JP4941811B2 - Manufacturing method of preform and FRP molded body - Google Patents

Description

The present invention relates to a preform and a method for producing FRP (fiber reinforced plastics), and in particular, a preform having a curved or bent surface, a plate-like body having a curved or bent surface, and a reinforcing fiber preform. preforms with integrated, FRP molded body formed by impregnating and curing the resin on their preforms, easily and inexpensively, yet about the possible production methods with high quality.

  As is well known, FRP is attracting attention in various industrial fields as a lightweight and high-strength material. In particular, the application has been expanded as structures in various fields such as vehicles, ships, aircraft, and building materials, and is a material that is expected to expand further in the future.

  In particular, an FRP structure that is subjected to a high load is a plate-like member or the like and a stringer member that reinforces the plate-like member (hereinafter also referred to as a “reinforcement member”. It is often molded as an integral structure. In a method of manufacturing an FRP molded body composed of a base material such as a plate-like member and a stringer that reinforces the base material, a method of mechanically connecting the base material and the stringer using a rivet or the like is widely used. However, this method has many problems in terms of manufacturing cost and weight. On the other hand, the method of joining each member with an adhesive is also widely used, but the interlayer strength on the adhesive surface is not sufficient, and there is a problem in quality assurance and manufacturing cost when applied on a wide adhesive surface. .

  Further, in the method described in Patent Document 1, two members are integrated by impregnating a thermosetting resin into a previously cured member (for example, a stringer member) and a dry preform member (for example, a base preform). It tries to become.

  When preparing the stringer member as a previously cured member, as in the method described in Patent Document 1, there is a change in the surface position due to a change in thickness, etc., particularly on the base material side on which the stringer member is to be placed. If there is, the stringer member must be pre-formed into a shape corresponding to the change, and if the change shape is different, it can no longer be applied to the formed body.

  It is also conceivable that the stringer preform is pre-shaped into a shape corresponding to the change in the shape of the substrate surface as described above at the stage of preforming the reinforcing fiber before resin impregnation for FRP molding. However, stringer preforms corresponding to changes in the surface shape on the substrate side must be formed, and the individual stringer preforms have fixed dimensions, and are not versatile. In addition, each stringer preform must be shaped according to the surface shape of the FRP molded product to be finally molded, which is difficult to automate and makes stringer preforms expensive to manufacture. Become. Also, if a straight stringer preform fixed with stitches or the like is bent in advance in accordance with the change in the surface shape or the like, the reinforcing fibers will be bent, disconnected, meandered, etc. due to restraint by the stitch yarn at the time of bending. Sometimes. Furthermore, it is difficult to adapt the stringer preform to a steep change, and filling a reinforcing fiber material or the like in a location where the stringer preform cannot be accommodated increases the overall weight.

  For example, Patent Document 2 discloses a method of forming a reinforcing member using a mandrel made of an elastic material. Patent Document 3 discloses a method of forming an outer plate and a reinforcing member by a vacuum RTM (Resin Transfer Molding) method using a mandrel made of a rigid material or silicone. Furthermore, Patent Literature 4 and Patent Literature 5 disclose a method in which a reinforcing fiber preform is formed into a desired shape in advance and then cured.

  As described in Patent Documents 2 and 3, when molding is performed using a mandrel made of an elastic material, the mandrel is elastically deformed. Therefore, it is not necessary to process the mandrel into a complicated shape, and a straight mandrel is formed. It seems to be good to use. However, since elastic materials are easily deformed by pressure, there is a quality problem that the dimensional stability during molding is poor. Furthermore, the elastic material has a high coefficient of thermal expansion, and in thermoforming, since the mandrel expands greatly, it is difficult to produce a molded product having a desired dimension.

  In addition, as described in Patent Document 4 and Patent Document 5, an FRP reinforcing member that is curved or bent in the axial direction is manufactured using a fiber reinforced preform that has been molded into a required three-dimensional shape. It is also possible to do. However, in this case as well, if a preform with a shape applied in advance is manufactured, as described above, it is necessary to manufacture a plurality of types of preforms, which increases the manufacturing cost of the preform.

And when it is necessary to use multiple types of preforms and mandrels as in these methods, there is also a problem that the manufacturing process becomes complicated.
Japanese Patent No. 3320051 Japanese Patent Laid-Open No. 5-116162 US Patent Application Publication No. 2003/0019567 JP-A 64-52845 JP 2003-286539 A

Accordingly, an object of the present invention is to use a straight stringer preform having a predetermined cross-sectional shape that can be easily mass-produced, for example, and having a surface shape that changes, that is, a plate shape having a curved or bent surface It is possible to easily conform to the body without causing problems, and the target FRP molded body can be manufactured with high quality without causing an unnecessary increase in weight at low cost and efficiently. An object of the present invention is to provide a method for producing a preform and an FRP molded body.

