JP4396057B2 - FRP laminate and FRP molding method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to FRP (Fiber Reinforced Plastic) molding technology, and more particularly to an improvement in molding quality at a reinforced location.
[0002]
[Prior art]
Normally, FRP is made by laminating high-strength fibers such as glass fiber and carbon fiber impregnated with epoxy resin and resin, and removing the excess resin component from the laminated FRP material by vacuum suction or the like. After that, it is obtained by performing high temperature and high pressure curing. FRP that binds each fiber and fiber layer with a resin and makes it into an arbitrary form is from various aerospace equipment parts to everyday products due to its light weight, high rigidity, high strength, and high weather resistance. Used in a wide range of fields.
[0003]
Basically, FRP can obtain a three-dimensional molded product because the fiber layers are bonded together and molded with a synthetic resin. In addition, since the size of the molded product to be manufactured is formed by bonding the fiber layers together, theoretically, even a large-scale product can be integrally manufactured. In reality, due to the constraints of production space, etc., it is divided into a certain size and molded, but a large-scale structure can be obtained by joining the molded FRPs together.
[0004]
On the other hand, even in a small-scale FRP molded product, it is often necessary to couple with other members such as bonding of FRP and FRP or bonding of FRP and metal frame or the like in the manufacturing process.
[0005]
In joining such molded FRPs and joining other members, or joining a molded FRP molding material and another FRP molding material, the member and the member are fused and connected by welding or the like like a metal material. This method cannot be employed, and is generally joined by a method such as joining with an adhesive or a bolt, or rivet joining.
[0006]
In the case of the above-described bolt joining or rivet joining, it is necessary to provide through holes for fasteners such as bolts and rivets at joints in the FRP molded product. The fastener is inserted through and fastened.
[0007]
However, while FRP has high strength and rigidity, it also has fragility. For this reason, when a fastener such as a bolt is inserted into the through-hole and tightened with this fastener, the degree of stress concentration is higher than that of metal and may only be lower than that of metal due to brittleness. .
[0008]
Therefore, in order to reinforce the portion provided with the through hole for fastening as described above, when laminating the FRP material which is a fiber layer impregnated with resin, a metal plate as a reinforcing material around the portion where the through hole is provided This reinforcing material may be laminated between the FRP materials.
[0009]
If it does in this way, the brittleness which FRP has can be supplemented and the intensity | strength of the through-hole periphery of the FRP molding which penetrated the fastener can be improved.
[0010]
[Problems to be solved by the invention]
As described above, the brittleness of the FRP can be improved by inserting the metal plate or the like between the FRP materials at the time of laminating the reinforcing material. There are cases where the synthetic resin where the reinforcing material is inserted and the air enclosed between the reinforcing materials are not sufficiently discharged to the outside.
[0011]
Generally, FRP can be obtained by reducing the proportion of the resin in the unit volume in the molding stage, so that high quality FRP can be obtained. Therefore, vacuum suction is performed on the laminated FRP material to discharge excess resin or the like to the outside. .
[0012]
However, as shown in FIG. 10, when the reinforcing material 50 is present, the excessive resin at the location where the reinforcing material 50 is not sufficiently sucked and discharged, and even after the suction, the resin pool due to the surplus resin and the air are discharged. If not, an air bubble 51 is formed. Therefore, the molded product 52 may be of low quality with non-uniform thickness and the like.
[0013]
The present invention has been made in view of the above problems, and it is a technique to obtain an FRP molded body free from quality deterioration by discharging resin and air surplus from the FRP material sandwiched between reinforcing materials to the outside. As an objective.
[0014]
[Means for Solving the Problems]
In order to solve the above-described problems, the present invention has the following configuration. That is, an FRP laminate that is formed by laminating a plurality of FRP materials and includes a reinforcing portion at least partially laminated with a reinforcing material together with the FRP material, and the surface of the reinforcing material in contact with the FRP material is surplus during molding. A space for discharging resin and air is provided. Therefore, at the time of molding, excess resin and air are discharged from the space to the outside of the FRP material. By using such an FRP laminate, it is possible to obtain an FRP molded product having a high density without excess resin or air being discharged to the outside and without bubbles or the like inside.
[0015]
As a space provided in the reinforcing material, for example, a through hole can be formed, and excess resin and air can be discharged from the through hole to the outside.
