher elastic modulus than the injected first resin, and disposed on one side of the fiber bundle layer unit. A first step in which a laminate comprising a surface layer for imparting designability is prepared in a mold, and the first resin is injected into the mold to inject the first resin into the surface layer. The resin is impregnated and cured to form a surface fiber base material, and the first resin is contained in the fiber bundle layer. Cured are formed reinforcing fiber base material is made of a second step of producing a fiber reinforced resin material from.

  In the production method of the present invention, the fiber bundle layer constituting the fiber bundle layer unit formed in the first step includes two or more layers, for example, a layered structure of four layers and five layers. There may be a fiber bundle layer in which the orientation of the fiber bundles is the same orientation (for example, a five-layer laminated structure in which the second layer and the fourth layer have the same orientation). A form having a fiber bundle layer). In any case, an intermediate layer formed of a second resin having a higher elastic modulus than the first resin injected and injected into the fiber bundle layer is interposed between the planar fiber bundle layers. Thus, a fiber bundle layer unit is formed, and a surface layer that imparts design properties is disposed on one side of the fiber bundle layer unit to form a laminate.

  Here, examples of the fiber include carbon fiber and glass fiber, and the surface layer can include a form made of a carbon fiber or glass fiber cloth material. The cloth material has, for example, a structure in which the glass fiber or the carbon fiber is warp knitted or a weft knitted structure, and forms a cross stitch that imparts a desired design.

  In the second step, the laminate is transferred into a cavity of a mold such as a mold, or the laminate constituent members are sequentially laminated in the cavity to form a laminate, and the matrix resin is formed. A fiber reinforced resin material is produced by impregnating a laminate constituting member (more strictly, a laminate constituting member other than the intermediate layer) with 1 resin, and press molding a mold. In addition, as a method of injecting and molding the resin, a general injection molding method (a method in which a movable mold is not moved and pressurized, but a molten resin is high-pressure filled in a completely closed cavity) In addition, an injection compression method (a method in which an extra space is provided in a cavity and a movable mold is moved after filling with a molten resin to perform pressure molding), an RTM method, and the like are included.

  Further, as the first resin to be the matrix resin, any resin material including a thermosetting resin such as an epoxy resin, a vinyl ester resin, and an unsaturated polyester resin can be used.

  Further, as the second resin having a higher elastic modulus than the first resin, in addition to a material having a higher elastic modulus after curing than the first resin, a desired filler is added to the resin material of the same material as the first resin. By mixing talc or talc, it is possible to apply a material having an increased elastic modulus after curing. Examples of the filler and talc include silica, alumina, boron nitride, silicon nitride, silicon carbide, and magnesium oxide.

  Due to the intermediate layer having a relatively high elastic modulus inside the laminate, for example, the planar fiber bundle layer below it is displaced at the shape deformation part such as the protrusion on the cavity wall surface, resulting from this. Even if the injected first resin is impregnated while meandering in the planar fiber bundle layer, the pressure caused by the meandering flow of the impregnating first resin flow is effectively reduced in the intermediate layer. It is possible to prevent the pressure due to the meandering flow from acting on the planar fiber bundle layer above the intermediate layer and the surface layer above the intermediate layer. That is, the intermediate layer having a relatively high elasticity is not easily deformed even when subjected to this pressure, or is not easily deformed. The surface layer positioned above the intermediate layer has this meandering. The pressure due to the flow can be prevented from acting. Further, when the shape deformed portion is a concave groove, the impregnating resin now flows in a meandering direction away from the intermediate layer in the planar fiber bundle layer below the intermediate layer, and pressure is applied. Instead, a deformation that causes the planar fiber bundle layer to collapse due to the meandering flow may be caused. Even in this case, since the highly elastic intermediate layer itself does not easily cause such deformation, the risk of cross-over due to the depression of the surface layer above the intermediate layer is still avoided. It is.

  Since the influence of the meandering flow of the first resin due to the deformed portion of the cavity wall surface does not act on at least the surface layer, the crossing of the cloth material forming the surface layer is suppressed, and high design characteristics It is possible to produce a surface layer fiber base material rich in, and thus a fiber reinforced resin material.

  Further, the fiber reinforced resin material according to the present invention includes a reinforced fiber base material in which a plurality of fiber bundles obtained by bundling fibers are arranged in a posture having the same orientation and integrated with a first resin, and the first resin A plurality of fiber bundles oriented in a different direction from the fiber bundle layer are arranged in a posture having the same orientation, and a separate reinforcing fiber substrate integrated with the first resin, and a reinforcing fiber substrate and a separate reinforcement An intermediate layer made of a second resin having a higher elastic modulus than that of the first resin and a cloth material of carbon fiber or glass fiber are integrated with the first resin so as to be interposed between the fiber base materials. And a surface fiber base material that imparts designability.

  Here, the fiber is made of either one of carbon fiber or glass fiber, and therefore the reinforcing fiber substrate is made of either one of CFRP (carbon fiber reinforced plastic) or GFRP (glass fiber reinforced plastic). It is.

