JP2016078433A - Manufacturing method of frp sandwich structure, and frp sandwich structure - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of an FRP sandwich structure in which an FRP sandwich structure having excellent adhesive strength and high dimensional accuracy in a thickness direction can be obtained.SOLUTION: After first and second FRP skin material 101, 102 each having a plurality of through-holes are molded, the first FRP skin material 101 is mounted on resin 82 for adhesion which is coated on one surface of a foamed core material 103, which is decompressed in a hermetically sealed state. Thus, the foamed core material 103 and the first FRP skin material 101 are adhered while air bubbles 84 in the resin 82 for adhesion are discharged via the through-holes 101a of the first FRP skin material 101, and the second FRP skin material 102 is adhered to the other surface of the foamed core material 103 in a similar manner.SELECTED DRAWING: Figure 7

Description

  The present invention relates to a method for manufacturing an FRP sandwich structure in which a core material is sandwiched by a skin material made of fiber reinforced plastic (hereinafter referred to as FRP) and an FRP sandwich structure.

  As a conventional method of manufacturing an FRP sandwich structure, a laminated body in which at least one frequency selection plate is laminated on both sides of a foam core material and integrally formed is placed on a metal base member, and the laminated body is placed on the laminated body. In a state where the fiber reinforced base material is laminated, the whole is covered with a vacuum bag, and a resin is impregnated and cured in the fiber reinforced base material while the laminated body is vacuumed to form a sandwich structure FRP structure. There was a thing (for example, refer to patent documents 1).

JP 2006-198790 A

  However, in the manufacturing method of the FRP structure as described above, when the fiber reinforced base material is impregnated and cured with the laminated body in the vacuum bag being vacuumed, it is laminated on the side opposite to the base member of the foam core material. Since the fiber-reinforced base material is deformed by atmospheric pressure and enters the irregularities on the surface of the foamed core material, the surface of the fiber-reinforced base material is molded in a wavy state. There was a problem that accuracy could not be obtained. Therefore, after forming the FRP skin material in advance, a method of bonding the foam core material and the FRP skin material using an adhesive resin is also conceivable, but in this method, when the foam core material and the FRP skin material are bonded, There is a problem that air bubbles mixed in the adhesive resin remain after the resin is cured, resulting in a decrease in adhesive strength.

  The present invention has been made to solve the above problems, and a method for manufacturing an FRP sandwich structure capable of obtaining an FRP sandwich structure having good adhesive strength and high dimensional accuracy in the thickness direction. The purpose is to provide.

  In the method of manufacturing an FRP sandwich structure according to the present invention, the laminated fiber cloths are penetrated by the plurality of cone-shaped members, and the tip portions of the plurality of cone-shaped members are covered with a flat elastic body. A step of forming first and second FRP skin materials each having a plurality of through holes by impregnating and curing a resin in the fiber cloth in a state where the fiber cloth is sealed by a bagging film laminated on the elastic body And the first FRP skin material is placed on the first adhesive resin applied to one surface of the foamed core material, and the first FRP skin material is reduced in pressure in a sealed state, thereby penetrating the first FRP skin material. A step of adhering the foam core material and the first FRP skin material while discharging air bubbles in the first adhesive resin through the holes, and applying the second FRP skin material to the other surface of the foam core material Placed on the second adhesive resin Then, by reducing the pressure in a sealed state, the foam core material and the second FRP skin material are bonded together while discharging the bubbles in the second adhesive resin through the through holes of the second FRP skin material. And a step of causing the

  According to the present invention, an FRP skin material having a plurality of through holes is molded in advance, and the FRP skin material and the foamed core material are bonded to each other, thereby providing good adhesive strength and high dimensional accuracy in the thickness direction. An FRP sandwich structure can be obtained.

