JP2013136193A - Method for manufacturing fiber-reinforced composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a large-sized composite material component of high quality and low cost that can reduce an environmental load while saving energy without requiring the movement of a large-sized die after maintaining the desired product strength of a final composite material in manufacturing a fiber-reinforced composite material.SOLUTION: A method for manufacturing a composite material includes at least a laminating process for laminating a fiber-reinforced base material 2 on a die 3; a bagging process for covering the laminated fiber-reinforced base material 2 with an airtightly sealable sheet 4 and performing evacuation; and a curing process for curing resin impregnated in the fiber-reinforced base material 2 in which at least the laminating process is performed in a clean room 10 having an opening/closing function.

Description

  The present invention relates to a method for producing a fiber-reinforced composite material composed of reinforcing fibers and a matrix resin, and more particularly to a method for minimizing the movement of a mold during the process of producing a fiber-reinforced composite material.

  In recent years, fiber reinforced composite materials composed of reinforced fibers and a matrix resin, which can reduce the weight of components, have been widely used due to increasing interest in global environmental problems. As a method for producing a fiber reinforced composite material, for example, there is a method in which a reinforcing fiber base material is laminated and shaped on a shaping mold having irregularities, a resin is injected, and then heated to produce a molded product (Patent Document) 1). Below, the manufacturing method of a fiber reinforced composite material is demonstrated in order of a process.

  First, in the cutting step of (A) the reinforcing fiber base, the reinforcing fiber base is cut into a desired shape. Thereafter, (B) in the step of laminating the reinforcing fiber base, a predetermined number of the cut reinforcing fiber bases are stacked on the product-shaped mold, and are made to conform to the mold shape. Furthermore, (C) in the bagging process of the reinforcing fiber base material, the base material and the entire mold are covered with a film or the like so that the reinforcing fiber base material firmly follows the shape of the mold, and then vacuumed (bagging) ) Thereafter, in the (D) curing step, a resin is injected into the reinforcing fiber base in a vacuumed state, and further heated to cure the resin, thereby forming a molded product of the fiber reinforced composite material. After curing, in (E) demolding and processing step, the molded product is removed from the mold and processed into a predetermined shape by machining to obtain a product of fiber reinforced composite material.

  In the laminating step, a predetermined number of reinforcing fiber substrates cut to a predetermined size are stacked on a mold. At this time, if the cleanliness of the working environment is low, foreign substances such as dust may be mixed in the middle of the lamination of the reinforcing fiber base. If foreign matter is mixed during the stacking operation, it is impossible to remove the foreign matter in the subsequent process, and the foreign matter remains in the product. If foreign matter is mixed in the product, it may be a starting point for damage or destruction when an external force such as an impact is applied during use of the product. In addition, if the working environment conditions such as the temperature and humidity during cutting, laminating, and bagging process of the reinforcing fiber base are bad, the raw material such as the reinforcing fiber base may be condensed. The surface treatment agent coated on the surface of the fiber base material, resin physical properties, etc. are changed, which adversely affects the strength of the product after molding. In particular, when manufacturing aircraft parts, it is important to control the above working conditions that affect product quality.

  Generally, as described in Patent Document 2, the lamination and bagging process of fiber reinforced composite material is performed in a clean room, and the curing process is performed in a heating facility such as an oven or an autoclave. It is necessary to laminate a reinforcing fiber base material on this mold and heat it. However, in general equipment configurations and molding environments such as conventional stationary clean rooms and heating facilities, the size of clean room openings is limited, so large molds can be carried into and installed in clean rooms. Have difficulty. In addition, it is necessary to carry the mold into the clean room, carry out the reinforcing fiber base material on the mold, and then carry it out of the clean room again with the reinforcing fiber base material laminated, and move to a heating facility. However, in a general installation type clean room where the size of the opening is limited, it is difficult to move a mold with laminated reinforcing fiber bases so that the reinforcing fiber bases are not displaced. there were. Therefore, when installing a clean room large enough to carry in a large mold, a large air conditioning facility capacity is required to maintain the specified cleanliness, temperature, and humidity, resulting in enormous power consumption and environmental impact. There was a problem that the load applied to was increased.

