JP2014159099A - Substrate for preparation of preform, method and apparatus for production of the same, preform and methods of producing preform and fiber-reinforced plastic - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a substrate for preparation of a preform capable of improving formability into a three-dimensional shape, a method and an apparatus for production of the substrate, a method of producing a preform and a method of producing a fiber-reinforced plastic which use the substrate for preparation of a preform produced by the method.SOLUTION: A method of producing a substrate for preparation of a preform comprises arranging a plurality of reinforcing fiber bundles at specified positions at least in one direction on a sheet-like base material and adhering them to form a substrate for preparation of a preform and uses, as the base material, a substrate having cuts which extend in the direction intersecting the reinforced fiber bundles. A substrate for preparation of a preform, an apparatus of producing the substrate, a method of producing a preform and a method of producing a fiber-reinforced plastic are also provided.

Description

  The present invention relates to a preform manufacturing substrate, a manufacturing method and a manufacturing apparatus thereof, a preform manufacturing method using the preform manufacturing substrate manufactured by the method, a fiber reinforced plastic manufacturing method, and a method thereof. It relates to manufactured preforms.

  Various methods are known as methods for producing preforms of reinforcing fibers used in the production of fiber reinforced plastics. For example, a method is known in which a predetermined cut pattern is cut out from a fabric such as a woven fabric substrate of reinforcing fibers, and a preform is shaped by pressing. In this method, the substrate portion outside the cut pattern is discarded. For this reason, the yield of the base material for manufacturing the preform is poor, and the cost for manufacturing the preform is increased.

  There are known methods such as AFP (Automated Fiber Placement) and TFP (Tailored Fiber Placement) as a shaping method for placing reinforcing fibers only in the necessary locations. Although it is possible to arrange reinforcing fibers in the conventional AFP and TFP, it has been difficult to accurately shape a complicated three-dimensional shape, for example, a three-dimensional shape having relatively fine irregularities and curved surfaces.

  For example, Patent Document 1 discloses a method of manufacturing a preform by arranging reinforcing fiber bases on a preform molding jig with a movable laminated head. In this method, when the first layer is arranged, An adhesive is arranged around the mold, and the preform is fixed to the surface of the forming jig by the adhesive.

  Patent Document 2 discloses a preform manufacturing method in which a plurality of dry fiber rovings are arranged on a mold at different speeds, and each can be cut independently. Examples of the fixing method of the binder for fixing a plurality of dry fiber rovings include thermal radiation, microwave, infrared, UV, laser, induction energy, contact heating and the like.

  However, with these conventional methods, although the yield of the substrate can be improved to some extent, it is still difficult to accurately form a three-dimensional shape with fine irregularities and curved surfaces.

JP 2011-57767 A Special table 2011-516752 gazette

  Therefore, the object of the present invention is to improve the shapeability in particular so that the three-dimensional shape having fine irregularities and curved surfaces can be shaped accurately and easily. A new preform production base material, a production method and a production apparatus thereof, and a preform production method and a fiber reinforced plastic production method using the preform production substrate produced by the method, It is to provide a preform manufactured by the method.

  In order to solve the above-described problems, a method for producing a preform-producing base material according to the present invention includes arranging a plurality of reinforcing fiber bundles in a predetermined position on a sheet-like base base material in at least one direction and bonding them. A method for producing a reforming base material, wherein the base base material is a base material having a notch extending in a direction intersecting the reinforcing fiber bundle. Here, the incisions are cuts of the base material provided in a large number on the base material and extending intermittently in a predetermined direction. Of course, the notches are provided by a cutting means such as a cutter. It is also a concept including a break in a net-like base material having a discontinuous structure.

  In such a method for producing a preform-forming base material according to the present invention, since the sheet-like base base material to which a plurality of reinforcing fiber bundles are arranged and bonded in at least one direction has a cut, the base base material itself The base substrate itself can be finely deformed in virtually every direction. And since this sheet-like base substrate has a cut extending in a direction intersecting with the reinforcing fiber bundle, the plurality of reinforcing fiber bundles are arranged in a direction in which the plurality of reinforcing fiber bundles are arranged and bonded together with the base substrate. Needless to say, the shape can be easily deformed in any direction including the direction intersecting the reinforcing fiber bundle, and the shapeability of the reinforcing fiber bundle, that is, the shapeability of the preform is greatly improved. As a result, a three-dimensional shape having fine irregularities and curved surfaces, which could not be achieved by the conventional method, can be shaped accurately and easily.