In addition, the object of the present invention is to solve the above-mentioned problems of the prior art, and to curb or bend the FRP reinforcing member itself that is curved or bent in the axial direction with high dimensional accuracy while reducing cost. An object of the present invention is to provide a preform capable of producing an FRP structure integrated with a plate-like body having a surface, and a method for producing an FRP molded body.

In order to solve the above-described problem, a method for producing a preform according to the present invention has a curved or bent surface on the surface of a plate-like body made of any of a mold, a reinforcing fiber, and FRP . A reinforcing fiber preform for a stringer made of a laminate of reinforcing fiber materials dispersed and applied with a resin composition containing a thermoplastic resin as a main component at least on one side is disposed, and a plurality of reinforcing fiber preforms are arranged along the reinforcing fiber preform. By placing the divided mandrels , covering the whole with a sealing medium, and depressurizing the inside of the sealing medium, atmospheric pressure is applied to the reinforcing fiber preform, and the reinforcing fiber preform is placed on the plate-like body. It consists of a method characterized in that it is deformed along the surface and brought into close contact with the plate-like body and heated, or heated after being brought into close contact . That is, it is a method of manufacturing a stringer preform (preform for reinforcing member) itself having a curved or bent surface.

In addition, the method for producing an FRP molded body according to the present invention includes a thermoplastic resin on at least one surface of the plate-shaped body that has a curved or bent surface and is made of any of a mold, a reinforcing fiber, and FRP . A reinforcing fiber preform for a stringer made of a laminate of reinforcing fiber materials to which a resin composition containing a resin as a main component is dispersed and disposed, and a mandrel divided into a plurality of pieces along the reinforcing fiber preform. By placing and covering the whole with a sealing medium and reducing the pressure inside the sealing medium , the reinforcing fiber preform is loaded with atmospheric pressure so that the reinforcing fiber preform is along the surface of the plate-like body. is deformed into close contact with the plate-like body and Rutotomoni heated or warmed to after adhesion, the resin to the reinforcing fiber preforms in close contact with the plate-like body with internal pressure has been reduced thereafter Consists method characterized by molding the FRP by entering. In other words, this is a method of manufacturing an FRP stringer (FRP reinforcing member) itself having a curved or bent surface.

Furthermore, the manufacturing method of the FRP molded body according to the present invention reinforces the plate-shaped body when manufacturing the FRP molded body in which a stringer is provided on the surface of the plate-shaped body having a curved or bent surface. For the stringer comprising a laminate of reinforcing fiber materials composed of any one of fiber and FRP, and having a resin composition containing a thermoplastic resin as a main component dispersed on at least one surface of the plate-like body. The reinforcing fiber preform is arranged, a mandrel divided into a plurality of pieces is arranged along the stringer reinforcing fiber preform, the whole is covered with a sealing medium, and the inside of the sealing medium is decompressed, Rutoto deformed so by close contact with the plate-like body along the load reinforced fiber preform for the stringer atmospheric pressure to the reinforcing fiber preform for the stringer on the surface of the plate-like body It warmed to after heating, or contact made at inside thereof is depressurized thereafter, to mold the FRP by injecting at least the plate-like body in contact resinous reinforcing fiber preform for the stringers It consists of a characteristic method. That is, it is a method of manufacturing an FRP molded body provided with an FRP stringer (FRP reinforcing member) having a curved or bent surface. Also in this method, the plate-like body can be made of a reinforcing fiber, or the plate-like body can be made of another material such as FRP, steel, aluminum, or invar.

  In the preform and FRP molded body manufacturing method according to the present invention as described above, the shape of the reinforcing fiber preform before being deformed along the surface of the plate-like body is from a shape extending straight. It is preferable to become. The straight fiber reinforced preform can be easily mass-produced at low cost, and it is possible to produce a preform and FRP molded body having a predetermined target shape efficiently and accurately using the preform.

Further, the resin composition, it is preferably dispersed granted in the range of 0.1 to 30 wt% relative to the reinforcing fiber material.

  The reinforcing fiber of the reinforcing fiber preform is not particularly limited, but the present invention is particularly effective when carbon fiber is included.

  The method according to the present invention can sufficiently cope with a case where the surface of the plate-like body includes a portion having an inclination in a range of 1/10 to 1/200.

  The method according to the present invention can sufficiently cope with a case where the surface of the plate-like body includes a portion having a surface displacement of 5 mm or less in the thickness direction.

In the method as described above according to the present invention, as the mandrel, it is also possible to use those having a shape along the shape of the surface of the plate-like body, the reinforcing fiber preforms of the plate-like body to deform along the surface, it is possible to use those which are divided into a plurality. When a mandrel divided into a plurality of parts is used, the mandrel itself can be manufactured easily and inexpensively, and it is possible to improve the handleability during molding and increase the degree of freedom, which is particularly preferable. .

  Moreover, when using the said mandrel divided | segmented into plurality, it is preferable to arrange | position the mandrel divided | segmented into plurality to a reinforcement fiber preform so that a space | gap may arise between adjacent mandrels.

  Further, it is preferable to provide a gap fixing means between the mandrels and maintain the size of the gap between the mandrels in a certain range by the gap fixing means. As the gap fixing means, for example, a spacer member can be arranged.