  Similar to the manufacturing method described above, the fiber-reinforced resin material of the present invention is provided between the laminated reinforcing fiber base materials than the first resin (cured body thereof) which is a matrix resin of the reinforcing fiber base materials. By interposing the intermediate layer made of the second resin having a high elastic modulus, the influence caused by the meandering flow of the first resin caused by the shape deformed portion of the cavity wall surface at the time of molding does not act on at least the surface layer. The crossing of the cloth material forming the surface layer is suppressed, and a fiber-reinforced resin material having a high design property is obtained.

  Since the fiber reinforced resin material of the present invention is a laminate of base materials made of fiber reinforced plastic in addition to this high design property, the fiber reinforced resin material is lightweight and has high rigidity and excellent quality. Become a material.

  As can be understood from the above description, according to the fiber reinforced resin material and the manufacturing method thereof of the present invention, an intermediate layer made of a resin having higher elasticity than the matrix resin forming the substrate is formed in the laminated substrate. By interposing, the matrix resin causes a meandering flow due to the shape deformation part of the cavity wall surface during molding, and even if the influence of this meandering flow acts on the intermediate layer, this intermediate layer is deformed by its high elasticity. The surface layer surface is not given any action because it is not or hardly deformed. As a result, it is possible to suppress the crossing of the cross material of the cloth material forming the surface layer, which is highly designable. A fiber-reinforced resin material can be provided.

It is the schematic diagram explaining one Embodiment of the condition where resin is inject | poured in a shaping | molding die and the laminated body is impregnated. It is the perspective view which showed the fiber reinforced resin material of this invention. It is the schematic diagram explaining other embodiment of the condition where resin is inject | poured in a shaping | molding die and the laminated body is impregnated.

  Embodiments of the present invention will be described below with reference to the drawings. The illustrated example is a fiber in which a four-layer reinforcing fiber base material, an intermediate layer (interlayer between the third and fourth base materials from the bottom), and a surface fiber base material are integrally formed. Although the reinforced resin material is shown, the base number of the reinforcing fiber base is not limited to this, and further, the interposition position of the intermediate layer is of course not limited to the illustrated example. .

  FIG. 1 is a schematic diagram illustrating an embodiment in which a resin is injected into a mold and the laminate is impregnated, and FIG. 2 is a fiber molded by injection molding shown in FIG. The reinforced resin material is shown.

First, with reference to FIG. 1, the manufacturing method of the fiber reinforced resin material of this invention is outlined.
A molding die (mold) consisting of a fixed die S1 and a movable die S2 is prepared, and the laminate 20 is transferred into the cavity C, or its constituent members are placed in the cavity C in order.

  The laminated body 20 includes a fiber bundle layer unit 10 placed directly on the lower surface of the cavity C, and a surface layer 3 placed thereon.

  In the fiber bundle layer unit 10, four planar fiber bundle layers 14, 13, 12, and 11 are laminated in order from the lower surface side of the cavity C, and each planar fiber bundle layer is formed by bundling carbon fibers. A plurality of fiber bundles are arranged in a posture with the same orientation to form a planar shape, and at least the upper and lower fiber bundle layers and fiber bundle layers adjacent to each other in the lamination posture are oriented in different directions. .

  The intermediate layer 2 is interposed between the planar fiber bundle layers 11 and 12. The intermediate layer 2 also has, for example, a fiber bundle oriented in a desired direction, and is a prepreg in which a resin (second resin) is impregnated and cured in advance prior to injection molding.

  The surface layer 3 is made of a cloth material obtained by warp knitting or weft knitting glass fiber or carbon fiber, and forms a cross stitch that imparts a desired design property.

  The laminated body 20 including the fiber bundle layer unit 10 and the surface layer 3 is accommodated in the cavity C, and after closing the mold, an epoxy resin (first resin) as a matrix resin is injected through the injection hole S2a formed in the movable mold S2. Resin) is injected (X direction).

  Here, the resin (second resin) forming the intermediate layer 2 has a higher elastic modulus when cured than the first resin. As such a high elastic modulus resin, a material containing a filler such as silica, alumina, boron nitride, silicon nitride, silicon carbide, magnesium oxide in the epoxy resin as the first resin can be applied.

  In FIG. 1, a protrusion T, which is a shape deforming portion, protrudes toward the cavity inner side on the lower surface of the cavity C.

  When the stacked body 20 is placed on the protrusion T, the shape of the stacked body 20 is deformed due to the protrusion T.

  For example, when the matrix resin is injected at high pressure into the deformed laminate 20 and impregnated inside each of the planar fiber bundle layers 14, 13, 12, 11, the matrix is formed in the region deformed upward by the protrusion T. The resin is also impregnated while meandering such that it flows upward and then downwards (X1 direction).

During the meandering impregnation, a pressure P from below to above acts on the intermediate layer 2.
If the intermediate layer 2 does not exist, the pressure P acts on the planar fiber bundle layer 11 and the surface layer 3 thereabove, which may cause crossing of the cloth material forming the surface layer 3. High nature.