  In the method for producing a preform-producing base material according to the present invention, the reinforcing fiber bundle is preferably bonded intermittently on the base substrate in the extending direction of the reinforcing fiber bundle. By adhering the arranged reinforcing fiber bundles intermittently (that is, partially) without adhering to the entire surface, it can be easily deformed into a three-dimensional shape, and a desired preform with better formability. Can be manufactured.

  The base substrate preferably has a cut extending at least in a direction orthogonal to the reinforcing fiber bundle. By having a cut perpendicular to the reinforcing fiber bundle, it becomes easier to deform from a two-dimensional planar shape to a three-dimensional shape more reliably. However, the extending direction of the cut may be a direction that is skewed with respect to the extending direction of the reinforcing fiber bundle, or may be a combination of a direction that is orthogonal and a direction that is skewed.

  The base substrate may have cuts extending in a plurality of different directions. For example, as described above, a combination of an orthogonal direction and an oblique direction, or a combination of mutually different oblique directions can be employed. The extending direction of the cut can be appropriately set according to the three-dimensional shape to be shaped.

  In the method for producing a preform production substrate according to the present invention, a preform production substrate is produced by providing at least one layer composed of the plurality of reinforcing fiber bundles on the base substrate.

  If necessary, a plurality of layers in which the plurality of reinforcing fiber bundles are arranged in different directions can be provided on the base substrate. By providing a plurality of layers, a preform preparation substrate having a desired thickness can be easily produced.

  When laminating a plurality of layers in which a plurality of reinforcing fiber bundles are arranged in different directions on the base substrate, a reinforcing fiber bundle to which a binder is applied may be used for the second and higher layers. preferable. By using the reinforcing fiber bundle to which the binder is applied, it is possible to appropriately bond the layers, and it is possible to maintain a predetermined laminated form satisfactorily.

  In addition, when the reinforcing fiber bundle is disposed and bonded by laminating one layer or a plurality of layers on the base substrate, the reinforcing fiber bundle can be point bonded to the base substrate. By performing point bonding, a desired form can be maintained without greatly degrading the degree of freedom of deformation of the arranged reinforcing fiber bundle layers. In other words, it is possible to maintain an easy-to-handle form until shaping while maintaining excellent shaping properties to the preform.

  In addition, the reinforcing fiber bundle can be point-bonded randomly on the base substrate, or, for example, point-bonded so that the point bonding positions are sequentially shifted (for example, at a staggered position). it can. Even if bonding is performed by random point bonding or point bonding at positions shifted from each other, the excellent degree of freedom of deformation of the reinforcing fiber bundle layer can be appropriately maintained.

  Alternatively, instead of the point bonding as described above, the reinforcing fiber bundle can be bonded over the entire surface of the base substrate. Since the base substrate originally has a high degree of freedom due to the notch, it is only necessary that the layer of the reinforcing fiber bundle can be easily deformed together with the base substrate even if the entire surface is bonded. By adhering over the entire surface, it is possible to develop high portability of the reinforcing fiber bundle layer.

  Moreover, in the manufacturing method of the preform preparation base material which concerns on this invention, what has a stretching property is preferable as said base base material. The base material for preform preparation according to the present invention is basically formed by transforming the base base material and the reinforcing fiber bundle layer disposed and bonded on the base base material into a predetermined shape when forming the preform. Therefore, if the base substrate itself is extensible, it can be more easily deformed in virtually any direction, and has a three-dimensional shape with fine irregularities and curved surfaces. In addition, it becomes possible to shape the shape more accurately and more easily.

  Examples of a preferable base substrate in the method for manufacturing a preform production substrate according to the present invention include a nonwoven fabric and a mat.

  Moreover, a thermoplastic resin can be mentioned as a material of a base substrate. Moreover, what consists of a reinforced fiber different from the reinforced fiber which comprises the said reinforced fiber bundle can also be used as a base substrate.

  Further, in the method for producing a preform production substrate according to the present invention, a plurality of preform production substrates composed of the base substrate and the reinforcing fiber bundles are laminated to obtain a target preform production substrate. The material can also be manufactured. In such a method, a substrate having a target thickness can be easily obtained.

