JP5014715B2 - FRP molded product, molding method thereof and molding die thereof - Google Patents

Description

  The present invention relates to an FRP molded product provided with a flange portion, a molding method thereof, and a molding die thereof.

  Conventionally, a reinforced fiber plastic (FRP) molded product made of a resin material and a fiber material has been used.

  For example, Patent Document 1 discloses an FRP molded product formed by winding a plurality of layers of fiber material. However, in this molded product, fiber disturbances when the fiber material is wound, and fiber materials overlap. Variations in the thickness of the FRP layer due to the above occur, the strength varies, and the desired quality cannot be obtained.

Therefore, in order to prevent variation in the plate thickness of the FRP layer, FRP can be formed by abutting the ends of the fiber material, but the joint between the fiber material ends is only the attached tip and bonded. Low strength. In addition, it is difficult to adjust the length of the fiber material for attaching the fiber material ends to each other, for example, the fiber material is insufficient or too long. is there.
JP-A-11-76478

  The present invention has been made in order to solve the problems associated with the above-described conventional technology, and an object thereof is to provide an FRP molded product having high quality and high adhesive strength, a molding method thereof, and a molding die thereof. And

A method for molding an FRP molded product according to the present invention that achieves the above object is a method for molding an FRP molded product in which at least one layer of skin made of a fiber material and a resin material is bonded to the outside of a core material. A step of disposing a fiber material on one of the molds with the inner surface on the core material side as an upper side, and placing the core material on one end side of the fiber material, on one end side of the fiber material A step of providing a surplus portion protruding from the core material having a surface continuous with a portion on which the core material of the fiber material is placed, covering the other end side of the fiber material over the core material, and a fiber A step of overlapping the inner surface of the other end portion of the material with an inner surface of the surplus portion of the fiber material, a step of closing the pair of molding dies, and sandwiching the overlapping portion of the fiber material between the molding dies, , have a, site ends of the fibrous material overlap, along the core member In a cross section in a plane that intersects the extending directions, the core member has a rectangular shaped cross section, each of the pair of molds, characterized in that it is formed corresponding to the two sides of the rectangular shape. In addition, even if the fiber material is sandwiched between the molds in the state of a dry fiber base not impregnated with the resin material, the mold in the state of the prepreg base material in which the resin material is pre-impregnated with the fiber material Although it may be pinched | interposed between each other, when it corresponds to a dry fiber base material, it has the process of inject | pouring resin into the said shaping | molding die, It is characterized by the above-mentioned.

A mold for an FRP molded product according to the present invention that achieves the above object is a mold for an FRP molded product in which at least one layer of skin made of a fiber material and a resin material is bonded to the outside of a core material, The molds are configured in pairs, and one of the molds is formed with a cavity surface corresponding to one surface of the FRP molded product and a first flange pressing surface continuous with the cavity surface. Is formed with a second flange pressing surface facing the first flange pressing surface, and when the pair of molding dies are closed, the first flange pressing surface and the second flange pressing surface, A flange housing space is formed in which the end portions of the fiber material covering the periphery of the core material are accommodated in a state in which the end surfaces of the fiber material are in contact with each other on the inner surface on the core material side. Along the core material In a cross section in a plane intersecting the direction of extending the core member has a rectangular shaped cross section, each of said mold, characterized in that it is formed corresponding to the two sides of the rectangular shape.

In the molding method of the FRP molded product according to the present invention configured as described above, the inner surface of the other end of the fiber material is molded over the inner surface of the surplus portion of the fiber material, so that the fibers are less likely to vary. Variations in quality can be suppressed. Moreover, since the inner side surfaces of the fiber material are bonded to each other, the adhesive strength can be increased. Furthermore, the core material has a rectangular cross section, and each of the pair of molding dies corresponds to the two sides of the rectangular shape. It is not necessary to set, and mold opening and demolding are facilitated. Therefore, for example, even a molded product in which adjacent surfaces are at right angles can be easily molded.

The molding die of the FRP molded product according to the present invention configured as described above has a flange housing space that accommodates the inner surfaces of the fiber materials in contact with each other. Can be suppressed. Moreover, since the inner surface of a fiber material can be joined, adhesive strength can be raised. Furthermore, the core material has a rectangular cross section, and each of the pair of molding dies corresponds to the two sides of the rectangular shape. It is not necessary to set, and mold opening and demolding are facilitated. Therefore, for example, even a molded product in which adjacent surfaces are at right angles can be easily molded.

  The best mode for carrying out the present invention will be described below with reference to the drawings.

<First Embodiment>
FIG. 1 is a partial perspective view of a vehicle member to which an FRP molded product according to the present invention is applied, and FIG. 2 is a cross-sectional view of the FRP molded product according to the first embodiment of the present invention.

