JP3311851B2 - Reinforced fiber sheet - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforcing fiber sheet in which reinforcing fibers are arranged and bonded in one direction on a support via an adhesive layer.

[0002]

2. Description of the Related Art At present, fiber reinforced composite materials (FRP) in which reinforcing fibers are solidified with resin are used in various fields such as automobiles, aircrafts, building materials, sports goods and the like. 2. Description of the Related Art Production of a prepreg semi-cured by impregnating a reinforcing fiber with a matrix resin has been performed.

According to such a prepreg, a fiber-reinforced composite material molded article can be manufactured by hand lay-up. That is, a desired number of prepregs are manually laminated on the surface of a mold of a molded product, and the prepreg laminate is heated or pressed and heated to cure the matrix resin, thereby obtaining a fiber-reinforced composite material molded product. Can be

[0004] However, the prepreg must be stored in a refrigeration facility because the matrix resin hardens during storage, and it is not convenient to cut the prepreg into an appropriate size and shape for use. was there.

[0005] In view of the above, a unidirectional reinforcing fiber sheet has been developed in which reinforcing fibers are arranged and bonded in one direction via an adhesive layer on a support having releasability, and a fiber-reinforced composite material has been developed. It is being used in the manufacture of molded articles.

In order to manufacture a fiber-reinforced composite material molded article using this one-way reinforcing fiber sheet, a reinforcing resin sheet is impregnated with a matrix resin, and the reinforcing fiber sheet is manually laminated on the surface of a mold to form a support. Or after laminating the reinforcing fiber sheet on the surface of the mold, laminating the support, impregnating the matrix resin, and then heating the reinforcing fiber sheet laminate as in the case of the prepreg. Alternatively, heating and pressing may be performed.

According to such a reinforcing fiber sheet, it is sufficient to impregnate the matrix resin at the time of use, so there is no problem of hardening of the resin during storage, and it is easy to cut into a desired size and shape. There is also. In addition, when used for reinforcing a structure, the use of a room-temperature-curable resin as the matrix resin eliminates the need to heat the reinforcing fiber sheet applied to the reinforcing portion of the structure, and the resin is cured by leaving the resin as it is to leave the fiber. It can be made into a reinforced composite material and has the advantage of good workability.

[0008]

However, in the conventional reinforcing fiber sheet, the support could not be stretched in the width direction perpendicular to the direction in which the reinforcing fibers were arranged.
When a molded product having a large three-dimensional curved surface such as a ship P is created by hand lay-up, there is a disadvantage that the reinforcing fiber sheet cannot be fitted exactly to the three-dimensional curved surface of the mold.

[0009] For this reason, there have been problems such as wrinkling of the obtained molded product and yarn fluctuations in which the arrangement of the reinforcing fibers is largely disturbed.

[0010] An object of the present invention is to extend a support fiber sheet in the width direction by extending a support in the width direction perpendicular to the direction in which the unidirectional reinforcing fibers are arranged by human power, thereby increasing the curvature of an FRP ship or the like. An object of the present invention is to provide a reinforced fiber sheet that enables a fiber-reinforced composite material molded article having a three-dimensional curved surface to be manufactured by hand lay-up without causing problems such as wrinkles and yarn fluctuation.

[0011]

The above object is achieved by a reinforcing fiber sheet according to the present invention. In summary, the present invention provides:
In reinforcing fiber sheet reinforcing fibers bonded and arranged in one direction via a resin layer on a support having a releasing property, the support is, arrangement direction perpendicular width direction of the variable of the reinforcing fibers
High-density polyethylene fill with stretching amount of 3% or more
System, low-density polyethylene film or casting point
It is a reinforced fiber sheet characterized by being a propylene film .

[0012]

FIG. 1 is a sectional view showing one embodiment of the reinforcing fiber sheet of the present invention. In the reinforcing fiber sheet 1 of the present invention, reinforcing fibers 4 such as carbon fibers are bonded and arranged in one direction via a small amount of an adhesive layer 3 on a support 2 having releasability. The fibers 4 are provided on the support 2 in a thin layer in one direction.