  The present invention also provides a preform preparation substrate manufactured by the method as described above.

  In addition, the present invention also provides a preform manufacturing method for forming a preform having a predetermined three-dimensional shape using a preform production base and a shaping mold manufactured by the method as described above. .

  The present invention also provides a preform manufactured by the preform manufacturing method as described above.

  The present invention also provides a method for producing a fiber reinforced plastic in which fiber reinforced plastic is RTM molded (Resin Transfer Molding) using the preform produced by the above method.

  Furthermore, the present invention provides a fiber reinforcement that forms a preform having a predetermined three-dimensional shape by using the preform-preparing substrate and the mold produced by the method as described above and RTM-molds the fiber-reinforced plastic. A method for producing plastic is also provided. In this method, a preform having a predetermined three-dimensional shape is shaped using a mold, and a fiber-reinforced plastic having a three-dimensional shape is RTM molded using the mold.

  An apparatus for manufacturing a preform manufacturing base manufactured by the above-described method according to the present invention includes a sheet-like base base having a notch extending in a predetermined direction, and a predetermined on the base base. At least one of a plurality of reinforcing fiber bundles that are arranged and bonded in at least one direction at a position of the above-mentioned position. That is, in this apparatus, at the time of producing a preform production base material, at least one of a sheet-like base base material having a cut and a plurality of reinforcing fiber bundles arranged and bonded on the base base material, The movement is controlled relatively in the two-dimensional direction. Unlike the conventional apparatus, it is possible to control the movement of the base substrate side, that is, the holding means side of the base substrate.

  Thus, according to the method and apparatus for producing a preform for producing a preform according to the present invention, it is possible to produce a substrate that can be accurately and easily shaped even in a three-dimensional shape having fine irregularities and curved surfaces, In addition, the yield of the base material used can be improved.

  In addition, according to the preform manufacturing method and the fiber reinforced plastic manufacturing method according to the present invention, since the preform-preparing base material having excellent formability as described above is used, high-precision shaping and molding can be performed. It becomes possible to carry out easily and efficiently.

1 is a schematic plan view of a preform production base material produced by a preform production substrate production method and production apparatus according to an embodiment of the present invention. It is a schematic block diagram of the manufacturing apparatus of the preform preparation base material which concerns on one embodiment of this invention. It is a schematic plan view of the preform preparation base material which concerns on another embodiment in this invention. It is a schematic plan view of the preform preparation base material which concerns on another embodiment in this invention. It is a schematic plan view of the preform preparation base material which concerns on another embodiment in this invention. It is a schematic block diagram which shows the manufacturing method of the preform which concerns on one embodiment of this invention.

Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 shows a preform production substrate produced by a preform production substrate production method and production apparatus according to an embodiment of the present invention. In FIG. 1, a preform-forming base material 1 uses a sheet-like base base material 2 having extensibility, and a plurality of reinforcing fiber bundles 3 (for example, carbon fiber bundles) are arranged in a predetermined position on at least one direction. It is produced by arranging and adhering to. As the sheet-like base substrate 2, a substrate having a notch 4 extending in a direction intersecting with the reinforcing fiber bundle 3 (in the illustrated example, a direction orthogonal to the reinforcing fiber bundle 3) is used. The cut 4 extends intermittently in a predetermined direction.

  A plurality of reinforcing fiber bundles 3 arranged at predetermined positions on the sheet-like base substrate 2 are intermittently provided in the extending direction of the reinforcing fiber bundles 3. Point bonding is performed on the sheet-like base substrate 2 by the binder applied to the substrate 2 or both of them (reference numeral 5 indicates each bonding position). Bonding may be performed by a technique such as heat bonding or fusion using a binder. Even when the layers of the reinforcing fiber bundle 3 are laminated, the second and subsequent layers are bonded by the same method. After bonding, the outer periphery of the predetermined preform-forming substrate 1 may be cut along the two-dimensional contour 6 to separate the outer sheet-like base substrate 2. Only the unnecessary portion of the sheet-like base substrate 2 is separated, and the reinforcing fiber bundle 3 is disposed only in a necessary portion for producing the preform, so that the yield of the reinforcing fiber bundle 3 is extremely high. .