  In the field other than the composite material, there is an example of using a booth for partitioning with the surroundings, for example, during the operation of the reaction kettle, as in Patent Document 3. This is an example of partitioning the work area with a booth so that dust or the like is not mixed into the reaction kettle in a work where a pharmaceutical raw material is charged into the reaction kettle at a pharmaceutical manufacturing site in a narrow environment with many obstacles. However, in this example, the work area is narrow and the dust is only prevented from entering by partitioning it with the surroundings, and there is no function to adjust the work conditions such as temperature and humidity. The necessary work environment could not be provided.

  In addition, as in Patent Document 4, there is an example in which a clean hood for locally increasing the cleanness in a clean room is used. This is to install a hood locally in a clean room where a higher degree of cleanliness is required than the surrounding cleanliness, and raise the atmospheric pressure more than the surroundings to increase the cleanliness locally. . However, this method is a method that requires a stationary clean room, and, like the known document 2, the work area is narrow and the purpose is simply to partition the surroundings. It was not possible to solve the problem.

  As described above, if the atmosphere in the work area necessary for the large mold in any place and its surroundings can be maintained at the desired cleanliness, temperature and humidity without moving the large mold, The technology to meet these requirements was required because it reduces foreign matter contamination due to mold movement and leads to the production of high-quality products.

JP 2010-120167 A JP 2010-533098 A JP 2003-260678 A JP 2000-257932 A

  The object of the present invention is to solve the above-mentioned problems of the prior art and require the movement of a large mold while maintaining the desired product strength of the final composite material when manufacturing a fiber-reinforced composite material. It is another object of the present invention to provide a method for producing a high-quality and low-cost large-sized composite material part that can reduce the environmental burden by energy saving.

(1) Lamination process of laminating a reinforcing fiber base material on a mold, a bagging process of covering the laminated reinforcing fiber base material with an airtightly sealable sheet and drawing a vacuum, and curing the resin impregnated in the reinforcing fiber base material A method for producing a composite material, comprising at least a curing step, wherein at least the laminating step is performed in a clean room having an opening / closing function.
(2) The method for producing a composite material according to (1), wherein the clean room is movable.
(3) The method for producing a composite material according to (1) or (2), wherein the bagging step is performed in the clean room.
(4) The composite according to any one of (1) to (3), wherein the process is performed at a certain place without substantially moving the mold from the stacking process to the bagging process and the curing process. Material manufacturing method.
(5) The method for producing a composite material according to any one of (1) to (4), wherein the mold has a function capable of being heated by an external heating device.
(6) The method for producing a composite material according to any one of (1) to (5), wherein a length of at least one side of the mold is 3 m or more.
(7) The composite material according to any one of (1) to (6), wherein the clean room includes a work room for managing cleanliness and an indoor environment control device, each of which is separable and movable. Manufacturing method.

  According to the present invention, even if it is a molding process of a large member where it is difficult to move the mold, it is not necessary to move the mold while maintaining the desired product strength of the final composite material, and energy saving The load can be reduced and high quality and large composite parts can be manufactured.

It is the schematic which shows the VaRTM shaping | molding flow conventionally implemented. It is the schematic which shows the VaRTM shaping | molding flow based on this invention. It is a schematic diagram which shows the state which installed the movable clean room which concerns on this invention.

  FIG. 1 shows a VaRTM (vacuum assisted resin transfer molding) molding flow of a composite material. The present invention includes a form in which a reinforcing fiber base is impregnated with a resin in advance, such as a prepreg, and the form of the reinforcing fiber base is not limited by the presence or absence of the resin impregnation.

  An embodiment of a method for producing a composite material according to the present invention will be described in the order of steps with reference to FIGS.