In the present invention, the support 2 is made of a film (including a thick sheet) having stretchability in the width direction perpendicular to the direction in which the reinforcing fibers 4 are arranged. This is because the reinforcing fiber sheet 1 can be spread in the width direction by human power so that the reinforcing fiber sheet 1 can be fitted to the surface of a mold having a three-dimensional curved surface having a large curvature, such as an FRP ship. For this reason, it is preferable to make the support 2 wider in the width direction than the thin layer of the reinforcing fiber 4 so that both ends 2a are projected outward so that both ends 2a in the width direction of the support 2 can be grasped by hand. .

When both ends 2a of the extensible support 2 are gripped by hand and the support 2 is pulled in the width direction, the support 2 spreads in the width direction and is placed on the support 2. The thin layer of the reinforcing fibers 4 in one direction bonded via the adhesive layer 3 is also spread in the width direction, and the reinforcing fiber sheet 1 spreads in the width direction.
When the pulling of the spread support 2 is stopped, the support 2 remains spread, that is, the reinforcing fiber sheet 1
Will remain widespread. Therefore, if the reinforcing fiber sheet 1 is applied to the mold in the spread state, the reinforcing fiber sheet 1 can be fitted exactly on the surface of the three-dimensional curved surface having a large curvature of the mold. The extendable amount of the support 2 by the human power is as follows:
Although it depends on the curvature of the three-dimensional curved surface, it is practically required to be 3% or more, preferably 5% or more.

[0015] Stretchable films having such properties include HDPE (high-density polyethylene) films,
LDPE (low density polyethylene) film or CPP
(Casting polypropylene) film or the like can be used. These have a large stretchability in one specific direction and are suitable for use as the support 2 having stretchability in the width direction.

The thickness of the support 2 is 1 to 500 μm, preferably 5 to 100 μm, from the viewpoint of having flexibility and supporting the reinforcing fibers 4.

The adhesive used for the adhesive layer 3 may be, in principle, any material that can at least temporarily adhere the reinforcing fibers 4 to the support 2. A resin having good compatibility with the thermosetting resin is used. It is preferable to use, for example, when an epoxy resin is used as the thermosetting resin, an epoxy adhesive is preferably used. The thickness of the adhesive layer 3 is
Since it is sufficient that the reinforcing fiber 4 can be temporarily bonded,
The thickness is 500 μm, preferably 5 to 30 μm.

As the reinforcing fiber 4, one kind of carbon fiber, metal fiber such as SUS fiber or titanium fiber, inorganic fiber such as boron fiber, organic fiber such as glass fiber or Kevlar fiber, or a combination of plural kinds thereof is used. Can be used.

The reinforcing fibers 4 are formed by arranging a plurality of bundles of filaments or a bundle of fibers which are lightly twisted and converged on a support 2 in one direction via an adhesive layer 3 and crushed from above. Thereby, a thin layer is provided on the support 2. The fiber bundle is slightly disintegrated by the crushing of the fiber bundle, and the filaments are arranged in one direction on the support 2 via the adhesive layer 3 on the support 2 in a state where the filaments are laminated in a plurality of layers by a binding agent or twisting. Thus, the desired reinforcing fiber sheet 1 is obtained.

In this case, the fiber bundles can be arranged densely or sparsely spaced apart from each other. The fiber bundle may or may not have been subjected to filament opening. The degree of squashing of the fiber bundle depends on the layer thickness to be obtained in the reinforcing fibers 4 arranged in this manner. However, in the case of carbon fiber, when a fiber bundle in which about 12,000 filaments having a diameter of 5 to 15 μm are converged is shown. As an example, crushing this so as to have a width of about 5 mm in the lateral direction can be mentioned.

As the matrix resin impregnated in the reinforcing fibers 4, a thermosetting resin such as epoxy, unsaturated polyester, vinyl ester, urethane or the like can be used. In particular, a room temperature-curable resin that is cured at room temperature by adjusting the curing agent or the curing accelerator of the thermosetting resin can be suitably used. When a normal thermosetting resin is used, it is necessary to heat the reinforcing fiber sheet and cure the impregnated thermosetting resin after applying the resin-impregnated reinforcing fiber sheet to the surface of the mold. According to the mold resin, facilities the reinforcing fiber sheet impregnated with this type of surface
By leaving the work as it is, the thermosetting resin can be cured, so that the workability is good.