  In this case, the contact area between the spacer member and the mandrel is preferably ½ or less of the cross-sectional area of the mandrel. Further, the spacer member preferably has a curved contact surface with the mandrel. Moreover, it is also preferable to provide a convex part in a spacer member and to provide the said mandrel with the recessed part fitted to this convex part. Further, the spacer member and the mandrel can be integrated.

  Further, the gap fixing means may be a connecting member that movably connects the mandrels divided into a plurality of parts, and the connecting member maintains the size of the gap between the mandrels within a certain range.

  Further, when the mandrel divided into a plurality of pieces as described above is a rectangular parallelepiped, the height of the rectangular parallelepiped is H, the deformation height of the curved or bent surface of the plate-like body is T, and the deformation length is When L is set, the size of the gap between the mandrels is preferably set to H × T / L or more.

  In the method for producing an FRP molded body as described above, when molding the inside of the sealed medium by reducing the pressure, a resin is put inside the sealed medium by utilizing a differential pressure between the internal pressure of the sealed medium and the atmospheric pressure. The FRP is preferably molded by pouring and curing the resin.

  In such a method for producing a preform or FRP molded body according to the present invention, the reinforcing fiber preform is, for example, a crossing selected from I type, T type, C type, L type, Z type, and J type. It can be formed to have a surface shape.

Preform definitive to the present invention consists of those produced by the method as described above. Also, FRP molded definitive to the present invention consists of those produced by the method as described above.

  According to the present invention, for example, a straight stringer preform having a predetermined constant cross-sectional shape is used, and it can be appropriately deformed without difficulty so as to be brought into close contact with the curved or bent surface of the plate-like body. Become. Since it is possible to use a straight stringer preform that can be easily mass-produced without adapting to the shape of each molded body, it is possible to reduce the cost of manufacturing a preform and, consequently, an FRP molded body.

  Moreover, since it becomes possible to cope with a steep thickness change, the weight of the preform, and thus the FRP molded body, can be reduced.

  In addition, the stringer preform can be adhered well along the surface shape of the plate-like body, and even if there is a thickness change etc. on the plate-like body side, it can be absorbed well. Obtainable.

  In addition, if a mandrel is used, especially a mandrel divided into a plurality of parts, the mandrel configuration and manufacturing process can be simplified while improving the dimensional accuracy, and the curve is bent or bent in the axial direction at a reduced cost. A reformed and FRP molded product can be easily and accurately manufactured.

In the following, the present invention will be described in more detail with preferred embodiments.
FIG. 1 shows a method for manufacturing a preform according to an embodiment of the present invention. FIG. 1 shows an example of a stringer part having an I-shaped cross-sectional shape integrated with a flat base material part as a plate-like body having a curved or bent surface (hereinafter also referred to as a first surface). The case where the preform for the FRP molded body to be molded is manufactured is shown. In this embodiment, the case where the preform for the FRP molded body in which the plate-like body and the stringer part are integrated is shown, but the present embodiment can be applied to the case where only the stringer part preform is manufactured. The method according to can be similarly applied. In FIG. 1, as shown in FIG. 1A, reference numeral 1 denotes a stringer preform made of reinforcing fibers and having a cross-sectional shape extending straight I-shaped. Such a straight stringer preform 1 can be easily shaped and can be easily mass-produced.

  With respect to such a straight stringer preform 1, in this embodiment, as shown in FIG. 1B, the straight stringer preform 1 is bent into a shape that conforms to the shape of the first surface of the base material described later (particularly, a flat plate). A mandrel 2 is prepared which is bent in accordance with the thickness change of the substrate. A pair (two) of the mandrels 2 are prepared. As shown in FIG. 1C, the mandrels 2 are mounted in the I-types on both sides of the stringer preform 1 having the I-shaped cross section, The combined body 3 is in a combined state with the mandrel 2. In this combination 3, the stringer preform 1 is still in a straight state, and between the mandrels 2 mounted in the type I and the upper and lower inner surfaces of the stringer preform 1, The gap is intermittently formed corresponding to the bending.

  As shown in FIG. 1D, the thickness changes on the lower mold a4 (the surface plate in this example) (the position of the first surface 5a, which is the upper surface of the figure) changes in the plane direction. ) A flat substrate preform 5 as a plate-like body is arranged, and the above-mentioned combination 3 is arranged thereon, and these are entirely covered with a bag material 6 and the periphery thereof is sealed with a sealing material 7 so that the inside is sealed. Sealed. Through these series of operations, preparation for preform shaping (molding) is completed. At this stage, the stringer preform 1 is still in a straight state, and intermittently between the lower surface of the stringer preform 1 and the upper surface of the base material preform 5 whose surface position is changed. A gap is formed in

  Then, as shown in FIG. 1 (E), the stringer preform 1 that has been extended straight due to the decompression and the shrinkage of the bag material 6 is reduced to the surface position. Is deformed along the shape of the upper surface of the substrate preform 5 and the shape of the mandrel 2 having the same shape and attached to both sides, and is closely attached to the upper surface of the substrate preform 5 and the mandrel 2 The At this time, as shown in the drawing, when a heating step with heating is used in combination, the stringer preform 1 is more easily along the desired shape. In particular, as will be described later, when the stringer preform 1 is composed of a laminate of reinforcing fiber materials, and the resin composition mainly composed of a thermoplastic resin is dispersed and applied to the reinforcing fiber materials, the resin composition Is appropriately softened or melted, and it is possible to satisfactorily follow the above-mentioned surface change shape while maintaining the laminated form.

