JP4438944B2 - Manufacturing method of zigzag shaped fiber reinforced resin molding - Google Patents

Description

The present application relates to an invention in which a zigzag-shaped fiber-reinforced thermosetting resin molded article is manufactured by pultrusion and the obtained product can be used in various fields.

  Conventionally, rod-like and pipe-like long fiber reinforced resins are often formed by pultrusion molding. The pultruded product can extend the reinforcing fibers at high density in the axial direction, and is particularly excellent in strength in the axial direction. However, a pultruded product is generally linear, and it has been difficult to directly mold it into a shape other than a straight line.

A pultruded product (see Patent Document 1) is known in which a continuous fiber group impregnated with a thermosetting resin is converged into a rod shape, wound around a winding jig in a semi-cured state and cured, and unnecessary portions are cut and removed. However, this is hard to work because it is cured in a batch system. In addition, attempts have been made to obtain a molded product bent in the longitudinal direction by pultrusion molding using at least two types of fibers having different linear expansion coefficients. However, in such a method, there is a limitation on the curvature of the obtained molded product. is there. (Refer to Patent Document 2) The present applicant impregnates a plurality of longitudinal fiber bundles with a thermosetting resin, pulls out the longitudinal fiber bundles while twisting them by reciprocating movement by meshing of the rack and the pinion, and intersects them. An invention was made in which rods made of fiber reinforced plastics formed into a shape were fed at intervals to be hardened into a lattice shape. (See Patent Document 3)
Japanese Patent Laid-Open No. 2-255323 (first page, claims 1 and 3) Japanese Patent Publication No. 3-47181 (page 1, column 2, lines 2-7) Japanese Unexamined Patent Publication No. 3284800 (first page, claims 2 and 1 and 3)

As described above, the fiber reinforced resin has excellent strength and rigidity and durability, and has a very wide and useful application as a reinforcing material. Only a fiber-reinforced resin molded product having a certain curvature is obtained. The present invention provides a zigzag-shaped fiber by continuous pultrusion by forming and curing on a belt conveyor provided with a plurality of pins in a stage where a fiber bundle such as glass fiber is impregnated with a resin and a curing agent and cured. An object of the present invention is to efficiently produce a reinforced thermosetting resin molded article, and to obtain composite reinforcing members made of FRP having various shapes by using the zigzag fiber reinforced thermosetting resin molded article thus obtained. To do.

  The method of the present invention involves impregnating a reinforcing fiber bundle with a thermosetting resin, drawing through a shaping nozzle, curing the thermosetting resin in a curing region, and obtaining a long molded body. In the curing zone, a plurality of pins are aligned in two rows at a predetermined interval along the drawing direction, and the two rows of pins are arranged in a zigzag manner so that the two rows of pins are moved and applied. Of zigzag pultruded molded body in which thermosetting resin including reinforcing fiber bundles is alternately applied to two rows of pins and cured by reciprocating the nozzle in a direction perpendicular to the drawing direction relative to the rows of pins. Is the method.

According to the method of the present invention, a zigzag rod-shaped fiber-reinforced thermosetting resin molded article having a bent portion and manufactured by pultrusion in which reinforcing fibers extend in the axial direction is obtained.
This zigzag shaped rod-shaped fiber reinforced thermosetting resin molded product is a pultruded molded product containing 50 to 80% by weight of reinforced fiber with respect to the total weight of the molded product, and the reinforced fiber continuously extends in the axial direction. The bent portions are formed continuously at a predetermined interval, and the bent angle of the bent portions is preferably in the range of 50 ° ± 20 °.
The zigzag rod-shaped fiber reinforced thermosetting resin molded article in which the bent portions are continuously formed at a predetermined interval and the bent angle of the bent portion is in the range of 50 ° ± 20 ° is formed on the outer side in contact with the bent portion. One side or both sides can be a planar composite reinforcing member having a zigzag rod-like fiber reinforced thermosetting resin molded product formed by joining linear reinforcing members, and a plurality of zigzag rods A three-dimensional composite reinforcing member can be obtained by combining planar reinforcing members on one side or both sides of the fiber-reinforced thermosetting resin molded product that are in contact with the respective bent portions.

Further, by joining the intersections of the lattice-shaped reinforcing members to the respective bent portions on the outer one side or both outer sides in contact with the respective bent portions of the plurality of zigzag rod-shaped fiber reinforced thermosetting resin molded products. The composite reinforcing member having a large space, light weight and excellent strength can be obtained.