It is sectional drawing which shows the process of shape | molding the FRP skin material in Embodiment 1 of this invention. It is a top view which shows a fiber cloth. It is sectional drawing which shows the mold release process process of the FRP skin material in Embodiment 1 of this invention. It is sectional drawing which shows the adhesion process of the 1st FRP skin material in Embodiment 1 of this invention. It is a partial expanded sectional view in the B section of Drawing 4. It is sectional drawing which shows the adhesion process of the 2nd FRP skin material in Embodiment 1 of this invention. It is a partial expanded sectional view in the C section of Drawing 6. It is a perspective view which shows the FRP sandwich structure in Embodiment 1 of this invention. It is a partial expanded sectional view which shows the D section of the FRP sandwich structure in Embodiment 1 of this invention. It is the elements on larger scale which show the D section of FIG. It is sectional drawing which shows the example of the shaping | molding die of a skin material.

Embodiment 1 FIG.
Embodiment 1 of the present invention will be described below with reference to FIGS. As shown in FIG. 1 (a), a conical protrusion 10a, that is, a conical member is integrally formed on the skin material forming die 10 used in the present embodiment. The protrusions 10a of the skin material forming die 10 have a height of about 3 mm and a diameter of about 1 mm, and are arranged in a grid at regular intervals. The shape of the protrusion 10a may be a pyramid as long as it is a cone. Further, as described above, the diameter of the protrusion 10a and the distance between the adjacent protrusions 10a are constant. However, it is possible to effectively discharge bubbles in the adhesive resin described later, and the fiber characteristics of the fiber cloth 20 described later. From the standpoint of achieving both reduction and reduction, the diameter of the protrusion 10a that penetrates the center of the fiber cloth 20 is made larger than the diameter of the protrusion 10a that penetrates the outer periphery of the fiber cloth 20, The arrangement of the protrusions 10a penetrating the central part may be made denser than the arrangement of the protrusions 10a penetrating the outer peripheral part of the fiber cloth 20. And from a viewpoint of suppressing the fiber characteristic fall of the fiber cloth 20, it is preferable that the diameter of the processus | protrusion 10a is 1/10 times or more and less than 2 times the fiber bundle space | interval A shown to Fig.2 (a). Here, the upper surface of the skin material mold 10 is a flat surface, but is not limited to this, and may be a curved surface.

  On the other hand, the fiber cloth 20 may be a woven fabric obtained by weaving a bundle of fibers in a two-dimensional plane, and is not limited by the woven structure. Moreover, although the material of the fiber in the fiber cloth 20 is carbon fiber here, it is not restricted to this, Other fibers, such as glass fiber, may be sufficient. The number of fiber cloths 20 to be laminated may be in a range where the thickness of the laminated fiber cloths 20 does not exceed the height of the protrusion 10a.

  Next, the process for forming the FRP skin material will be described. First, a fiber cloth 20 in which carbon fibers are plain woven as shown in FIG. 1 (b) is laminated on a surface mold 10 having a surface release treatment as shown in FIG. 1 (a). . At this time, the protrusion 10a penetrates the fiber cloth 20, but the protrusion 10a passes through the gap 20b formed between the fiber bundles 20a shown in FIG. 2A, and as shown in FIG. Since the fiber bundle 20a is bent, the fiber is not broken and its continuity is maintained. For this reason, strength is not reduced by penetrating the protrusion 10a.

  Next, as shown in FIG. 1C, the peel ply 71 and the flow medium 72 are sequentially stacked on the stacked fiber cloth 20, and the tip of the protrusion 10 a is protruded from the flow medium 72.

  Next, an elastic body 73 made of a fluorine-based resin such as polytetrafluoroethylene and having a flat upper surface is laminated on the laminated flow media 72 as shown in FIG. 73, the tip of the protrusion 10a is covered without a gap. Further, a sealant tape 75 is laid around the fiber cloth 20, a resin injection port 761 is installed at one end, and a suction port 762 is installed at the opposite end. Then, a bagging film 74 is laminated on the flat elastic body 73, and an outer edge portion of the bagging film 74 is sealed with a sealant tape 75. The resin suction port 761 is connected to a resin tank (not shown), and the suction port 762 is connected to a vacuum pump (not shown). Then, the fiber cloth 20 is shaped by reducing the pressure inside the bagging film 74 by suction of a vacuum pump.

  Then, after the fiber cloth 20 is molded, the filling resin 77 which is, for example, a vinyl ester resin is injected from the resin injection port 761 as shown in FIG. After the filling resin 77 is impregnated and filled in the entire fiber cloth 20, the filling resin 77 is cured at room temperature or under heating according to the type of the filling resin 77.