  In this way, the stringer preform 1 is in good contact with the base material preform 5 in a shape along the surface shape of the base material preform 5, and a target FRP molding preform is formed. Since the straight stringer preform 1 is used and bent along the surface of the base material preform 5 by bending or the like, it is easy to manufacture a preform having a target shape, and the cost can be reduced. That is, a straight stringer preform 1 having the same cross-sectional shape may be manufactured and subjected to a preform manufacturing process as shown in FIG. 1, so that the stringer preform is previously formed into a predetermined shape by bending or the like. Compared to the method, the cost can be greatly reduced. In addition, since a desired preform can be formed on the base material preform 5 having a different surface shape by using the straight stringer preform 1 having the same cross-sectional shape, it becomes easy to continue and automate preform manufacturing. Therefore, further cost reduction can be achieved from this aspect. Furthermore, in this method, even when the surface of the base material preform 5 has a relatively steep surface inclination or thickness change as described above, it becomes possible to sufficiently cope with the cross section of the stringer preform 1. The required minimum size is sufficient, and since it is not necessary to fill an extra reinforcing fiber material between the stringer preform 1 and the base material preform 5, the overall weight can be reduced.

  Using the preform formed in this way, for example, as shown in FIG. 2, an FRP molded body is manufactured. In manufacturing the FRP molded body, the lower mold a4 and the like used for the preform formation may be used as they are, or may be molded using another mold. Further, the mandrel can be used as it is as a holding mold on both sides of the I-shaped cross section, and may be molded using another mold. Further, the bag material can be used as it is, and may be molded using another bag material.

  In the manufacturing method of the FRP molded body shown in FIG. 2, the stringer preform 1 shaped into the target bent shape as described above, and the substrate preform 5 in which the stringer preform 1 is closely adhered to the surface, A preform 11 having a predetermined shape is disposed on a flat plate-like lower mold b12, and as many other molds as necessary are disposed, and a resin diffusion medium 13 for favorably diffusing the resin. Further, a peel ply 14 for peeling after molding is disposed, the whole of which is covered with a bag material 15 and the periphery thereof is sealed with a sealing material 16 to seal the inside. After the sealed interior is depressurized by the vacuum pump 17, the FRP matrix resin accommodated in the resin pot 18 is injected, diffused through the resin diffusion medium 13, and the inside of the reinforcing fiber throughout the preform 11. Impregnated into. After the resin impregnation, the resin is cured at a predetermined temperature, removed from the mold, and peel peel 14 and resin diffusion medium 13 are peeled and removed as required, and a predetermined FRP molded body is taken out.

  As described above, since the stringer preform 1 is in good contact with the base material preform 5 at the stage of the preform 11 before FRP molding, the target final shape FRP molded body 21 as shown in FIG. Can be molded with high accuracy, and high-quality FRP can be obtained at low cost.

  In the above embodiment, an example of FRP molding by vacuuming using the bag material 15 has been shown. However, when the mandrel 2 is used as it is for FRP molding or has the same shape as the mandrel during FRP molding. When using the I-type cross-section holding mold, it is not always necessary to perform FRP molding by vacuuming using the bag material 15, and it is also possible to adopt a molding method by pressure injection of resin into a predetermined mold. is there.

  In the above embodiment, the stringer preform 1 itself and the FRP stringer molded using the stringer preform 1 are arranged with a plate-like member having the same shape as the substrate preform 5, and the plate-like member is formed at the molding stage. It can manufacture similarly by making it peel.

  In the present invention, the reinforcing fibers of the preform are not particularly limited, and examples thereof include inorganic fibers such as glass fibers, carbon fibers, aramid fibers, and other organic fibers. In particular, the present invention is effective when a reinforcing fiber that is likely to be bent, disconnected, or meandered when a stringer preform is bent is used. Especially, it is more preferable to use the reinforced fiber containing the carbon fiber which is excellent in the lightweight property as a structure, and intensity | strength.