  Such a preform production substrate 1 is produced, for example, by a preform production substrate manufacturing apparatus 11 as shown in FIG. In the manufacturing apparatus 11 shown in FIG. 2, the sheet-like base substrate 12 having a notch extending in a predetermined direction, which is prepared in advance by another apparatus (not shown), is a predetermined position on a predetermined table 13. The reinforcing fiber bundle 15 that is placed on the base substrate 12 and supplied from the reinforcing fiber bundle supply means 14 (for example, a plurality of creels around which the reinforcing fiber bundle is wound) After being supplied at a predetermined position in a predetermined direction and supplied for a predetermined length, it is cut by the cutting means 16. When the reinforcing fiber bundle is arranged at a predetermined position, at least one of the base substrate 12 and the plurality of reinforcing fiber bundles 15 arranged and bonded to the predetermined position on the base substrate 12 in at least one direction is: Although the movement is controlled relatively in the two-dimensional direction, in this embodiment, the table 13 is configured as a movable table, that is, the table 13 can control the angle in the position in the XY direction and the rotation direction θ. It is comprised as a means, and comprises the said relative movement control means. At this time, for example, the bonding by the bonding means 17 is performed at an appropriate timing so that the intermittent bonding position is realized as described above. After bonding, the outer base substrate 12 may be cut off along the contour of the preform manufacturing substrate 1 as described above. In the illustrated example, the cutting means 16 and the bonding means 17 are incorporated in the same apparatus.

  As for the bonding position, for example, as shown in FIG. 3, the bonding position is indicated by reference numeral 22, and it is also possible to use the preform manufacturing base material 21 that is point-bonded at random positions. Although illustration is omitted, as described above, it is also possible to bond substantially the entire surface instead of point bonding.

  Further, regarding the arrangement of the plurality of reinforcing fiber bundles on the sheet-like base substrate, for example, as shown in FIG. 4, the reinforcing fiber bundle 32 is formed on a part of the preform-forming substrate 31 and the sheet-like base substrate. It is also possible to set a portion that is not disposed on 33 (in the illustrated example, a perforated portion 34), and point-bond the reinforcing fiber bundles 32 disposed in other portions at the bonding position 35.

  Furthermore, for example, as shown in FIG. 5, with respect to the arrangement of the plurality of reinforcing fiber bundles 43 arranged on the sheet-like base substrate 42 constituting the preform production base 41, a plurality of reinforcing fiber bundles 43 are arranged on the base substrate 42. It is also possible to adopt a form in which a plurality of layers in which the reinforcing fiber bundles 43 are arranged in different directions (in the illustrated example, arranged in directions orthogonal to each other) are provided. In this case, a plurality of layers in which a plurality of reinforcing fiber bundles 43 are arranged in different directions are laminated, and a reinforcing fiber bundle to which a binder is applied is used for the second and higher layers in the lamination. Can do. The second and higher layers can be bonded at, for example, a bonding position 44 different from the lower layer.

  The preform production substrate (for example, preform production substrate 1) produced as described above is used for production of a preform as shown in FIG. 6, for example, and a preform having a predetermined shape having a three-dimensional shape is used. Reform is easily shaped with high accuracy. That is, as shown in FIG. 6 (A), a plurality of preform preparation substrates 1 are stacked and arranged in a form of a laminate 51 in a shaping mold 54 composed of an upper mold 52 and a lower mold 53. As shown in FIG. 6 (B), the upper mold 52 is closed, and a preform 55 having a predetermined three-dimensional shape is shaped.

  The preform shaped in this way is placed in another mold, for example, and a predetermined matrix resin is injected and impregnated to mold a fiber reinforced plastic having a predetermined three-dimensional shape. . Alternatively, the preform shaping mold and the fiber reinforced plastic molding mold can be used together, and the preform production substrate produced as described above is placed in the molding mold in a predetermined laminated form, for example. It is also possible to shape a preform having a predetermined shape and to RTM-mold the fiber reinforced plastic after the shaping.

  Thus, the manufacturing method and manufacturing apparatus of the preform manufacturing substrate according to the present invention, and the preform manufacturing method and the fiber reinforced plastic manufacturing method using the preform manufacturing substrate manufactured by the method are as follows. The present invention is not limited to the above-described embodiment, and various forms can be adopted.