  The thickness of the elastic body 73 is not less than the height of the tip of the protrusion 10a protruding from the flow media 72. The elastic body 73 may be made of any material as long as it has a small coefficient of friction and surface tension, is excellent in releasability, and has heat resistance enough to withstand the curing temperature of the filling resin 77. The hardness of the elastic body 73 is preferably 50 or less according to a JIS standard K6253 type A durometer. Further, the filling resin 77 is not particularly limited as long as it is a low-viscosity resin, and an epoxy resin, a polyester resin, or the like may be used in addition to the vinyl aether resin. Among them, those that can be cured at room temperature such as vinyl ester resins are preferable.

  After the filling resin 77 is cured as described above, the fiber cloth 20 filled with the filling resin 77 is removed from the mold 10 of the skin material, and the peel ply 72 and the flow media 72 are peeled off. As shown in 1 (f), a first FRP skin material 101 having a through hole 101a is obtained. In the first FRP skin material 101, the surface facing the skin material mold 10 is the outer surface 101c, and the surface opposite to the outer surface 101c is the adhesive surface 101b. Further, since the through hole 101a has a truncated cone shape, the bottom surface on the outer surface 101c side is larger than the bottom surface on the bonding surface 101b side.

  In addition, although the process which shape | molds the 1st FRP skin material 101 was demonstrated so far, the 2nd FRP skin material 102 can also be shape | molded by the process similar to this. As shown in FIG. 1 (f), the second FRP skin material 102 also has a through-hole 102a like the first FRP skin material 101, and the surface facing the molding die 10 of the skin material is the outer surface 102c. Thus, the surface opposite to the outer surface 102c becomes the adhesive surface 102b. Further, since the through hole 102a has a truncated trapezoidal shape, the bottom surface on the outer surface 102c side is larger than the bottom surface on the bonding surface 102b side.

  Next, the mold release process will be described. The first and second FRP skin materials 101 and 102 formed as described above are turned upside down as shown in FIG. 3, and a release agent 78 is applied to the outer surfaces 101c and 102c, respectively.

  Next, the bonding process between the first FRP skin material 101 and the foam core material 103 will be described. As shown in FIG. 4, the foam core material 103 placed on the mold 30 via the peel ply 81 and the first foam material 103 placed on one surface of the foam core material 103 via the adhesive resin 82. One FRP skin material 101 is covered with a bagging film 83, arranged on the outer periphery of the foam core material 103, and sealed with a sealant tape 85 together with a jig 863 provided with a bleeder 861. Then, the suction port 862 provided in one sealant tape 85 is connected to a vacuum pump (not shown), and the inside of the foam core material 103 is reduced in pressure by the vacuum pump, whereby the first FRP skin is formed on one surface. The material 101 is bonded. Hereinafter, this adhesion process will be specifically described.

  FIG. 5 is a partial enlarged cross-sectional view showing the bonding process in the portion B of FIG. As shown in FIG. 5A, the foam core material 103 is placed on the mold 30 via the peel ply 81, and an adhesive resin such as a vinyl ester resin is provided on the surface opposite to the mold 30. 82 is applied. Further, as shown in FIG. 5B, an adhesive resin 82 is applied to the adhesive surface 101b of the first FRP skin material 101 that has been subjected to the release processing in the release processing step, and this adhesive surface 101b is applied to the foam core. The first FRP skin material 101 is placed on the adhesive resin 82 applied to the foam core material 103 so as to face the material 103. Thereafter, the first FRP skin material 101 is pressurized from above, and a part of the bubbles contained in the adhesive resin 82 is discharged.

  Next, a jig 863 provided with a bleeder 861 is installed on the outer peripheral portion of the foam core material 103, and a sealant tape 85 is laid around the jig 863. Further, a suction port 862 is provided in one sealant tape 85, and this suction port 862 is connected to a vacuum pump (not shown).

  After the suction port 862 is installed, as shown in FIG. 5C, the bagging film 83 is overlaid on the first FRP skin material 101 placed on the foam core material 103 to cover the whole. The outer edge of the bagging film 83 is sealed with a sealant tape 85.