  In addition, when the preform has a structure in which a plurality of layers of reinforcing fiber materials are stacked, a thermoplastic resin is mainly used on at least one surface from the viewpoint of improving the interlayer strength of the reinforcing fiber material of the molded product and stabilizing the dimensions of the preform. A structure in which a plurality of reinforcing fiber materials, to which the resin composition as a component is dispersed and applied, is stacked is preferable. In that case, it is desirable that the resin composition is dispersed and applied to the reinforcing fiber material in the range of 0.1 to 30% by weight, preferably 0.5 to 20% by weight. Strengthening the interlayer not only improves mechanical properties, but also has a preform tack function, and easily forms a preform with a high fiber content and excellent dimensional accuracy. Further, by improving the accuracy of the preform, it is possible to improve the mechanical properties of the FRP molded body and stabilize the dimensional accuracy. Also, as shown in FIG. 1 (E), by providing a preform heating step, the resin composition between the reinforcing fiber materials forming the preform is softened, and the stringer preform is easily attached to the surface of the base preform. The shape of the preform can be easily changed along the shape, so that the reinforcing fiber is less likely to bend, break, meander, etc., so that the target preform can be obtained more easily and better. As a result, the quality of the FRP molded product can be improved. Furthermore, it is preferable that the resin composition containing the thermoplastic resin as a main component is dispersed and applied between the stringer preform and the base material preform. By dispersing and imparting the resin composition between them, the effect of improving the bonding strength between the two parts can be obtained without hindering the flow of the matrix resin during FRP molding.

  Next, a method according to another embodiment of the present invention, particularly, a method for manufacturing an FRP molded body using a mandrel divided into a plurality of parts (in this embodiment, sometimes referred to as an FRP reinforcing member). One process is shown as a perspective view in FIG. FIG. 5 is a side view showing one step of the method of manufacturing the FRP reinforcing member according to this embodiment. FIG. 6 is a schematic configuration diagram showing a molding process in the method for manufacturing an FRP reinforcing member according to this embodiment.

  The present invention relates to a method of manufacturing an FRP reinforcing member 80 that is curved or bent in the axial direction as shown in FIG. 9, for example. Conventionally, for example, as shown in FIG. 8, reinforcing fibers are arranged in a desired shape in advance on a mandrel 70 that is originally bent to form a reinforcing member preform, and then impregnated with a resin. The FRP reinforcing member 80 as shown was manufactured. In the manufacturing method according to the present invention, first, for example, as shown in FIG. 5A, the plate-like body 31 having a surface curved or bent in the axial direction is reinforced on the curved surface or the bent surface. A member reinforcing fiber preform 32 is disposed, and mandrels 33 a to 33 c divided into a plurality of portions in the longitudinal direction are provided on the reinforcing fiber preform 32. Here, the mandrels 33a to 33c are divided in the longitudinal direction so as to correspond to the curved surface or the bent surface of the plate-like body 31, and are arranged so as to provide a gap between the adjacent mandrels. In addition, the mandrels 33a to 33c may be disposed side by side with the reinforcing fiber preform 32 disposed on the plate-like body 31 as described above, or the reinforcing fiber preform 32 of the plate-like body 31 may be disposed. It may be provided in advance with the reinforcing fiber preform 32 before being placed on top.

  Next, the entire reinforcing fiber preform 32 and mandrels 33a to 33c disposed on the plate-like body are covered with a sealing medium 43 such as a nylon bagging film as shown in FIG. At this time, a forming jig 37 is disposed above the reinforcing fiber preform 32, and a peel ply 35 and a resin diffusion medium 36 as a release material are disposed between the reinforcing fiber preform 32 and the mandrel 33. Then, the inside of the sealing medium 43 is depressurized by the vacuum pump 44. As a result, the atmospheric pressure is applied to the reinforcing fiber preform 32 and the mandrels 33a to 33c by the pressure difference between the pressure in the sealed medium 43 and the atmospheric pressure, and the mandrels 33a to 33c receive a load in the height direction. Then, the gap shape formed between the adjacent mandrels following the shape of the plate-like body 31 is deformed as shown in FIG. 5B, and the preform 32 follows the mandrels 33a to 33c and is axially oriented. Curved or bent. Thereafter, as shown in FIG. 6, a reinforcing member is formed by injecting, impregnating, and curing the resin 46 into the reinforcing fiber preform 32 using the pressure difference between the pressure in the sealed medium and the atmospheric pressure. At this time, VaRTM (Vacuum Assisted Resin Transfer Molding) molding method is preferable from the viewpoint of cost.

  According to the present invention, a mandrel having a simple shape that is simply divided into a plurality of parts so as to be deformed along a curved surface or a bent surface of the plate-like body 31 is used. Therefore, it is necessary to manufacture a mandrel having a complicated shape. The initial cost can be reduced. In addition, in the case of a mandrel with a complicated shape, it was necessary to carry out a dimensional inspection periodically and to perform processing such as correction if deformation occurred, but since the mandrel configuration can be simplified, Management costs can also be reduced. Furthermore, since the material of the mandrel can be freely selected, the reinforcing member can be manufactured with high dimensional accuracy. Therefore, according to the present invention, the FRP reinforcing member can be obtained at low cost and with high dimensional accuracy.