In the present invention, a rod-like zigzag fiber-reinforced resin molded product can be obtained continuously and efficiently. By combining this rod-like zigzag-shaped fiber-reinforced thermosetting resin molded product with other reinforcing members, in particular, fiber-reinforced resin molded products, various shapes of FRP reinforcing materials can be obtained. Fiber-reinforced thermosetting resin molding zigzag, since enhanced continuously in the axial direction the fibers extend, when a composite reinforcement member, vertical, horizontal, diagonal, to pressure from any direction Has the strength to withstand. FRP reinforcement is superior in terms of weight reduction and rust resistance of the reinforcement, such as a structural reinforcement instead of steel, a panel reinforcement, a water gutter, and a precast floor for concrete placement. It is useful as a reinforcing material for materials.

  The matrix resin used in the present invention is a thermosetting resin such as unsaturated polyester resin, epoxy or phenol resin, and the reinforcing substrate is glass fiber, aramid fiber, carbon fiber or the like, and these are fiber bundles (rovings). ), But can also be used in combination with a cloth or chop strand mat for reinforcement and prevention of vertical cracks. The content of reinforcing fibers extending continuously in the axial direction is 50 to 80% by weight. The reinforcing fiber extending in the axial direction of the fiber bundle (roving) can be arbitrarily selected and set in consideration of the diameter of the rod-shaped molded product, the bending angle, etc., but preferably the count is 1000 to 10,000 tex, the filament diameter is 7 to 50 μm. A fiber bundle can be used, and this fiber bundle is used by combining an arbitrary number of yarns.

In the method of manufacturing the zigzag rod-shaped fiber reinforced thermosetting resin molded article of the present invention, the reinforcing fiber bundle is impregnated with the thermosetting resin, pulled out through the forming nozzle, and the thermosetting resin is supplied onto the belt conveyor. . On the belt that moves along the pulling direction, plural pins stand upright in two rows, the pins in each row are shifted by a half pitch in the pulling direction, and the two rows of pins are arranged in a zigzag manner. Is provided so as to pass through the curing furnace. The thermosetting resin impregnated with the reinforcing fiber bundle is supplied onto the belt conveyor by reciprocating the shaping nozzle in a direction relatively perpendicular to the two rows of pins on the moving belt. The curable resin is alternately applied to the two rows of pins, and is cured in a state where the pins are zigzag on the pins in a curing furnace.

The manufacturing process will be described in more detail with reference to FIG. 1 schematically showing the manufacturing process.
The fiber bundle 1 is impregnated with a polyester resin or the like in the impregnation tank 2 and is supplied onto the belt conveyor 5 through a nozzle 4 (not shown) provided in the shaping device 3. On the upper surface of the belt conveyor 5, as shown in FIG. 2, for one nozzle, pins 6 are provided in two rows alternately with an interval between the rows of pins being X and a pitch Y of the pins of each row. . The shaping device 3 reciprocates at predetermined positions so as to sew between the pins 6, the nozzle 4 passes through the outside of each pin 6, and the fiber bundle 1 impregnated with unsaturated polyester resin or the like is pinned. Hook to 6 in turn.

  This process will be further described with reference to FIGS. In this figure, the shaping apparatus 3 reciprocates at the same place. In (a), the shaping device 3 is hooking the fiber bundle 1 on the pin P5 and moving to the pin P6. In (b), the shaping device 3 is where the fiber bundle 1 is hooked on the pin P6 and moved to the pin P7. In (c), the shaping device 3 is moving to the pin P8. In (d), the shaping device 3 is moved to the pin P7. A state where the fiber bundle 1 is hooked on P8 and waiting for the pin P9 to come is shown. The size of the pins provided on the belt conveyor 5 is related to the fiber bundle to be used and can be determined as appropriate. In practice, the pin diameter is 5 to 20 mm and the height is 10 to 50 mm. It is preferable to use it. The distance between the two rows of pins, the pitch of the pins in the row, and the moving speed of the belt conveyor can be appropriately determined in consideration of the shape and productivity of the molded product.

  The outline of the shaping apparatus 3 is shown in FIG. The shape of the hole of the nozzle 4 is such that the roving of the fiber bundle impregnated with the resin is swung to the left and right by the reciprocating motion of the shaping device 3, so that the opening is wide, unlike the shaping nozzle for ordinary pultrusion molding. In some cases, the nozzle can be bent as shown in FIGS. 4A and 4B so that the roving does not contact the pin before the shaping device. As a reciprocating mechanism of the shaping device 3, it can be reciprocated by an arbitrary means such as a hydraulic cylinder, a screw, a belt, and a chain in addition to an air cylinder.

  The fiber bundle 1 containing the resin hung in a zigzag manner on the upper surface of the belt conveyor 5 is cured while passing through the curing furnace 7, and the cured zigzag shaped product is detached from the belt conveyor and is predetermined by the cutter 8. Cut to length. The length of the curing zone can be set as appropriate, and the heat curing temperature is set between 100 and 180 ° C. A preferable range of the heating time is 2 to 10 minutes.