  Next, by depressurizing the inside covered with the bagging film 83 by the suction of the vacuum pump, the bubbles 84 remaining inside the adhesive resin 82 as shown in FIG. 5 (d) are passed through the through holes 101a. It is discharged to the top. At this time, the adhesive resin 82 is filled in the through-hole 101a, and a part of the adhesive resin oozes out between the first FRP skin material 101 and the bagging film 84 to become excess resin 82a. In the outer peripheral portion, the bubbles 84 are also discharged from the outer edge portion.

  After the bubbles 84 are discharged as described above, the suction port 862 is closed, and the adhesive resin 82 is cured at room temperature or under heating according to the type of the adhesive resin 82 while maintaining the reduced pressure state. Form. Next, as shown in FIG. 5E, the foam core material 103 is removed from the mold 30 and the peel ply 81 is peeled off. Then, as shown in FIG. 5 (f), the excess resin 82 a on the first FRP skin material 101 is removed together with the release agent 78. Since the release agent 78 is not applied on the through hole 101a, the surplus resin 82a remains. Therefore, the surplus resin 82a on the through hole 101a is removed by polishing or the like as necessary.

  The foam core material 103 has a thickness of about 5 mm to 10 cm, and the type is not limited as long as it is a closed cell foam material, and acrylic, phenol, polystyrene, or the like can be used. Further, the type of the adhesive resin 82 is not limited as long as it is a resin having a low viscosity and a liquid at normal temperature. A vinyl ester resin curable at room temperature is preferable, and a resin of the same type as the filling resin 77 is more preferable.

  Next, the bonding process between the second FRP skin material 102 and the foam core material 103 will be described. After bonding the first FRP skin material 101 and the foam core material 103 as described above, as shown in FIG. 6, the foam core material 103 having the first FRP skin material 101 bonded to one surface is provided. Then, it is placed on the mold 30 via the peel ply 81. Then, this foam core material 103 and the second FRP skin material 102 placed on the other surface of the foam core material 103 via the adhesive resin 82 are covered with a bagging film 83, and the foam core material 103 Sealed with a sealant tape 85 together with a jig 863 provided on the outer periphery and provided with a bleeder 861. Then, the suction port 862 provided in one sealant tape 85 is connected to a vacuum pump (not shown), and the inside of the foam core material 103 is reduced in pressure by the vacuum pump, whereby the second FRP skin is formed on the other surface. The material 102 is bonded. Hereinafter, this adhesion process will be specifically described.

  FIG. 7 is a partially enlarged cross-sectional view showing the bonding process in part C of FIG. As shown in FIG. 7A, the foam core material 103 to which the first FRP skin material is bonded is placed on the mold 30 via the peel ply 81, and the first FRP skin material 101 is connected to the foam core material 103. A bonding resin 82 is applied to the surface opposite to the bonding surface. Further, as shown in FIG. 7B, an adhesive resin 82 is applied to the adhesive surface 102b of the second FRP skin material 102 that has been subjected to the release processing in the release processing step, and the adhesive surface 102b is formed into a foamed core material. The second FRP skin material 102 is placed on the adhesive resin 82 applied to the foam core material 103 so as to face the surface 103. Thereafter, the second FRP skin material 102 is pressurized from above, and some of the bubbles contained in the adhesive resin 82 are discharged.

  Next, a jig 863 provided with a bleeder 861 is installed on the outer peripheral portion of the foam core material 103, and a sealant tape 85 is laid around the jig 863. Further, a suction port 862 is provided in one sealant tape 85, and this suction port 862 is connected to a vacuum pump (not shown).

  After the suction port 862 is installed, as shown in FIG. 7C, the bagging film 83 is overlaid on the second FRP skin material 102 placed on the foam core material 103 to cover the whole. The outer edge of the bagging film 83 is sealed with a sealant tape 85.