  Further, according to the present invention, the reinforcing fiber preform 32 having a straight shape over the direction (axial direction) along the plate-like body 31 can be used. Conventionally, for example, it has been necessary to use a preform previously shaped into a desired shape, but in the case of the present invention, a reinforcing fiber preform 32 having a straight shape in a direction along the plate-like body 31 is used. However, since the reinforcing fiber preform 32 is deformed following the deformation of the mandrel, a straight reinforcing fiber preform can be used.

  In the present invention, the plate-like body 31 can be used as a mold as described above. In this case, FRP, steel, aluminum, invar, or the like can be used as the material. Further, when the plate-like body 31 and the reinforcing fiber preform 32 are finally integrated into a reinforcing member, it is preferable from the viewpoint of adhesion that the FRP is made of the same material as the reinforcing fiber preform 32.

  The material of the mandrels 33a to 33c is not particularly limited. For example, it is preferable to use a rigid material such as aluminum, invar, steel, or aluminum from the viewpoint of stabilizing the dimensional accuracy. In the case of thermoforming, it is more preferable to use a material having a low coefficient of thermal expansion such as Invar or CFRP in view of the influence of thermal expansion.

  And in the aspect mentioned above, although the rectangular parallelepiped mandrel is used as the mandrels 33a-33c and it arrange | positions so that a space | gap may be provided between adjacent mandrels, the magnitude | size of this space | gap is a fixed range. It is preferable to control to be within. When the height of the rectangular parallelepiped mandrel is H, the deformation height of the curved or bent surface of the plate-like body 1 is T, and the deformation length is L, the size of the gap is H × T / L or more. It is preferable to set to. Here, the size of the gap is the length in the longitudinal direction of the plate-like body 31, and the height H of the mandrel is the length in the direction perpendicular to the longitudinal direction of the plate-like body 31. Further, the deformation height T and the deformation length L of the curved or bent surface are the height and length of the non-planar portion of the plate-like body 31, and are perpendicular to the longitudinal direction of the plate-like body 31. The length in the long direction, and the length in the longitudinal direction of the plate-like body 31. By setting the size of the gap 4 to be equal to or higher than H × T / L, the mandrel can easily follow in accordance with the deformed portion, and the reinforcing fiber preform 32 can be deformed with higher accuracy. The size of the gap is more preferably 10 mm or less. When the gap between the mandrels is too large, the reinforcing fibers of the reinforcing fiber preform 32 are likely to enter the gap. In this case, after forming the FRP reinforcing member, irregularities are generated on the surface, and the surface smoothness is lowered. Further, the reinforcing fiber is locally bent, and the strength of the FRP reinforcing member is likely to be lowered.

  And in order to make the magnitude | size of a space | gap in a fixed range in this way, as shown in FIG. 7, it is preferable to provide space | gap fixing means, such as the spacer member 50 and the connection member 60, between mandrels. 7 (a) and 7 (b) show that the spacer member 50 is arranged between the mandrels and the size of the gap is maintained within a certain range, thereby enabling molding with stable dimensional accuracy. It becomes.

  The spacer member 50 may be made of a deformable material such as an elastic member such as silicone. For example, a rigid member such as aluminum, steel, FRP, or invar is used, and the contact area between the spacer member and the mandrel is used. Can be made ½ or less of the cross-sectional area of the mandrel, and the mandrel can be deformed with the spacer member 50 as a fulcrum.

  The shape of the spacer member 50 is not particularly limited, and the surface in contact with the mandrel may be a flat surface or a curved surface. However, the deformation of the mandrel can be smoothed by using the curved surface. Accuracy can be stabilized. The spacer member 50 may be integrated with the mandrel. Since the spacer member 50 is integrated with the mandrel, the position of the spacer is fixed, so that the gap between the mandrels can be stably controlled, and the dimensional accuracy of the FRP reinforcing member can be stabilized.

  Further, as shown in FIG. 7C, for example, a convex portion 51 may be provided on the spacer member 50, and a concave portion 52 (fitting hole) that fits into the convex portion may be provided on an adjacent mandrel. By fitting in this way, the relative positional accuracy between mandrels can be improved, and the dimensional accuracy of the FRP reinforcing member can be improved.

  Further, as a gap fixing means between the mandrels, a connecting member 60 as shown in FIG. By connecting the adjacent mandrels movably by the connecting member 60, not only the size of the gap between the mandrels is controlled, but also the relative positional accuracy between the mandrels is improved. Moreover, since the mandrel can be easily deformed by a load of atmospheric pressure by making the connecting portion movable, an FRP reinforcing member with higher dimensional accuracy can be obtained.

  Next, an embodiment in the case of using a mandrel divided into a plurality of parts as described above will be described.