(A) Cutting process of reinforcing fiber base The reinforcing fiber base 1 is generally wound into a roll, and is unwound and cut into a desired shape and number. In order to prevent deterioration of the reinforcing fibers, it is desirable to manage the temperature and humidity, and to perform the work in a space where the pressure is higher than the surrounding environment and the degree of cleanliness is controlled to prevent contamination. Is not good. Generally, the cutting work is performed in a clean room 9 installed in this room. However, if the movable clean room 10 is used, the cutting operation is not restricted to the place where the clean room is installed, so cutting is performed at an arbitrary place. It is possible to work.

  In addition, when using an automatic laminating apparatus, since a reinforcement fiber base material is laminated | stacked directly from a roll, this process can be abbreviate | omitted.

(B) Laminating step of reinforcing fiber substrate The reinforcing fiber substrate 2 cut into a desired shape and number is laminated on the mold 3 in a desired order. In this process, it is desirable to control the temperature and humidity in order to prevent deterioration of the reinforcing fibers.

  Also, in this process, if foreign matter enters between the laminated reinforcing fiber base materials, the foreign matter remains in the final molded product, and when external force such as impact is applied to the molded product, this foreign matter is the starting point. Therefore, there is a possibility of causing damage and destruction, and therefore it is necessary to prevent foreign matters from being mixed in at a high level and to control the cleanliness.

  This process is generally performed by installing a clean room 9 and carrying a mold into the room, but if a movable clean room 10 is used, the process is not restricted to the place where the clean room 9 is installed. It is possible to perform a laminating operation at an arbitrary place.

  The clean room 10 has a shape that can be expanded and contracted so that the volume of the room can be changed. For example, it is good also as a structure provided with the sheet | seat for interrupting | blocking outside air and an air-conditioning area supported by the folding frame structure. As in this example, the air conditioning unit that controls the temperature, humidity, and pressurization, and the clean room area and the intermediate room area that can be divided into three parts can be moved, so the mold is installed. Can be transported to the place. Further, in the present embodiment, the clean room area and the intermediate room are movable, open and close, and have a bellows shape that can be expanded and contracted, so that a clean room area and an intermediate room area of a necessary size can be provided. . Further, the air conditioning unit can control the temperature and humidity, and can be pressurized by adjusting the damper of the blower. Thus, there is no limitation on the method of covering the mold, and if an apparatus capable of controlling the air conditioning conditions of the covered space is used, it is possible to perform an operation requiring a clean level at an arbitrary place.

(C) Bagging process of reinforcing fiber base material A process of laminating a reinforcing fiber base material and a mold with a sheet 4 such as a film or rubber after laminating in a desired number and order on a metal mold and vacuum suction is called bagging. . The sheet | seat which covers a metal mold | die and a reinforced fiber base material should just maintain airtightness, for example, a film material, a rubber sheet, etc. can be used. In this state, for example, vacuum suction is performed by the vacuum pump 5 or the like, so that the reinforcing fiber base is firmly aligned with the mold shape. In this process, if the cleanliness of the working environment is low, there is a possibility that foreign matters such as dust may be mixed between the reinforcing fiber base material, the mold and the film covering them. If foreign matter is mixed in this step, irregularities that are not assumed in the design are formed on the surface of the laminate, and there is a concern about the adverse effect on the product shape after molding.

  It is desirable to perform in a clean environment to prevent the deterioration of the reinforcing fibers and to prevent foreign matters from being mixed. If a movable clean room is used, bagging can be performed in any place without being restricted to the place where the clean room is installed. It is.

  In the case of a molding method that requires resin injection, a dry reinforcing fiber base not impregnated with resin is shaped into a mold shape, and then a resin injector 6 is set and the resin is injected. Also in this process, the reinforcing fiber base and the mold itself are covered with a bag material such as a film material and a rubber sheet, and since a vacuum is maintained, there is no possibility of contamination. However, since the container containing the resin to be injected may be mixed with foreign matter, the area around the injected resin container may be a clean room environment. It is especially difficult to install heating equipment in a clean room, and to perform shaping and resin injection work in it, especially when the mold is large, but if you use a movable clean room, it will be necessary place, for example, injection resin It is also possible to keep a clean environment only around the container. In addition, when using the reinforced fiber base material which resin impregnated beforehand, such as a prepreg, the process of injecting resin is unnecessary.