In the above description, an apparatus and a method for providing a pair of two rows of pins arranged in a zigzag manner on the belt conveyor have been described. However, in the present invention, a plurality of pairs of pins, each having two rows of pins. Are provided on a belt conveyor, and a plurality of zigzag rod-shaped fiber reinforced thermosetting resin molded products can be simultaneously obtained by simultaneously reciprocating a plurality of nozzles for supplying fiber bundles to each set of pins. .

FIG. 5A is a side view showing the bent portion 12 of the zigzag-shaped fiber-reinforced thermosetting resin molded product 11, and the bending angle α is determined considering the productivity related to the drawing speed, the strength of the product, and the like. The angle is preferably in the range of 50 ° ± 20 °. That is, when the bending angle α is small and 30 ° or less, the drawing speed decreases, which is not preferable in terms of productivity. In addition, when the bending angle α is large and 70 ° or more, it becomes difficult to maintain the bending angle with respect to pressurization, and the composite reinforcing member combined with other members is also inferior in crushing strength. Absent.

As shown in FIG. 5 (b), the linear reinforcing member 13 made of the same linear material or other resin, metal, etc. is formed into the bent portion 12 of the zigzag fiber-reinforced thermosetting resin molded product 11 shown in FIG. 5 (b). By attaching to one or both sides of the outer side by any means such as bonding, screwing, and tightening, a composite reinforcing member can be obtained, and the bending strength and pressing strength in the width direction during use can be increased. Further, although not shown, the linear reinforcing member 13 is changed to a planar reinforcing member, and a plurality of zigzag rod-shaped fiber reinforced thermosetting resin molded articles 11 are formed between the two planar reinforcing members. Are aligned in the vertical direction so that the bent portions 12 are in contact with the planar reinforcing member, and the zigzag rod-shaped fiber reinforced thermosetting resin molded article 11 is joined to the planar reinforcing member at the joining point to form a sandwich shape. When a composite reinforcing member is used, a reinforcing member that is lightweight and excellent in bending strength and pressing strength that reinforces a large area can be obtained. In particular, the reinforcing member of the present invention has excellent strength in the thickness direction because the reinforcing fibers are disposed obliquely in the thickness direction.

Further, as shown in FIG. 5 (c), a plurality of zigzag rod-like fiber reinforced thermosetting resin molded articles 11 obtained in the present invention are arranged in parallel, and the same lattice-like material or other resin is molded. The grid intersection 15 of the grid-like reinforcing member 14 such as a body, a metal grid, etc. is arbitrarily bonded to the outside of the bent portion 12 of the zigzag rod-shaped fiber-reinforced thermosetting resin molded article 11 with an appropriate adhesive, screwed, tightened, etc. It can attach by the means of and can be set as a composite reinforcement member.
In addition, in FIG.5 (c), although the description of the lattice-shaped reinforcement material attached to the outer side of the bending part 12 of the lower side of the rod-shaped fiber reinforced thermosetting resin molded article 11 in drawing is abbreviate | omitted, it is not only one side. It is preferable to arrange the zigzag rod-shaped fiber reinforced thermosetting resin molded product 11 between the two lattice-like reinforcing members 14.
As a lattice-shaped member, a lattice-shaped reinforcing base member composed of a fiber-reinforced plastic fiber bundle and a fiber-reinforced plastic rod described in the above-mentioned Japanese Patent No. 3284800 invented by the present applicant is used as a lattice-shaped reinforcing member. If used, the reinforcing fibers are arranged in all the vertical, horizontal, and diagonal directions, so it is extremely strong in strength, and it can be used as a reinforcing member for a rectangular parallelepiped of any shape and size. I can do it.

EXAMPLES Hereinafter, although an Example demonstrates this invention concretely, this invention is not limited to this range.
A glass fiber roving was prepared by combining 4400 tex, a glass fiber bundle having a filament diameter of 25 μm, and 15 bundles. Glass roving is a resin comprising 100 parts by weight of unsaturated polyester resin (Dainippon Ink & Chemicals, trade name Polylite HN-131) and 1 part by weight of a curing agent (trade name Percure HO, made by Nippon Oil & Fats Co., Ltd.). And was subjected to pultrusion molding by the following method. The principal part of the apparatus used for pultrusion is shown in FIGS.