<Example 1>
A reinforcing fiber preform having an I-shaped cross section was shaped by the following means. First, a reinforced fiber base material obtained by dispersing and imparting toughening particles made of polyethersulfone (PES) and epoxy to a unidirectional woven fabric of carbon fiber (T800S manufactured by Toray Industries, Inc.) is cut into a quasi-isotropic orientation. 8ply laminated, shaped along the three sides of the R-processed rectangular parallelepiped mandrel with a cross section of 100mm x 50mm, length of 500mm, and each corner 5mm in diameter so that no wrinkles occur. After sealing and evacuating, it was heated at 60 ° C. for 1 hour to form a C-type preform. Two of these were formed, and the obtained two C-shaped preforms were back-to-back with each other, and a unidirectional woven fabric made of carbon fiber T800S manufactured by Toray Industries, Inc. was packed into the hollow portion formed in the curved surface portion between the two. Overlay the top and bottom surfaces of a C-shaped preform with back-to-back laminates of 100mm x 500mm made of carbon fiber fabric made by Toray Industries, Inc. with the same toughening particles dispersed and applied 8ply in a pseudo-isotropic manner, and again with a bagging film Sealed, evacuated, and heated at 60 ° C. for 1 hour to form an I-type reinforcing fiber reinforcing member preform having a straight shape in the longitudinal direction.

  Next, as shown in FIG. 5, the I-type reinforcing fiber preform having a straight shape in the longitudinal direction was placed on the bent surface of an aluminum plate-shaped jig (plate-shaped body) having a bent surface. Then, three aluminum cuboid mandrels having a cross-section of 100 mm × 50 mm and R-processed lengths of 200 mm, 100 mm, and 200 mm each having a diameter of 5 mm, each having a 1 mm gap at each bent portion of the plate-like jig. Was placed on a reinforced fiber preform. Next, using a nylon taffeta as the peel ply, a polypropylene mesh material as the resin diffusion medium, and a nylon bagging film as the sealing medium, the reinforcing fiber preform was sealed as shown in FIG. A sealant was disposed around the reinforcing fiber preform.

  Thereafter, the inside of the sealed medium was vacuumed and atmospheric pressure was applied to the bagging film by differential pressure. As a result, the mandrel moved along the shape of the plate-shaped jig, and the I-type reinforcing fiber preform followed the shape, and was deformed into a shape as shown in FIG. Thereafter, the temperature was raised to 60 ° C. and an epoxy resin was injected. After completion of the resin injection, the temperature was raised to 130 ° C., left for 2 hours, cooled and primarily cured, and the FRP reinforcing member was taken out from the jig. The FRP reinforcing member was placed in an oven heated to 180 ° C. and allowed to stand for 2 hours to be cured to complete the target FRP reinforcing member.

  As a result of measuring the shape of the deformed part of the FRP reinforcing member and the plate thickness of each part, the shape of the bent part is accurate to within ± 0.1mm in the direction perpendicular to the longitudinal direction with respect to the design dimension, and the cross section of each part The variation of the plate thickness is within ± 0.05mm, and it was confirmed that it can be molded with high precision dimensions.

  Moreover, as a result of observing the state by cutting a cross section of the obtained FRP reinforcing member, it was confirmed that there were no problems that caused problems such as voids, local resin richness, and fiber waviness.

  The present invention is preferable from the point that it can be more applicable to the manufacture of FRP reinforcing members used in various fields such as vehicles, ships, aircraft, or building members, but other industrial uses, sports uses, etc. It can be applied to manufacture a wide range of FRP molded products.

It is a schematic longitudinal cross-sectional view of each process which shows the manufacturing method of the preform which concerns on one embodiment of this invention. It is a schematic block diagram which shows an example of the method of manufacturing a FRP molded object using the preform obtained by the method of FIG. It is a schematic sectional drawing of the FRP molded object obtained by the method of FIG. It is a perspective view which shows 1 process of the manufacturing method of the reinforcement member made from FRP which concerns on another embodiment of this invention. It is a side view which shows 1 process of the manufacturing method of the reinforcement member made from FRP which concerns on another embodiment shown in FIG. It is a schematic block diagram which shows the formation process in the manufacturing method of the reinforcement member made from FRP which concerns on another embodiment shown in FIG. It is a schematic longitudinal cross-sectional view of the space | gap fixing means and mandrel in 1 process of the manufacturing method of the FRP reinforcement member which concerns on another embodiment shown in FIG. It is a perspective view which shows an example of the mandrel in a prior art. It is a schematic perspective view which shows an example of the reinforcing member made from FRP bent in the axial direction.

Explanation of symbols

1 Stringer preform 2 Mandrel 3 Combination 4 Lower mold a
5 Flat substrate preform 5a as plate-like body First surface 6 Bag material 7 Seal material 11 Preform 12 Lower mold b
13 Resin diffusion medium 14 Peel ply 15 Bag material 16 Seal material 17 Vacuum pump 18 Resin pot 19 Matrix resin 21 FRP molded body 31 Plate-like body 32 Reinforced fiber preforms 33a to 33b Split mandrels 34 Gaps 35 Peel ply 36 Resin diffusion medium 37 Molding treatment Tool 38 Inlet 39 Suction port 42 Sealant 43 Sealing medium 44 Vacuum pump 46 Resin 50 Spacer member 51 Convex part 52 Concave part (fitting hole)
60 connecting member 70 conventional mandrel 80 reinforcing member made of FRP bent in the axial direction