[0016]
Or the groove | channel as a space can be provided in the said reinforcing material, and it can be set as the structure which discharges surplus resin and air outside by the groove | channel.
[0017]
When opening a through hole in the reinforcing material, a hole may be provided at a location where a fastener such as a bolt is attached later, and a small hole is provided in the entire reinforcing plate, such as a punching metal. Such a reinforcing material may be used. However, the former is more desirable if high strength is required.
[0018]
In order to provide grooves in the reinforcing material, for example, grooves that reach the end of the reinforcing material from the center of the reinforcing material to the outside can be provided radially, or lattice-like grooves can be provided on the surface of the reinforcing material.
[0019]
The groove can be formed such that a groove portion provided in the reinforcing material is thinner than other portions of the reinforcing material, or a part of the reinforcing material can be bent into the shape of the groove to form the groove. .
[0020]
Of course, it is possible to provide both the through hole and the groove in the reinforcing material, and it is possible to efficiently discharge the surplus resin by appropriately combining them as necessary. .
[0021]
According to the present invention, by providing the space between the reinforcing material and the FRP material in this way, it is possible to effectively discharge the excess resin and air in the reinforcing portion when the FRP is molded.
[0022]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, examples suitable as embodiments of the present invention will be shown.
(Embodiment 1)
As Embodiment 1, a case where FRP lamination molding is performed using a circular metal plate having a through hole in the center as a reinforcing material will be described with reference to the drawings.
[0023]
As shown in FIG. 1A, a carbon fiber is immersed in a resin, and a sheet-like carbon fiber composite material (hereinafter referred to as a CFRP material) impregnated with the resin is formed. A CFRP molded product is obtained by laminating a plurality of such CFRP materials 1, but a thin portion having a through-hole 8 in the center between layers where a plurality of CFRP materials 1 are laminated is provided for a portion that requires reinforcement such as a joint. The reinforcing plates 2 are arranged and laminated so that they are alternately positioned.
[0024]
As described above, the FRP laminate S in which the sheet-like CFRP materials 1 and the reinforcing plates 2 are alternately laminated is obtained. Next, as shown in FIG. 1B, the CFRP laminate S is installed in the mold 3. The opening of the mold 3 is covered with a bleeder 4 that functions as a resin absorbent paper, and a vinyl sheet 5 serving as a packing is covered on the opening, and a suction port 6 is provided in the vinyl sheet 5.
[0025]
A vacuum pump (not shown) is connected to the suction port 6 for suction, and the layers are bonded while discharging the excess epoxy resin 7 impregnated in the CFRP material.
[0026]
During this suction, the epoxy resin 7 contained in the CFRP material 1 in contact with the reinforcing plate 2 passes through the through hole 8 and is discharged outside the CFRP material 1 without accumulating inside. At this time, the excess epoxy resin is discharged to the outside of the CFRP material 1 as indicated by an arrow 7. Similarly, air existing between the reinforcing plate 2 and the CFRP material 1 is also discharged to the outside of the CFRP material 1.
[0027]
Thus, the CFRP laminated body S which consists of the CFRP material 1 and the reinforcement board 2 in the state in which each layer was united is moved in the pressure cooker which is not shown in figure. In this pressure cooker, curing is performed under high temperature and high pressure, and as shown in FIG. 1C, a CFRP molded product 9 in which the CFRP materials are combined and integrated is obtained.
[0028]
In the present embodiment, the through-hole 8 is provided only at the center of the reinforcing plate 2, and this through-hole 8 can be used as a pilot hole when a fastener such as a bolt is penetrated later.
[0029]
In the present embodiment, surplus resin and air can be discharged at the time of molding, and reinforcement is performed by the high-strength reinforcing plate 2 that does not have through holes other than necessary portions.
[0030]
Here, when laminating the CFRP material 1 and the reinforcing plate 2 of FIG. 1A, a through hole 8 smaller than the through hole of the fastener is previously installed in the reinforcing plate 2, and the reinforcing plate 2 and the like are based on this. It is desirable to form a through-hole that includes the through-hole 8 after the lamination and molding, and that matches the size of the accurate fastener having a larger diameter. In this manner, molding errors such as displacement of the through-holes when the reinforcing plate 2 is laminated are absorbed, so that inconveniences regarding the product are unlikely to occur. .
(Embodiment 2)
Here, a case will be described in which a circular reinforcing plate 11 having a shape in which grooves 12 are radially formed outward from the central portion of the reinforcing material as shown in FIG.