  Next, by depressurizing the inside covered with the bagging film 83 by the suction of the vacuum pump, the bubbles 84 remaining inside the adhesive resin 82 as shown in FIG. 7 (d) are passed through the through holes 102a. It is discharged to the top. At this time, the adhesive resin 82 is filled into the through-hole 102a, and a part of the adhesive resin oozes out between the second FRP skin material 102 and the bagging film 84 to become the surplus resin 82a. In the outer peripheral portion, the bubbles 84 are also discharged from the outer edge portion.

  After the bubbles 84 are discharged as described above, the suction port 862 is closed, and the filling resin 82 is cured at room temperature or under heating according to the type of the adhesive resin 82 while maintaining the reduced pressure state, and the adhesive layer 104 Form. Next, as shown in FIG. 7E, the foam core material 103 to which the first FRP skin material is bonded is removed from the mold 30 and the peel ply 81 is peeled off. Then, as shown in FIG. 7 (f), the excess resin 82 a on the second FRP skin material 102 is removed together with the release agent 78. Since the release agent 78 is not applied on the through hole 102a and the surplus resin 82a remains, the surplus resin 82a on the through hole 102a is removed by polishing or the like as necessary. The FRP sandwich structure 100 is obtained as described above.

  FIG. 8 is a perspective view of the FRP sandwich structure obtained in the present embodiment, FIG. 9 is a partially enlarged sectional view showing a D portion of the FRP sandwich structure, and FIG. 10 is a partially enlarged view showing the D portion of FIG. FIG. As shown in the figure, the FRP sandwich structure 100 is laminated and integrated in the order of a first FRP skin material 101, an adhesive layer 104, a foam core material 103, an adhesive layer 104, and a second FRP skin material 102. The through holes 101a and 102a are filled with an adhesive resin 82. In the present embodiment, the through holes 101a and 102a are arranged in a lattice pattern, but the arrangement of the through holes 101a and 102a is not limited to this. The gap between the fiber cloths 20 constituting the first and second FRP skin materials 101 and 102 is filled with a filling resin 77, and the fiber bundle 20a around the through hole 101a is bent to maintain its continuity. ing.

  According to the first embodiment, the first and second FRP skin materials each having a plurality of through holes are molded in advance, and the FRP skin material and the foamed core material are bonded to each other, whereby the adhesive strength is good. An FRP sandwich structure with high dimensional accuracy in the thickness direction can be obtained.

  In addition, when molding the FRP skin material, the tip of the protrusion penetrating the fiber cloth is covered with a flat elastic body, and the filling cloth is impregnated and cured in a state where the fiber cloth is uniformly pressurized. An FRP skin material with high dimensional accuracy in the thickness direction can be obtained.

  In addition, the continuity of the fibers in the fiber cloth is maintained by impregnating and curing the filling resin in a state where the protrusions are penetrated through the fiber cloth in advance to form the FRP skin material having the through holes, and the fiber breaks. It is possible to prevent the strength from being lowered.

  Further, when the foam core material and each FRP skin material are bonded, the outer surface of each FRP skin material is smoothed by removing the adhesive resin that has oozed out on the outer surface of the FRP skin material. be able to.

  Also, before each FRP skin material is placed on the adhesive resin applied to the foam core material, a release agent is applied to the outer surface of each FRP skin material, so the outer surface of the FRP skin material The excess resin that oozes out can be easily removed.

  In the first embodiment, the protrusion 10a is integrally formed with the first and second FRP skin molds 10; for example, as shown in FIG. 11, the protrusion and the mold are separated. You may comprise. This will be specifically described below.

  As shown in FIG. 11 (a), a plurality of pin holes 11a are provided in the molding die 11 of the skin material, and as shown in FIG. 11 (b), projections 11b can be attached to and detached from each pin hole 11a. It is installed. For this reason, even if the protrusion is damaged, the skin material forming die 11 can be used as it is simply by replacing the damaged protrusion with a new protrusion.

  Further, as shown in FIGS. 11C and 11D, the diameter of the through hole can be easily changed by replacing the protrusion 11b with the protrusions 11c and 11d having different tip diameters.

Furthermore, as shown in FIG. 11 (e), the number of through holes can be increased by attaching pins 11e having the same size as the pin holes 11a to some of the plurality of pin holes 11a provided in the mold. The arrangement and spacing can be easily changed.