(D) Curing Step Next, the reinforcing fiber base material and the mold in a state of bagging and maintaining a vacuum are heated by the heating device 8 to the curing temperature of the resin. In this step, the reinforcing fiber base material and the resin are covered with a bag material such as a film material or a rubber sheet and kept in a vacuum, so there is no fear of foreign matter mixing, and a clean room environment is not an essential step.

  When working in a conventional stationary type clean room, it is essential to carry the bagged reinforcing fiber substrate and mold to the heating facility. When the bagging process is performed in a conventional clean room, it is difficult to carry out the mold carry-out work from the limited opening to carry out a large and heavy mold. In particular, in the case of molding methods that require resin injection, the reinforcing fiber base is easy to shift while being laminated in a dry state on the mold until the resin is injected, and the stacking position shifts when the mold moves. There is also a risk. In addition, even after unloading from the clean room, it is necessary to move the large mold to the heating facility in the workplace, which may involve a risk of contact with surrounding workers and facilities. If a movable clean room is used, it is possible to prepare a clean room environment around the mold without being limited by the size of the mold, so that it is not necessary to move the mold.

  In addition, a mold using a mold having a heating medium passage such as hot water for heating the mold in the mold itself, and a mold using an external heating device for heating and controlling the temperature of the heating medium, If a mold that can heat the mold itself, such as a mold with an electric heater that is heated by applying an external power source with a built-in heater, there is no need to move the mold. In this case, the composite material can be manufactured without substantially moving a large and heavy mold from the stacking process to the bagging and curing processes. Note that substantially moving in the present invention means, for example, movement between work sites in each process, such as movement from a clean room that performs a lamination process to a curing furnace that performs a curing process. The operations such as the fine adjustment of the mold position performed in the above are not included.

(E) Demolding / Processing Step After curing, the step of releasing the vacuum, removing the bag material such as a film, and removing the cured fiber reinforced resin molded product from the mold is called demolding. After demolding, if necessary, the product is again heated to a desired temperature by the heating device 8 and then processed into a predetermined shape to obtain a product. In this state, the resin is impregnated and cured in the reinforcing fiber base material, so there is no fear of contamination and no change in physical properties of the reinforcing fiber base material. In the case of a clean room, the clean room equipment can be easily disassembled and removed in such a case, so there is no need to move the mold.

  As described above, any process can be performed in any place by using a movable clean room. In addition, when the distance between the clean room and the heating equipment is long, there is a concern about the displacement of the laminated reinforcing fiber base material when the mold is conveyed, but the mold can be conveyed by using a movable clean room. It can be minimized. Furthermore, it is also possible to eliminate the need to move the mold by directly adjusting the temperature of the mold with heating equipment and heating it. Moreover, when each operation | work is performed in the respectively separate clean room which can move, the foreign matter mixing prevention measures, such as sealing of the reinforced fiber base material at the time of conveyance of a reinforced fiber base material, become unnecessary.

In addition, since only the minimum necessary space can be air-conditioned, an energy saving effect can be expected as compared with a method of installing and air-conditioning a large clean room. For example, when laminating using a 1000 x 5000 x 300 mm mold, it is usually necessary to take into account the space around the mold, and it is necessary to install a clean room with a size of about 5000 x 10000 mm There is. However, if it is a movable clean room, there is no need to consider the mold handling space in the room, so only air conditioning the mold and the minimum space required for stacking work, for example, 2000 x 6000 mm That's it. In this case, the area required for air conditioning can be reduced from 50 m ² to 12 m ² , so the energy saving effect is simply about 75%.

  FIG. 3 shows an example of a schematic diagram of a manufacturing operation using a movable clean room used in the present invention.

  The movable clean room used in the present invention is a frame member provided with casters for enabling movement, a frame structure assembled so as to be independent by them, and the outside air supported by the frame and the air conditioning control area. The air conditioning unit 3 for controlling the internal pressure, the cleanliness, the temperature / humidity of the air conditioning control area.

