JP4597111B2 - Method for producing thermosetting FRP - Google Patents

Description

  The present invention relates to a method for producing a thermosetting FRP.

A technique is known in which a plurality of FRP (Fiber Reinforced Plastic) sheets called prepregs impregnated with a thermosetting adhesive resin are laminated and a composite material is manufactured by hot pressing.
This composite material is manufactured, for example, as a long channel material, and is used by cutting to a required length. A channel material made of a composite material is a lightweight and high-strength material, and the channel material is often joined to another panel or the like to constitute a structure.

FIG. 6 is an explanatory view showing a general hot press process of a thermosetting FRP.
As shown in FIG. 5, the FRP sheet 1 used for the material is made by weaving the weft yarns 10 and warp yarns 20 of the FRP fiber into a plain weave as shown in FIG. 5 (a), or as shown in FIG. The fabric sheet 1 is tilted.
The fabric sheet 1 has a gap 30 at the intersection of the weft 10 and the warp 20, and the gap 30 is impregnated with a thermosetting resin to obtain a prepreg sheet 2.

As shown in FIG. 7, release films 50 and 60 are stacked on the front and back surfaces of the prepreg sheet 2 and sandwiched between an upper die 70 and a lower die 80 of a hot press as shown in FIG. Heat and pressurize for hours.
The curing temperature of the thermosetting resin 40 is selected to be about 120 ° C to 130 ° C.
The release films 50 and 60 are for preventing the thermosetting resin 40 extruded from the prepreg sheet 2 from adhering to the surface of the press molds 70 and 80, and the softening temperature is the thermosetting resin. The one having a temperature of about 260 ° C. higher than the curing temperature is used.
When the hot pressing is completed, the release film is peeled off to complete the product 3. The surfaces 3a and 3b of the product 3 form a smooth surface.

FIG. 9 shows the channel material manufactured in this way, and constitutes a U-shaped channel material having three surfaces 3a, 3b, 3c.
This type of channel material is often joined to another sheet material or panel material to constitute a structure. In such a case, it is desirable to have fine irregularities on the surface of the product in order to improve adhesion.
The process of giving a concavo-convex pattern to the surface of a resin product is known as so-called embossing.

The following patent document discloses this kind of embossing.
JP-A-6-122143

The technique disclosed in the above-described patent document is to impart a texture pattern to the surface of a molded article using a transfer film having a texture pattern.
The present invention provides a method for producing a thermosetting FRP product having a texture pattern that does not require a transfer film.

The method for producing a thermosetting FRP of the present invention is a method for producing an FRP product by subjecting a prepreg sheet obtained by impregnating a reinforced fiber fabric sheet with a thermosetting resin to produce an FRP product. molds for machining, between at least one, by using the release film laminate and the adhesive film was laminated between two release films, the release film by heating the hot press softening said adhesive film is softened without let, by the previous hot pressing pressurized KiHanare type film laminate presses the thermosetting resin impregnated in the prepreg sheet, the thermosetting resin The upper surface is made lower than the reinforcing fiber, and a texture pattern is formed on the surface of the FRP product .

  As described above, the present invention can form a texture pattern on the surface of an FRP product without using a transfer film or the like. Thus, the adhesion with other members can be improved.

FIG. 1 is an explanatory view showing the production method of the present invention.
The structure of the FRP sheet 2 of the prepreg that is also a processing target according to the present invention is the same as that of the above-described conventional one.
The release film laminate 100 used in the present invention has a structure in which an adhesive film 130 is laminated between two release films 110 and 120.
As the two release films 110 and 120, for example, those having a softening temperature of 260 ° C. are used. For example, the adhesive film 130 having a softening temperature of 120 ° C. is used. That is, the softening temperature of the adhesive film 130 has a softening temperature close to the thermosetting temperature of the resin 40 impregnated in the FRP sheet of the prepreg material.

As shown in FIG. 2, this release film laminated body 100 is piled up on the surface of the prepreg sheet 2 to be subjected to the texturing, and hot pressing is performed.
When heated to about 120 ° C. by hot pressing, the adhesive film 130 inside the release film laminate 100 is softened.
When pressure is applied by the press, the part of the release film laminate 100 in contact with the high hardness FRP fiber 20 is pressed to form a recess. The other part of the release film laminate 100 presses the thermosetting resin impregnated in the prepreg sheet to give a step to the fiber part.

FIG. 3 is an explanatory view showing the structure of the FRP product 3a that has been thermally cured by hot pressing.
On the surface on the side subjected to hot pressing with the release film laminate 100 interposed therebetween, the position of the upper surface 42 of the thermosetting resin 40 is lowered with respect to the two upper surfaces of the fibers 20 to form a recess. Therefore, the fiber 20 and the resin 40 form a so-called wrinkle pattern 150.

FIG. 4 shows the channel material 5 manufactured by the above-described process, and a channel material having a U-shaped cross section having three surfaces 5a, 5b, and 5c is manufactured.
In the channel material 5, a texture pattern is formed on both surfaces of the three surfaces 3a, 3b, and 3c. In this case, hot pressing is performed with the release film laminate 100 of the present invention interposed on both surfaces of the prepreg material.
By forming a texture pattern on the surface of the FRP product, the appearance is improved and the adhesion to other members is also improved.

Explanatory drawing which shows the manufacturing method of this invention. Explanatory drawing which shows the manufacturing method of this invention. Explanatory drawing of the FRP product by this invention. Explanatory drawing of the FRP channel material by this invention. Explanatory drawing of a FRP fabric. Explanatory drawing which shows the conventional manufacturing method. Explanatory drawing which shows the conventional manufacturing method. Explanatory drawing of the conventional FRP product. Explanatory drawing of the conventional channel material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 FRP fabric 2 Prepreg material 5 Channel material 10 Weft 20 Warp 40 Thermosetting resin 50,60 Release film 70 Upper mold of hot press 80 Lower mold of hot press 100 Release film laminated body 110,120 Release film 130 Adhesive film

Claims (1)

A method of manufacturing an FRP product by hot-pressing a prepreg sheet obtained by impregnating a reinforced fiber fabric sheet with a thermosetting resin,
Between at least one of the prepreg sheet and the hot pressing mold, a release film laminate in which an adhesive film is laminated between two release films,
Wherein said release film by heating the hot press to soften the adhesive film without causing softening, wherein the heat-curable KiHanare type film laminate prior to the hot pressing pressurizing is impregnated in the prepreg sheet By pressing the resin, the upper surface of the thermosetting resin is lowered with respect to the reinforcing fiber,
A method for producing a thermosetting FRP in which a texture pattern is formed on the surface of an FRP product.

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