[0031]
As shown in FIGS. 3A and 3B, the reinforcing material 11 includes a plurality of radial grooves 12 from the central portion of the reinforcing material 11 outward.
[0032]
As shown in FIG. 2, after reinforcing plates 11 and the CFRP material 1 are alternately laminated, the surplus resin is sucked into the mold 3 as in the case shown in FIG. At this time, the CFRP is molded while discharging the excess resin of the CFRP material 1 in contact with the reinforcing plate 11 and the air contained in the groove 12 formed in the reinforcing plate 11 to the outside of the reinforcing plate 11.
[0033]
When the reinforcing plate 11 is laminated with the CFRP material 1, the gaps formed by the grooves 12 are reduced when the reinforcing plate grooves 12 in contact with the upper and lower CFRP materials 1 are superposed. Therefore, it is desirable that the reinforcing plates 11 are alternately rotated and laminated so that the grooves 12 formed on the reinforcing plate 11 do not overlap.
[0034]
Further, the reinforcing plate 2 is alternately rotated little by little to be laminated, whereby the convex portion 14 on the opposite surface of the concave portion 13 of the groove 12 and the reinforcing plate 11 and the CFRP material laminated on the upper portion of the convex portion 14. By overlapping the flat surfaces of 1, it can be expected that a new gap is generated and the resin and air are discharged.
[0035]
In the present embodiment, surplus resin and air can be discharged by a radial gap communicating from the central portion of the reinforcing plate 11 to the outside of the reinforcing plate 11.
[0036]
In addition, in the case where the thickness of the FRP molded product after lamination is increased by forming three-dimensional grooves so as to be uneven in the reinforcing material, a circular shape as shown in FIGS. It is also possible to provide the reinforcing material 16 with slits 17 that are radial spaces, and to discharge the excess resin and air inside the reinforcing material 16 to the outside from the space consisting of the slits 17.
[0037]
Further, by providing the reinforcing material 16 with a groove formed by the radial slits 17, it can be expected that the CFRP material 1, which is a different material, and the reinforcing material 16 are more rigid due to the anchoring effect of the slits 17.
(Embodiment 3)
Here, as shown in FIG. 5, a description will be given of a reinforcing material 21 having a through hole 22 and a groove 23.
[0038]
As shown in FIGS. 6 (a) and 6 (b), the reinforcing member has a groove 23a having unevenness extending radially in four directions from the central hole 22a and a through hole 22b. In other words, the groove 23a is composed of four grooves 23b provided in a tangential direction at quarter diameter points, and four through holes 22b provided on the intersections of the grooves 23a and 23b.
[0039]
In this embodiment, by any chance, there is a situation in which the reinforcing members 21, 21... Laminated at the time of FRP molding are displaced and the through holes 22 of the individual reinforcing members 21 do not penetrate from the lower surface to the upper surface. In addition, surplus resin and air are discharged to the outside from the grooves 23 a and 23 b provided in the reinforcing member 21.
[0040]
In this embodiment, in addition to the central through hole 22a, by providing the through holes 22b on the four sides, it is expected that the coupling rigidity of the composite material made of different materials of the CFRP material 1 and the reinforcing material 21 is increased. it can.
[0041]
Further, a through hole 27 is formed in the central portion with a reinforcing material 26 as shown in FIGS. 7A and 7B, and slits are provided radially around the through hole 27, and a groove 28 formed by the slit and the through hole are provided. It is possible to discharge excess resin and air by 27.
[0042]
As shown in FIGS. 8 and 9, the CFRP molded product 9 formed as described above is fastened by a bolt 31 after passing a bolt hole 30 through the center thereof.
[0043]
Moreover, although the bolt was shown as an example as said fastener, a fastener is not limited to this. Further, the shape, size, and number of through-holes and grooves that form a space for discharging excess resin and the like are not limited, and these can be appropriately selected and combined.
[0044]
Further, the number, size, and shape of the FRP material (prepreg) and reinforcing plates to be laminated are not limited, and the reinforcing plate may be one or two or more. In this case, the prepreg includes not only carbon fibers but also other fiber composite materials such as glass fibers and aramid fibers.