  As shown in FIG. 1, the FRP molded product 1 according to the present embodiment is applied to, for example, a side sill portion of a floor, which is a vehicle member, and imparts rigidity to the floor.

  As shown in FIG. 2, the FRP molded product 1 is formed by covering a core material 2 with a skin 5, which is a fiber reinforced plastic (FRP) made of a fiber material 3 and a resin material 4.

  For the core material 2, for example, a foam made of polyurethane, vinyl chloride, polyolefin, acrylic resin, polyimide resin (PMI (polymethacrylimide), PEI (polyetherimide)), or the like is appropriately used.

  Any resin can be used as the resin material 4 as long as it becomes a matrix resin of FRP. For example, thermosetting resins such as epoxy resins, unsaturated polyester resins, vinyl ester resins, phenol resins, polyesters, polyolefins, etc. Further, thermoplastic resins such as polyamide resins, and further mixed resins thereof can be used.

  The fiber material 3 is not particularly limited as long as it is a reinforcing material, and examples thereof include carbon fibers, graphite fibers, or glass fibers, organic fibers such as aramid, paraphenylene benzobisoxazole, polyvinyl alcohol, and polyarylate. Or a combination of two or more of these may be used. As a form of the fiber material 3, a fabric base material is preferable, and a UD (unidirectional) in which fibers are aligned in one direction, or a multiaxial base in which fibers are aligned in a plurality of directions and integrated by stitching or the like. Continuous fiber base materials such as materials, woven fabrics, knitted fabrics, and braids, and non-woven discontinuous fiber base materials are conceivable, but continuous fiber base materials should be used to suppress variations in quality that is the object of the present invention. Is preferred.

  The FRP molded product 1 includes a main body portion 7 in which a core material 2 is covered with a skin 5 and an end surface of a fiber material 3 covering the core material 2, and an inner side surface 8 on the core material 2 side of the fiber material 3. It has the flange part 9 joined together. The flange portion 9 extends along the core material 2. One surface of the flange portion 9 of the FRP molded product 1 is continuous with one side surface of the outer peripheral surface of the main body portion 7 to form a flange surface 10.

  In the FRP molded product 1, the core material 2 is rectangular in a cross section in a plane (hereinafter referred to as a “reference plane”) intersecting a direction in which the flange portion 9 extends along the core material 2 (depth direction in FIG. 2). It has a shape.

  In the conventional FRP molded product 100, as shown in FIG. 9, the bonding surface 102 between the ends of the fiber material 101 is only the thickness of the tip, whereas the FRP molded product according to this embodiment is used. Since the product 1 is joined at the flange portion 9 by the inner side surfaces 8 of the fiber material 3, the adhesive surface can be widened and the adhesive strength can be improved.

  The flange length l, which is the length from the main body portion 7 to the end of the flange portion 9, is preferably at least twice the flange thickness d.

  In addition, since the flange surface 10 of the FRP molded product 1 according to the present embodiment is widened by the flange portion 9, for example, when the flange surface 10 is used as an adhesive surface with multiple parts, a wide adhesive area is used. The adhesive strength can be increased.

  Moreover, the rigidity of the FRP molded product 1 can be improved by providing the flange portion 9 made of high-rigidity FRP. Therefore, for example, when the FRP molded product 1 is applied to the side sill portion of the floor shown in FIG. 1, the rigidity of the floor can be improved.

  Next, the FRP molded product mold 20 for forming the FRP molded product 1 will be described.

  FIG. 3 is a cross-sectional view showing a mold for an FRP molded product according to this embodiment. In addition, the arrow in a figure has shown the mold clamping direction.

  The mold 20 includes an upper mold 21 and a lower mold 22 that form a pair.

  The lower mold 22 is provided with a lower mold side wall 24 extending in the upper mold direction at one end of the lower mold surface 23 facing the upper mold 21.

  The upper mold 21 is provided with an upper mold side wall 27 extending toward the other end opposite to the side on which the side wall of the lower mold 22 is provided at one end of the upper mold surface 26 facing the lower mold 22.

  When the upper mold 21 and the lower mold 22 are relatively close to each other and reach the bottom dead center (or top dead center), the respective leading ends of the upper mold side wall 27 and the lower mold side wall 24 become the lower mold surface 23 of the lower mold 22 and A cavity 28 is formed between the upper mold side wall 27 and the lower mold side wall 24 in contact with the upper mold surface 26 of the upper mold 21.

  Therefore, the cavity 28 formed in the upper mold 21 and the lower mold 22 has a substantially rectangular shape in the reference plane cross section, and two sides of the rectangular shape are formed in the upper mold 21 and the lower mold 22, respectively.