  However, since the intermediate layer 2 having a relatively high elasticity with respect to the matrix resin (cured body thereof) is present, the intermediate layer 2 is not deformed or hardly deformed even when subjected to the pressure P from below. As a result, the surface layer 3 is not affected in such a way as to cause crossing.

  For the rigidity (or deformability) of the intermediate layer 2, the pressure P that can be generated in the cavity C is specified in advance based on experiments, empirical rules, etc., and is not deformed with respect to the assumed pressure P, or the surface It is necessary to set the rigidity to allow the deformation to the extent that does not impair the appearance design of the layer 3.

  The injected matrix resin is cured and the mold is opened to produce a fiber reinforced resin material 30 as shown in FIG.

  The fiber reinforced resin material 30 shown in the figure has a desired cross stitch, and the surface layer fiber base material 3A, the reinforcing fiber base materials 11A, 12A, 13A, and 14A and the intermediate layer 2 are laminated and integrated. Fiber reinforced resin material.

  FIG. 3 is a schematic diagram illustrating another embodiment in which a resin is injected into a mold and the laminated body is impregnated.

  In this embodiment, a groove M is present as a shape deforming portion on the lower surface of the cavity C.

  In this case, when the laminated body 20 is placed on the groove M, the sheet fiber bundle layers 14, 13, and 12 below the intermediate layer 2 correspond to the groove M by being dragged into the groove M. The area to be deformed downward.

  When the matrix resin is injected into the cavity C in this posture, the injected matrix resin is impregnated while meandering such that it flows downward as shown and then flows upward (direction X2).

  If the intermediate layer 2 is not present, the planar fiber bundle layer 11 and the surface layer 3 are similarly deformed downward in the region corresponding to the groove M, and the cloth material for forming the surface layer 3 is again formed. There is a high possibility that cross eyes will sag.

  However, since the intermediate layer 2 having a relatively high elasticity with respect to the matrix resin (cured body thereof) exists, the intermediate layer 2 resists downward deformation by its own rigidity. The plane posture can be maintained, and as a result, it is possible to prevent the surface layer 3 from being affected by the crossing eyes.

  In addition, although illustration is abbreviate | omitted, when the groove | channel M as shown in FIG. 3 exists in the wall surface of the cavity C, you may clog SMC (Sheet Molding Compound) in the groove | channel M previously.

  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.

  2 ... intermediate layer, 3 ... surface layer (cloth material), 3A ... surface layer fiber substrate, 10 ... fiber bundle layer unit, 11, 12, 13, 14 ... planar fiber bundle layer, 11A, 12A, 13A, 14A ... Reinforced fiber base material, 20 ... laminate, 30 ... fiber reinforced resin material, C ... cavity, T ... projection, M ... groove

Claims (5)

A plurality of fiber bundles formed by bundling fibers are arranged in a posture having the same orientation, and a first fiber bundle layer having a planar shape and a fiber bundle oriented in a different direction from the first fiber bundle layer have the same orientation. A plurality of second fiber bundle layers that are arranged in a posture and have a planar shape and are laminated at least, and are interposed in the fiber bundle layer and have a higher elastic modulus than the first resin to be injected. A laminate comprising a fiber bundle layer unit having an intermediate layer formed of resin 2 and a surface layer that is arranged on one side of the fiber bundle layer unit and imparts design properties is placed in a mold. A first step to be prepared;
By injecting the first resin into the mold, the surface resin is impregnated and cured to form a surface fiber substrate, and the fiber bundle layer is impregnated with the first resin. A method for producing a fiber-reinforced resin material, comprising: a second step of producing a fiber-reinforced resin material by curing to form a fiber-reinforced base material.   2. The fiber according to claim 1, wherein the fiber is made of any one of carbon fiber and glass fiber, and the reinforcing fiber base is made of any one of CFRP (carbon fiber reinforced plastic) or GFRP (glass fiber reinforced plastic). Manufacturing method of fiber reinforced resin material.   The said surface layer is a manufacturing method of the fiber reinforced resin material of Claim 1 or 2 which consists of a cloth material of carbon fiber or glass fiber. A plurality of fiber bundles formed by bundling fibers arranged in a posture having the same orientation, and a reinforced fiber base material integrated with the first resin,
A plurality of fiber bundles oriented in a different direction from the first fiber bundle layer are arranged in a posture having the same orientation, and a separate reinforcing fiber base material integrated with the first resin,
An intermediate layer made of a second resin having a higher elastic modulus than the first resin, interposed between the reinforcing fiber substrate and a separate reinforcing fiber substrate;
A fiber-reinforced resin material, comprising a carbon fiber or glass fiber cloth material integrated with the first resin and a surface layer fiber base material imparting design properties.   The said fiber consists of any one of carbon fiber or glass fiber, and the said reinforced fiber base material consists of any one of CFRP (carbon fiber reinforced plastic) or GFRP (glass fiber reinforced plastic). Fiber reinforced resin material.

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