[0045]
【The invention's effect】
As described above, according to the present invention, by using the FRP laminate in which a space is formed in the reinforcing portion of the FRP laminate in which the reinforcing material is laminated together with the FRP material, excess resin and air can be sufficiently discharged during molding. Can do. Therefore, the quality of the FRP molded product can be improved.
[Brief description of the drawings]
FIGS. 1A and 1B are diagrams showing a molding process of FRP according to Embodiment 1, wherein FIG. 1A is a conceptual diagram in which CFRP material and a reinforcing material are laminated, and FIG. 1B is a conceptual diagram in which resin components are sucked and discharged from the laminated FRP. FIG. 4C is a cross-sectional view of the reinforcing laminated portion after forming the FRP.
FIG. 2 is a conceptual diagram in which a CFRP material and a reinforcing material are stacked when the reinforcing material provided with a groove according to the second embodiment is used.
3A and 3B are diagrams showing a reinforcing plate according to a second embodiment, in which FIG. 3A is a plan view thereof, and FIG. 3B is a side view thereof.
4A and 4B are diagrams showing a reinforcing plate according to Embodiment 3, wherein FIG. 4A is a plan view thereof, and FIG. 4B is a side view thereof.
FIG. 5 is a conceptual diagram in which a reinforcing material provided with a through hole and a groove and a CFRP material are stacked according to the third embodiment.
6A and 6B are diagrams showing a reinforcing member provided with a through hole and a groove, in which FIG. 6A is a plan view thereof, and FIG. 6B is a side view thereof.
7A and 7B are diagrams showing a reinforcing member provided with a through hole and a groove due to scratches, in which FIG. 7A is a plan view and FIG. 7B is a side view thereof.
FIG. 8 is a partial cross-sectional view of an FRP molded body in which a bolt hole is provided in a reinforcing portion.
FIG. 9 is a partial cross-sectional view of an FRP molded body in which a bolt is attached to a reinforcing portion.
FIG. 10 is a partial cross-sectional view of a molded body from which excess resin or air is not discharged from a reinforcing portion.
[Explanation of symbols]
1 CFRP material 2 Reinforcement plate 3 Type 4 Breeder (resin absorbent paper)
5 Vinyl sheet 6 Suction port 7 Epoxy resin 8 Through hole 9 FRP composite material 11 Reinforcement plate 12 Radial groove 13 Recess 14 Convex 16 Reinforcement material 17 Radial flaw groove 21 Reinforcement material 22 Through hole 22a Central through hole 22b Four through holes 23 Groove 23a Radial groove 23b Tangential groove 26 Reinforcement material 27 Through hole 28 Radial scratch groove 30 Bolt hole 31 Bolt 50 Reinforcement material 51 Air bubble 52 Molded product

Claims (7)

A FRP laminate that is formed by laminating a plurality of FRP materials, and includes a reinforcing portion in which a reinforcing material is laminated together with the FRP material at least in part, and the reinforcing portion is fastened by a fastener,
Wherein the reinforcing member is a through-hole for discharging the excess resin and air at the time of molding, smaller than the through-holes that match the size of the fastener, stacked superimposed upon lamination, the excess resin and air after the molding An FRP laminate comprising a through hole that serves as a reference when forming a through hole that matches a dimension of the larger fastener including a through hole for discharging .   The FRP laminate according to claim 1, wherein a groove is provided on a surface of the reinforcing material in contact with the FRP material.   The said groove | channel is a FRP laminated body of Claim 2 formed radially from the center part of the said reinforcing material toward outward.   The FRP laminate according to claim 2, wherein the grooves are formed in a lattice shape.   The FRP molded product formed using the FRP laminated body in any one of Claim 1 to 4. When forming a FRP molded product by laminating a plurality of FRP materials, a reinforcing material is laminated together with the FRP material, these are integrally molded, and a reinforcing portion in which the reinforcing material is laminated together with at least a part of the FRP material is fastened by a fastener. In the FRP molding method,
The reinforcing member is a through hole for discharging excess resin and air, and has a through hole smaller than the through hole that matches the size of the fastener, and the through hole for discharging the excess resin and air The reinforcing material is laminated together with the FRP material, and the diameter further includes a through hole for discharging the surplus resin and air on the basis of the through hole for discharging the surplus resin and air stacked after lamination and molding. A method for forming an FRP, comprising forming a through hole that matches a size of a large fastener .   The FRP molding method according to claim 6, wherein a groove is provided on a surface of the reinforcing material in contact with the FRP material.

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