  A stopper 29 having a surface that comes into contact with the lower mold 22 and a second flange pressing surface 30 recessed from the stopper 29 by a predetermined length are formed at the tip of the upper mold side wall 27. The second flange pressing surface 30 and the upper mold A flange receiving space 31 between the surfaces 26 communicates with the cavity 28. The lower mold surface 23 of the lower mold 22 includes a lower mold cavity surface 33 that forms a cavity, and a first flange pressing surface 32 that faces the second flange pressing surface 30. The one flange pressing surface 32 is a continuous surface.

  The upper mold 21 is provided with an injection port 34 for injecting resin from the outside to the cavity 28.

  Next, a method for forming an FRP molded product using the above-described mold 20 will be described.

  4 is a cross-sectional view of a molding die showing a state in which a fiber material and a core material are arranged on the molding die, FIG. 5 is a cross-sectional view of the molding die showing a case where the core material is covered with the core material, and FIG. FIG. 7 is a cross-sectional view of a molded product made of FRP provided with a plurality of layers of the fiber material according to the present invention.

  First, as shown in FIG. 4, the fiber material 3 is arranged on the lower mold 22 with the surface that becomes the inner surface 8 of the FRP molded product 1 being the upper side. At this time, one end of the fiber material 3 is disposed at a position corresponding to the first flange pressing surface 32 of the lower mold 22. Thereafter, the core material 2 is placed on the fiber material 3. At this time, the surplus portion 35 corresponding to the first flange pressing surface 32 of the fiber material 3 is provided so as to protrude from the core material 2.

  Next, as shown in FIG. 5, the core material 2 is covered with the fiber material 3. At this time, the ends of the fiber material 3 covering the core material 2 overlap at positions corresponding to the flange pressing surfaces 30 and 32. In the overlapping portion, the inner side surfaces 8 which are the sides of the fiber material 3 in contact with the core material 2 are opposed to each other.

  Next, as shown in FIG. 6, the mold 20 is closed. Thereby, the stopper 29 of the upper mold side wall 27 is in contact with the lower mold surface 23 of the lower mold 22, and the tip of the lower mold side wall 24 is in contact with the upper mold surface 26 of the upper mold 21. Further, the portion where the end portions of the fiber material 3 are overlapped is accommodated in the flange accommodating space 31.

  Thereafter, the resin material 4 is injected from the injection port 34. At this time, the fiber material 3 accommodated in the flange accommodating space 31 is prevented from bulging by the flange pressing surfaces 30 and 32. The stopper 29 of the upper mold side wall 27 is in contact with the lower mold surface 23 of the lower mold 22 to prevent the resin material 4 from flowing out. Thereafter, after holding the mold 20 until the resin is cured, the upper mold 21 and the lower mold 22 are separated from each other, and the FRP molded product 1 is taken out.

  In this embodiment, when covering the core material 2 with the fiber material 3, it is not necessary to wind the fiber material 3 around the core material 2, and it is only necessary to overlap the ends of the fiber material 3. Variations in thickness are unlikely to occur, and variations in quality of molded products can be suppressed.

  Further, as in the conventional molded product 110 shown in FIG. 10, when a plurality of fiber materials 111 are wound in a plurality of layers, fiber disturbance, variation in plate thickness, or deflection may occur. Then, since it is not necessary to wind the fiber material 3 around the core material 2 when placing it on the molding die 20, as shown in FIG. 7, even in a state where the fibers are oriented by stacking a plurality of fiber materials facing different directions. It can be installed easily and work man-hours can be reduced.

  Further, in this embodiment, since two sides of the substantially rectangular cavity 28 in the cross section of the reference plane are formed in each of the upper mold 21 and the lower mold 22, the conventional mold 120 as shown in FIG. Thus, since the molded product 122 does not fit into the recess 121, it is not necessary to set a slipping gradient in the mold, and mold opening and demolding are easy. Therefore, for example, even a molded product in which adjacent surfaces are perpendicular to each other can be easily molded.

Second Embodiment
FIG. 8 is a cross-sectional view of an FRP molded product and a mold according to the second embodiment of the present invention. In addition, about the site | part which has a function similar to 1st Embodiment, in order to avoid duplication, the description is abbreviate | omitted in order to avoid duplication.

  As shown in FIG. 8, the upper die surface 42 of the upper die 41 and the lower die surface 44 of the lower die 43 are the first die 40 for molding the FRP molded product 1 according to the second embodiment. It is not perpendicular to the mold clamping direction (the arrow direction in the figure) as in the form, but is inclined to the mold clamping direction. Further, the upper mold side wall 45 and the lower mold side wall 46 are formed so as to be inclined in the mold clamping direction without extending in the mold clamping direction as in the first embodiment. Due to such a configuration, it is easy to remove the mold and open the mold, and it is not necessary to set a draft angle.