In this embodiment, five nozzle holes for supplying a glass fiber bundle impregnated with resin are provided, and a set of five pins is arranged on the belt conveyor in a direction perpendicular to the traveling direction of the belt conveyor. Arranged in a row, 5 rows of pins are arranged in 2 rows on the belt conveyor, and each row is shifted by a half pitch with respect to the drawing direction so that 5 zigzag shaped molded products can be obtained at the same time. is there.
The glass fiber bundle 101 impregnated with the resin is hung from a shaping device 103 onto a pin 106 provided on a belt conveyor 105 as shown in FIG. As shown in FIG. 7, the shaping device 103 reciprocated by the air cylinder 109 is provided with five nozzles 104 (not shown), and the glass fiber bundle 101 is simultaneously supplied to the five pins 106. . An arrangement of five sets of pins provided on the belt conveyor 105 is shown in FIG. From the rightmost nozzle of the shaping device 103 shown in FIG. 7 to the uppermost pin of the pin P101 to the uppermost pin of the pin P102 and from the uppermost pin of the pin P102 to the pin P103 in FIG. A glass fiber bundle is hung on the pins in the same manner from the other four nozzles at the same time by being hung on the uppermost pin, and at the same time, five zigzag rod-shaped molded articles are formed on the belt conveyor, A molded product is obtained by the process shown in FIG.

  The glass roving impregnated with the unsaturated polyester resin was passed through a shaping nozzle having a hole with an inner diameter of φ8 mm, and the tip of the resin-impregnated glass roving was attached to a pull-out pin to start drawing. Pin diameter φ8mm, pin height 30mm, spacing X in the direction perpendicular to the pulling direction of pins P101 and P102 is 190mm, pitch Y in the pulling direction of pins in each row such as pin P101 and pin P103 is 200mm, shaping The apparatus was reciprocated with a width of 220 mm, that is, with a width of 15 mm outward from the center line of each pin. The length of the curing zone was 4 m, the heat curing temperature was 150 ° C., the drawing speed was 1 m / min, and a zigzag pultruded product with a glass content of 70% by weight was obtained and cut into a length of 6 m. The diameter of the molded product was almost the same as the nozzle diameter of the shaping device, and the average diameter was 8 mm.

The rod-like zigzag fiber-reinforced thermosetting resin molded article of the present invention can be combined with reinforcing members such as other fiber-reinforced resin molded articles to obtain various shapes of FRP composite reinforcing materials. It is possible to arrange reinforcing fibers in all oblique directions, which is extremely excellent in strength. Moreover, if it is used as a cubic reinforcing member, it has a large space in the reinforcing material and is excellent in terms of weight reduction, rust resistance, etc. of the reinforcing material, structural reinforcing material instead of steel, panel reinforcing material, water It is useful as a reinforcing material for surrounding fences and precast flooring for concrete placement.

It is explanatory drawing which shows the process of manufacturing the zigzag-shaped fiber reinforced thermosetting resin molded product of this invention. It is a perspective view which shows the arrangement | sequence of the pin on the belt conveyor of FIG. (A)-(d) is explanatory drawing which shows the process of hanging a resin impregnation fiber base material on the pin on the belt conveyor of FIG. (A) is a front view which shows an example of a nozzle, (b) is a side view. (A) is a figure which shows the zigzag rod-shaped fiber reinforced thermosetting resin molded product of this invention, (b) is the reinforcing material formed by couple | bonding two rod-shaped reinforcement members to the molded product of (a). The figure shown, (c) is explanatory drawing which shows the state which couple | bonds a grid | lattice-shaped reinforcement member with the intersection of a grid | lattice-shaped reinforcement member with the molded product of (a) of two. It is explanatory drawing which shows a part of process of manufacturing simultaneously several zigzag-shaped fiber reinforced thermosetting resin molded products. It is explanatory drawing which shows a part of process of manufacturing simultaneously several zigzag-shaped fiber reinforced thermosetting resin molded products. It is explanatory drawing which shows the arrangement | sequence of the pin on the belt conveyor of FIG.

DESCRIPTION OF SYMBOLS 1,101 Fiber bundle 2,102 Impregnation tank 3,103 Shaping device 4,104 Nozzle 5,105 Belt conveyor 6,106 Pin 7 Curing furnace 8 Cutter 11 Zigzag-shaped fiber reinforced thermosetting resin molded product 12 Bending part 13 Linear reinforcing member 14 Lattice reinforcing member 15 Lattice intersection 109 Air cylinder α Bending angle P1 to P10, P101 to P110 Pin

Claims (1)

  In the manufacturing method of a pultruded molded body obtained by impregnating a reinforcing fiber bundle with a thermosetting resin, drawing through a shaping nozzle, and curing the thermosetting resin in a cured area to obtain a long molded body. A plurality of pins are aligned in two rows at predetermined intervals, and the two rows of pins are arranged in a zigzag manner so that the two rows of pins are moved. Zigzag drawn thermosetting, characterized by reciprocating in the direction perpendicular to the drawing direction relative to the pins and alternately curing the thermosetting resin containing the reinforcing fiber bundles on the two rows of pins Manufacturing method of resin molded product.

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