The reinforcing fibers 4 may be impregnated with the thermosetting resin either before or after the reinforcing fiber sheet 1 is attached to the surface of the mold, or both.

The reinforcing fiber sheet 1 of the present invention is configured as described above. Using this reinforcing fiber sheet 1, for example, F
In order to form the lower part of the bottom of the RP ship having a three-dimensional curved surface having a large curvature, the following method may be used.

As shown in FIG. 2 (a), the reinforcing fiber sheet 1 is applied to the three-dimensional curved surface 10 of the lower part of the bottom of the FRP ship.
In accordance with the length of the three-dimensional curved surface 10, the reinforcing fiber sheet 1 is cut in the width direction perpendicular to the direction in which the reinforcing fibers are arranged, and the reinforcing fiber sheet 1 thus prepared is impregnated with a matrix resin. . Next, as shown in FIG.
The reinforcing fiber sheet 1 is spread in the width direction by grasping the both ends 2a of the support 2 with the reinforcing fiber 4 side down and manually pulling the support 2 in the width direction. Then, in this state, the reinforcing fiber sheet 1 is laminated on the surface of the three-dimensional curved surface 10 with the arrangement direction of the reinforcing fibers 4 coincident with the longitudinal direction of the three-dimensional curved surface 10, and is attached with an impregnated resin. The laminated reinforcing fiber sheet 1 is made even with the surface of the three-dimensional curved surface 10 by pushing with a hand from above. Since this time the reinforcing fiber sheet 1 is extended in the width direction, it may be applied by Sowase snugly on the surface of the reinforcing fiber sheet 1 of three-dimensional curved surface 10.

Next, as shown in FIG. 2 (c), the support 2 is peeled from the reinforced fiber sheet 1 that has been applied, and the reinforcing fiber sheet 1 from which the support 2 has been peeled is heated. To cure the matrix resin to form the reinforced fiber sheet 1 into a fiber reinforced composite material (FRP). The above operation is performed for a desired number of the reinforcing fiber sheets 1, and thus, by hand lay-up, as shown in FIG. Molding without generation of

[0026] In the above, the following resin-impregnated reinforcing fiber sheet 1 has been the construction adhered to the three-dimensional curved surface 10 of the mold, after stuck to a curved surface 10 without resin-impregnated reinforcing fiber sheet 1, support It may be peeled body 2 and applying a resin impregnated, or a curved surface in advance 10 or the by applying a paste resin into the reinforcing fiber sheet 1 is, paste the reinforcing fiber sheet 1 thereon Therefore, the resin may be impregnated with the applied resin for construction .

[0027]

As described above, the reinforcing fiber sheet of the present invention has a structure in which reinforcing fibers are arranged and bonded in one direction via a resin layer on a support having releasability. The body has a stretchable amount of 3 in the width direction perpendicular to the reinforcing fiber arrangement direction.
% High density polyethylene film and low density polyethylene
Polyethylene film or casting polypropylene
Since the film is used , the reinforcing fiber sheet can be expanded in the width direction by stretching the support in the width direction by human power, and a fiber-reinforced composite material molded article having a large three-dimensional curved surface with a large curvature, such as an FRP ship, Manufacture can be performed without wrinkles or yarn fluctuations due to hand lay-up.

[Brief description of the drawings]

FIG. 1 is a sectional view showing one embodiment of a reinforcing fiber sheet of the present invention.

FIG. 2 is a process diagram showing a process of forming a lower portion of a bottom of a FRP ship having a three-dimensional curved surface with a large curvature using the reinforcing fiber sheet of FIG. 1;

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Reinforcing fiber sheet 2 Support 3 Adhesive layer 4 Reinforcing fiber 10 Three-dimensional curved surface 12 Fiber reinforced composite material

Claims (1)

(57) [Claims] 1. A reinforcing fiber sheet in which reinforcing fibers are arranged and bonded in one direction via a resin layer on a support having a releasing property, wherein the support has a width perpendicular to the direction in which the reinforcing fibers are arranged. High-density polymer whose stretchable amount in the direction is 3% or more
Tylene film, low density polyethylene film or
A reinforced fiber sheet, which is a sting polypropylene film .