  The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims. For example, not all of the upper mold surface 42, the lower mold surface 44, the upper mold side wall 45, and the lower mold side wall 46 are inclined as in the second embodiment, but at least one of them can be inclined. Yes, each of the sides constituting the rectangular shape in the reference plane cross section can be set at various angles. FIG. 12 shows a cross-sectional view of another example of the FRP molded product according to the present embodiment. One surface of the flange portion 9 of the FRP molded product 1 is formed on the same surface as one surface of the main body 9. Instead, it can be formed so as to protrude from the side surface of the main body 7. In the first and second embodiments described above, the fiber material 3 is sandwiched between the molds 20 (40) in the state of a dry fiber substrate not impregnated with the resin material 4, but the resin material 4 The material 4 may be sandwiched between the molds 20 (40) in a state of a prepreg base material in which the fiber material 3 is pre-impregnated. In this case, the resin material 4 is placed in the mold 20 (40). The step of injecting is unnecessary, and there is no need to provide the injection port 34 in the mold 20 (40).

It is a fragmentary perspective view of the member for vehicles to which the FRP molded product concerning the present invention was applied. It is sectional drawing of the FRP molded product which concerns on 1st Embodiment of this invention. It is sectional drawing which shows the shaping | molding die of the FRP molded product which concerns on this embodiment. It is sectional drawing of the shaping | molding die which shows the time of arrange | positioning a fiber material and a core material to a shaping | molding die. It is sectional drawing of the shaping | molding die which shows the time of covering the core material with the fiber material. It is sectional drawing of the shaping | molding die which shows the time of closing a shaping | molding die. It is sectional drawing of the FRP molded product which concerns on this invention in which multiple layers of fiber materials were provided. It is sectional drawing of the FRP molded product and the shaping | molding die which concern on 2nd Embodiment of this invention. It is sectional drawing which shows the conventional FRP molded product. It is sectional drawing of the conventional FRP molded product in which a fiber is provided with multiple layers. It is sectional drawing of the shaping | molding die of the conventional FRP molded product. It is sectional drawing which shows the other example of the FRP molded product which concerns on this embodiment.

Explanation of symbols

1 FRP molded product,
2 core material,
3 Fiber material,
4 resin material,
5 epidermis,
7 Body part
8 Inside surface,
9 flange part,
10 Flange surface,
20, 40 mold,
21, 41 Upper mold,
22, 43 Lower mold,
23,44 Lower mold surface,
24, 46 Lower mold side wall,
26, 42 Upper mold surface,
27,45 Upper mold side wall,
28 cavities,
29 Stopper,
30 Second flange pressing surface,
31 flange housing space,
32 first flange pressing surface,
33 Lower mold cavity surface,
34 Inlet,
d Flange thickness,
l Flange length.

Claims (4)

  A method of molding an FRP molded product in which at least one layer of skin composed of a fiber material and a resin material is bonded to the outside of a core material,
  A step of arranging the fiber material on one of the pair of molds with the inner surface on the core material side as the upper side;
  While the core material is placed on one end side of the fiber material, a surplus that protrudes from the core material having a surface continuous with a portion on which the core material of the fiber material is placed on one end side of the fiber material Providing a part;
  Covering the other end side of the fiber material over the core material, and overlapping the inner side surface of the other end side end portion of the fiber material with the inner side surface of the excess part of the fiber material;
  Closing the pair of molds and sandwiching the overlapping portion of the fiber material between the molds; and
  Have
  In the cross section of the surface where the ends of the fiber material overlap each other in the plane intersecting the direction extending along the core material, the core material has a rectangular cross section,
  Each of the pair of molds is formed corresponding to the two sides of the rectangular shape.   2. The method according to claim 1, further comprising a step of injecting a resin into the mold after the step of closing the pair of molds and sandwiching the overlapping portion of the fiber material between the molds. Molding method for FRP molded products.   A molding die for an FRP molded article in which at least one layer of a skin composed of a fiber material and a resin material is bonded to the outside of a core material,
  The molds are configured in pairs, and a cavity surface corresponding to one surface of the FRP molded product and a first flange surface continuous with the cavity surface are formed on one of the molds,
  A second flange pressing surface opposite to the first flange pressing surface is formed on the other of the molds, and the first flange pressing surface and the second flange pressing surface when the pair of molding dies are closed. Between, the flange accommodation space which accommodates the ends of the fiber material covering the periphery of the core material in a state of being in contact with each other on the inner surface which is the core material side of the fiber material,
  In the cross section of the surface where the ends of the fiber material overlap each other in the plane intersecting the direction extending along the core material, the core material has a rectangular cross section,
  Each of the said shaping | molding die is formed corresponding to two sides of the said rectangular shape, The shaping | molding die of the FRP molded product characterized by the above-mentioned.   One of the pair of molds has a stopper that contacts the other of the molds when the pair of molds is closed and isolates the flange housing portion from the outside of the molds. A mold for forming an FRP molded product according to claim 3.

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