  The main body part divides the outside air and the air conditioning control area with a sheet of vinyl chloride or the like, and further includes a skirt part 4 for sealing the gap between the lower part of the partition and the floor surface in order to improve the airtightness with the outside air. The main body part is provided with temperature, humidity, cleanliness and pressurization necessary for cutting, laminating, and bagging work. An intermediate chamber 2 having an openable / closable part is provided. The clean room portion 1 and the intermediate chamber 2 are each composed of a stretchable frame and a stretchable sheet for blocking outside air, and can be used in any size. Moreover, the clean room part 1 and the intermediate room 2 each have an opening that can be opened and closed, and can be used as one large clean room by connecting the clean room part 1 and the intermediate room 2 in some cases. It is. By covering the mold 7, the reinforcing fiber base, and the like used in the manufacturing operation with the clean room portion, it is possible to perform the lamination and bagging process at an arbitrary place.

  The air conditioning unit for applying the temperature, humidity, cleanness, and pressurization of the clean room includes a filter unit 5 for maintaining cleanliness and an air conditioning unit 6 for controlling temperature and humidity. In addition, about the pressurization of a clean room, it can adjust suitably with the external air introduction adjustment valve in an air-conditioning part.

  The clean room part, the intermediate room, and the air conditioning unit are connected by a magnet or a fitting, and can be separated from each other. Therefore, it is possible to separate easily when movement is required, and the clean room part and the intermediate room can be expanded and contracted to make it more compact, so the work space is narrow and large carts can be handled. Even if it is not possible, or even if the mold is large and cannot be carried into a normal clean room, it is possible to easily prepare a clean room environment at a necessary place. Also, if you prepare multiple air conditioning units and clean room parts, it is possible to prepare a clean room environment of any size in any place within the capacity range of the air conditioning unit, and produce different parts. Even in this case, it is possible to perform parallel work without worrying about the contamination of each foreign substance. In addition, since it is possible to prepare temperature, humidity, cleanliness, pressurized environment even in the immediate vicinity of operations that are prone to dust generation such as demolding, operations such as cutting, lamination, bagging, etc. are possible. Even in a small work place, it is possible to perform different work while suppressing the possibility of foreign matter contamination.

  The present invention can be applied to any method for producing reinforced fiber plastics. For example, a wide range of fiber reinforced plastics used in various fields such as industrial applications such as vehicles, ships, aircraft, and building materials, and sports applications. It can be applied to a manufacturing method. In particular, it is suitable for the manufacture of components for aircraft applications that require high safety and quality.

1 Reinforcing fiber substrate 2 Reinforcing fiber substrate (after cutting)
3 Mold 4 Sheet (cover)
5 Vacuum pump 6 Resin injection machine 7 Resin 8 Heating device 9 Clean room 10 Movable clean room 11 Mold temperature controller 12 Clean room part 13 Intermediate room 14 Air conditioning unit 15 Skirt 16 Filter part 17 Air conditioning part

Claims (7)

Laminating process for laminating reinforcing fiber base material on mold, bagging process for covering the laminated reinforcing fiber base material with a hermetic sealable sheet and evacuating, and curing process for curing resin impregnated in reinforcing fiber base material A method for producing a composite material, comprising at least the above-described laminating step in a clean room having an opening / closing function. The method for producing a composite material according to claim 1, wherein the clean room is movable. The method for producing a composite material according to claim 1, wherein the bagging process is performed in the clean room. The method for producing a composite material according to any one of claims 1 to 3, wherein the process is performed at a certain location without substantially moving the mold from the laminating process to the bagging process and the curing process. The method for producing a composite material according to claim 1, wherein the mold has a function capable of being heated by an external heating device. The method for producing a composite material according to claim 1, wherein a length of at least one side of the mold is 3 m or more. The method for producing a composite material according to any one of claims 1 to 6, wherein the clean room includes a work room for managing cleanliness and an indoor environment control device, each of which can be separated and moved.

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