  Then, as shown in FIG. 11 (f), by dividing the skin material mold 12 into an upper plate 12b having a pin hole 12a and a bottom plate 12c, the molded FRP skin material is formed into a skin material mold 12. When removing from the mold, first, the bottom plate 12c is removed, the protrusion 12d is extracted from the lower side of the upper plate 12b, and then the upper plate 12b is shifted in the lateral direction to remove the mold.

  10, 11, 12 Mold for skin material, 10a, 11b, 11c, 11d, 12d Protrusion (conical member), 20 Fiber cloth, 73 Elastic body, 74, 83 Bagging film, 77 Filling resin, 78 Mold release agent , 82 Adhesive resin, 84 bubbles, 100 FRP sandwich structure, 101 first FRP skin material, 102 second FRP skin material, 101a, 102a through-hole, 101b, 102b bonding surface, 103 foam core material.

Claims (11)

In a state in which the laminated fiber cloth is penetrated by the plurality of conical members, the tips of the plurality of conical members are covered with a flat elastic body, and the fibers are formed by a bagging film laminated on the elastic body. A step of molding the first and second FRP skin materials each having a plurality of through holes by impregnating and curing the resin in the fiber cloth with the cloth sealed;
The first FRP skin material is placed on the first adhesive resin applied to one surface of the foam core material, and the pressure is reduced in a sealed state, thereby penetrating the first FRP skin material. Adhering the foam core material and the first FRP skin material while discharging air bubbles in the first adhesive resin through holes;
The second FRP skin material is placed on the second adhesive resin applied to the other surface of the foamed core material, and is decompressed in a sealed state, whereby the second FRP skin material A step of adhering the foam core material and the second FRP skin material while discharging air bubbles in the second adhesive resin through a through-hole. Production method.   Before placing the first and second FRP skin materials on the adhesive resin applied to the foam core material, the surface of the first and second FRP skin materials opposite to the foam core material The method for producing an FRP sandwich structure according to claim 1, further comprising a step of applying a release agent to each.   When the first and second FRP skin materials and the foamed core material are bonded, a part of the first and second adhesive resins is in the through holes of the first and second FRP skin materials. The method for producing an FRP sandwich structure according to claim 1 or 2, wherein the FRP sandwich structure is filled.   When the first and second FRP skin materials and the foam core material are bonded, the adhesive resin that has oozed out of the through-hole is used as the first and second FRP skin materials and the adhesive resin. The method for producing an FRP sandwich structure according to any one of claims 1 to 3, wherein the FRP sandwich structure is removed by applying a shearing force to the interface.   5. The FRP sandwich structure according to claim 1, wherein the first and second FRP skin materials are molded using a molding die having the plurality of conical members. 6. Manufacturing method.   6. The method of manufacturing an FRP sandwich structure according to claim 5, wherein the thickness of the plurality of conical members is 1/10 or more and less than 2 times the fiber bundle interval.   7. The FRP according to claim 6, wherein the plurality of cone-shaped members are thicker in a cone-shaped member penetrating a central portion of the fiber cloth than in a cone-shaped member penetrating an outer peripheral portion. A method for manufacturing a sandwich structure.   The arrangement of the plurality of conical members is characterized in that the conical member penetrating through the center portion of the fiber cloth is denser than the conical member penetrating the outer peripheral portion. Manufacturing method of FRP sandwich structure.   9. The FRP sandwich according to any one of claims 5 to 8, wherein the plurality of conical members are detachably attached to the first and second FRP skin molds. Manufacturing method of structure. The molds for the first and second FRP skin materials are divided into an upper plate and a bottom plate,
When the first and second FRP skin materials are removed from the mold, the bottom plate is removed, and after removing the plurality of conical members from the lower side of the upper plate, the upper plate is shifted laterally to be removed. The manufacturing method of the FRP sandwich structure of Claim 9 characterized by the above-mentioned.   An FRP sandwich structure manufactured by the method for manufacturing an FRP sandwich structure according to any one of claims 1 to 10, wherein the FRP sandwich structure is bonded to both sides of the foam core material, and a part of the adhesive resin is An FRP sandwich structure comprising first and second FRP skin materials each having a plurality of filled through holes.

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