  The present invention is particularly suitable for the production of preforms and fiber-reinforced plastics having a three-dimensional shape, and can be used for the production to provide an optimum base material.

1, 21, 31, 41 Preform base material 2, 12, 33, 42 Base base material 3, 15, 32, 43 Reinforcing fiber bundle 4 Notches 5, 22, 35, 44 Adhesion position 6 Preform base Outline of material 11 Manufacturing apparatus for base material for preform preparation 13 Movable table 14 Reinforcing fiber bundle supply means 16 Cutting means 17 Adhesion means 34 Hole 51 Stack 52 Upper mold 53 Lower mold 54 Shaping mold 55 Preform

Claims (22)

  A method for producing a preform-forming base material by arranging and adhering a plurality of reinforcing fiber bundles at predetermined positions on a sheet-like base base material in at least one direction, wherein the reinforcing fiber bundle is used as the base base material. A method for producing a preform-preparing substrate, comprising using a substrate having a cut extending in a direction intersecting with the preform.   The manufacturing method of the preform preparation base material of Claim 1 which adhere | attaches the said reinforcing fiber bundle intermittently in the extension direction of this reinforcing fiber bundle on the said base substrate.   The manufacturing method of the preform preparation base material of Claim 1 or 2 with which the said base base material has a notch extended in the direction orthogonal to the said reinforcement fiber bundle at least.   The manufacturing method of the preform preparation base material in any one of Claims 1-3 in which the said base base material has the notch extended in the mutually different several direction.   The method for producing a preform-producing base material according to any one of claims 1 to 4, wherein at least one layer comprising the plurality of reinforcing fiber bundles is provided on the base base material.   The manufacturing method of the preform preparation base material in any one of Claims 1-5 which provides the several layer by which these several reinforcing fiber bundles are arrange | positioned in a mutually different direction on the said base base material.   A plurality of layers in which the plurality of reinforcing fiber bundles are arranged in different directions are laminated on the base substrate, and reinforcing fiber bundles to which a binder is applied are used for the second and higher layers. The manufacturing method of the base material for preform preparation in any one of 1-6.   The manufacturing method of the base material for preform preparation in any one of Claims 1-7 which adheres the said reinforcement fiber bundle on the said base base material.   The method for producing a preform-producing base material according to any one of claims 1 to 8, wherein the reinforcing fiber bundle is spot-bonded randomly on the base base material.   The manufacturing method of the preform preparation base material in any one of Claims 1-9 which adhere | attach the said reinforcement fiber bundle over the said base substrate over the whole surface.   The manufacturing method of the base material for preform preparation in any one of Claims 1-10 which the said base material consists of what has a stretching property.   The manufacturing method of the base material for preform preparation in any one of Claims 1-11 in which the said base material consists of a nonwoven fabric.   The manufacturing method of the base material for preform preparation in any one of Claims 1-11 in which the said base material consists of mats.   The manufacturing method of the base material for preform preparation in any one of Claims 1-13 in which the said base material consists of thermoplastic resins.   The manufacturing method of the base material for preform preparation in any one of Claims 1-13 in which the said base base material consists of a reinforced fiber different from the reinforced fiber which comprises the said reinforced fiber bundle.   The manufacturing method of the preform preparation base material in any one of Claims 1-15 which laminates | stacks two or more preform preparation base materials which consist of the said base base material and the said reinforced fiber bundle.   A preform production base produced by the method according to claim 1.   A preform manufacturing method, wherein a preform having a predetermined three-dimensional shape is shaped using the preform-producing base material and the shaping mold produced by the method according to claim 1.   A preform produced by the method according to claim 18.   The manufacturing method of a fiber reinforced plastic which carries out the RTM molding of the fiber reinforced plastic using the preform manufactured by the method of Claim 18.   Forming a preform having a predetermined three-dimensional shape using the preform-preparing substrate and a mold produced by the method according to any one of claims 1 to 16, and RTM-molding a fiber reinforced plastic, Manufacturing method of fiber reinforced plastic.   At least one of a sheet-like base substrate having a notch extending in a predetermined direction and a plurality of reinforcing fiber bundles that are arranged and bonded in a predetermined position on the base substrate in at least one direction is 2 An apparatus for manufacturing a preform-preparing substrate manufactured by the method according to any one of claims 1 to 16, further comprising means for relatively controlling movement in a dimensional direction.

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