Claims (20)

A resin composition having a thermoplastic resin as a main component at least on one surface is dispersed and applied on the surface of a plate-like body made of any of a mold, a reinforcing fiber, and FRP having a curved or bent surface . A stringer reinforcing fiber preform comprising a laminate of reinforcing fiber materials is arranged, a mandrel divided into a plurality of parts is arranged along the reinforcing fiber preform, and the whole is covered with a sealing medium, and the sealing medium by the internal pressure reduction, heating with is brought into close contact the reinforcing fibers of the reinforcing fibers preform loaded with atmospheric pressure preform deformed so along the surface of the plate-like body to said plate-like body, Alternatively, the method for producing a preform is characterized by heating after the contact . A resin composition having a thermoplastic resin as a main component at least on one surface is dispersed and applied on the surface of a plate-like body made of any of a mold, a reinforcing fiber, and FRP having a curved or bent surface . A stringer reinforcing fiber preform comprising a laminate of reinforcing fiber materials is arranged, a mandrel divided into a plurality of parts is arranged along the reinforcing fiber preform, and the whole is covered with a sealing medium, and the sealing medium by the internal pressure reduction, the reinforcing fibers preform atmospheric pressure loaded to the reinforcing fiber preforms deformed so along the surface of the plate-shaped body was heated Rutotomoni brought into close contact with the plate-like body , or contact heated on after being, characterized by forming the FRP by injecting resin into close contact to the reinforcing fiber preform to said plate-like body with internal pressure has been reduced thereafter, F Method of manufacturing the P-molded body. When manufacturing an FRP molded body having a stringer provided on a surface of a plate-like body having a curved or bent surface, the plate-like body is composed of either reinforcing fiber or FRP, and the plate-like body on the surface, placing the reinforcing fiber preform for at least a resin composition on one side a main component a thermoplastic resin is made of a laminate of reinforcing fiber material dispersed granted the stringer, said stringer reinforcing fibers A mandrel divided into a plurality of parts is arranged along the preform, the whole is covered with a sealing medium, and the inside of the sealing medium is depressurized, thereby applying atmospheric pressure to the stringer reinforcing fiber preform and warmed after the reinforcing fiber preforms deformed so along the surface of the plate-shaped body was heated Rutotomoni brought into close contact with the plate-like body for stringers, or are brought into close contact, accordingly Decompressed by the internal, characterized by forming the FRP by injecting at least the plate-like body in close contact to said stringer resin reinforcing fiber preform for a method of manufacturing a FRP molded body. Wherein the shape of the front reinforcing being deformed along the surface of the plate-like body of the fiber preform, a shape extending straight, the method according to any one of claims 1-3. The method according to any one of claims 1 to 4, wherein the resin composition is dispersed and applied to the reinforcing fiber material in a range of 0.1 to 30% by weight. Comprising said carbon fiber reinforcing fibers of the reinforcing fiber preform, method of any of claims 1-5. The surface of the plate-shaped body includes a portion having a slope in the range of 1 / 10-1 / 200 The method of any of claims 1-6. The surface of the plate-like body comprises a portion having the surface displacement 5mm in thickness direction, the method according to any one of claims 1-7. The method according to claim 1, wherein the mandrel has a shape along the shape of the surface of the plate-like body. The method according to any one of claims 1 to 9, wherein the mandrel divided into a plurality of parts is attached to a reinforcing fiber preform so that a gap is formed between adjacent mandrels. The method according to claim 10 , wherein a gap fixing means is provided between the mandrels, and the size of the gap between the mandrels is maintained within a certain range by the gap fixing means. The method according to claim 11 , wherein a spacer member is disposed as the gap fixing means. The method according to claim 12 , wherein a contact area between the spacer member and the mandrel is not more than ½ of a cross-sectional area of the mandrel. The method according to claim 12 or 13 , wherein the spacer member has a curved contact surface with the mandrel. The method according to any one of claims 12 to 14 , wherein a convex portion is provided on the spacer member, and a concave portion fitted to the convex portion is provided on the mandrel. The method according to claim 12 , wherein the spacer member and the mandrel are integrated. The method according to claim 11 , wherein the gap fixing means is a connecting member that movably connects the mandrels divided into a plurality of parts, and the size of the gap between the mandrels is maintained within a certain range by the connecting member. When the mandrel divided into a plurality is a rectangular parallelepiped, the height of the rectangular parallelepiped is H, the deformation height of the curved or bent surface of the plate-like body is T, and the deformation length is L, setting the size of the gap between the mandrel over H × T / L, the method of any of claims 1 to 17. In forming the inside of the sealing medium by reducing the pressure, a resin is injected into the inside of the sealing medium using a pressure difference between the internal pressure of the sealing medium and the atmospheric pressure, and the resin is cured to form an FRP. A method according to any of claims 2 to 18 , characterized in that It said reinforcing fibers preform type I, T-type, C-type, L-type, Z-type, having a cross sectional shape selected from J-type, method of any of claims 1-19.

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