JP5738061B2 - FRP structure manufacturing method and manufacturing apparatus - Google Patents

Description

  The present invention relates to a manufacturing method and a manufacturing apparatus for a large FRP structure such as a boat, a plant, a solar battery panel, a solar thermal power generation panel, and the like.

Conventionally, VARTM (Vacuum Assisted Resin Transfer Molding) molding method and RTM (Resin Transfer Molding) molding method are known as a manufacturing method of a large FRP structure (for example, Patent Document 1, Non-Patent Document 1, Patent Document 1).
The RTM molding method is a method of manufacturing a fiber reinforced plastic (hereinafter referred to as FRP) by placing a reinforced fiber cloth, a core material, or the like in a cavity generally formed of a metal mold or the like and press-fitting a resin therein.
On the other hand, the VARTM molding method does not use a mold or the like in which a cavity is formed as described above, but forms a closed space by covering a molding object on which a reinforcing fiber cloth or a core material is arranged with a vacuum film and forming a closed space. In this method, the space is evacuated and the resin is injected into the closed space by the atmospheric pressure applied to the resin reservoir in the supply unit.

As described above, in the VARTM molding method, the resin injection pressure is not applied to the molding die, so there is no need to improve the structural strength of the molding die even if it is large, and a conventional FRP molding die used as a so-called hand pile molding is used. Can do.
Further, since the VARTM molding method is a closed molding method, it is a clean molding method because volatile organic substances contained in the resin such as styrene, which are harmful even in a large-scale molding, are extremely rarely emitted into the air.
Furthermore, in this molding method, cloths woven with reinforcing materials such as glass fibers and carbon fibers are stacked on a mold, covered with a vacuum film, and the surroundings are sealed and vacuumed, and then the resin is sucked up and impregnated. Therefore, the resin impregnation step into the reinforcing fiber, which is the most important in the quality control of FRP, can be managed fairly strictly. Therefore, it is possible to prevent the generation of a region where the resin is excessive or the region where the impregnation is insufficient, and further the mixing of bubbles, which has an advantage that a high-quality FRP structure can be stably produced.
Due to the circumstances as described above, the VARTM molding method has recently been used for the production of large FRP structures.

A conventional molding method utilizing the VARTM molding method is shown in FIG. 6 is a schematic top view of a manufacturing apparatus showing, for example, a case where an FRP sandwich panel is formed, and FIG. 7 is a cross-sectional view taken along line BB of FIG. FIG. 8 is a perspective view showing a grooved core material.
In these figures, reference numeral 1 denotes a molding die having a flat surface such as a surface plate, 2 denotes a molded body, and a core material (grooved) having grooves 3a through which resin flows vertically and horizontally as shown in FIG. (Core material) 3 and fiber reinforced fabrics 4a and 4b placed on the upper and lower surfaces of the grooved core material 3.

  Then, a peel ply 5 (release sheet) is stacked on the molded body 2, and the resin supply spiral tubes 10 a and 10 b connected to the resin tank 6 through the resin supply hose 7 and the on-off valve 8 are covered. The molded body 2 is arranged substantially vertically above and below the edge of one side of the molded body 2, and above and below the edge of the opposite side of the molded body 2 via a vacuum hose 11. The degassing spiral tubes 12a and 12b connected to a vacuum pump (not shown) are also arranged substantially parallel to the sides. Then, the whole is covered with the vacuum film 13 and the periphery is hermetically sealed with the seal member 14.

  Next, air in the vacuum film 13 is sucked through the degassing spiral tubes 12a and 12b, and the liquid resin in the resin tank 6 is supplied from the resin supply spiral tubes 10a and 10b while the internal space is evacuated. Then, the resin flows vertically and horizontally in the groove 3a of the grooved core material 3 and diffuses, and is impregnated over the entire surface of the fiber reinforced fabrics 4a and 4b on the upper and lower surfaces of the molded body 2. Thereafter, the FRP sandwich panel in which the grooved core 3 and the fiber reinforced fabrics 4a and 4b on the upper and lower surfaces thereof are integrally molded can be manufactured by gelling and curing the resin.

JP-A-11-235776

Kiyoshi Serizawa, “From the topic of recent FRP ship construction”, Ship Technical Report, p. 2-7, April 2009, Ship Association of Japan

As described above, in the conventional method for manufacturing an FRP structure by the VARTM molding method, for example, in a quadrilateral sandwich panel, the resin is impregnated from the edge supplying the resin toward the opposite edge provided with the deaeration line. Therefore, since the required impregnation time is determined according to the impregnation distance (resin path length), there is a problem that it is difficult to speed up the production.
In addition, since the viscosity of the resin is high, it takes time to impregnate, and it is difficult to apply a resin that cannot be impregnated over a long distance due to a short gel time.
Furthermore, in order to shorten the impregnation distance, even if the resin is impregnated from both opposite edges, the resin is not impregnated in the region where the resin impregnated from both sides meets, or the impregnation is insufficient due to the presence of air. There is also a problem that the generation of a defective area cannot be prevented.

  The present invention has been made to solve the above-described problems. The impregnation distance is shortened to shorten the production time, and a high-quality FRP structure free from resin non-impregnation and voids is produced. An object of the present invention is to provide a method for manufacturing an FRP structure and an apparatus for manufacturing the FRP structure.

The manufacturing method of the FRP structure according to the present invention comprises a core material provided with a plurality of resin flow grooves on at least one surface, and a reinforcing fiber cloth placed on the surface of the core material on the resin flow groove side. A method of manufacturing an FRP structure by covering a molded object having a gas tightly with a vacuum film and impregnating the molded object with a resin by a VARTM molding method ,
A resin supply part is arranged in parallel with the side edge of each of the opposing sides of the molded body,
Waterproof and breathable along an intermediate line connecting intermediate points between the resin supply part disposed on one side of the molded body and the resin supply part disposed on the other side of the molded body A deaeration part having a cloth having a membrane and a ventilation means,
While degassing from the said intermediate line of the molded body by degassing unit, in which by supplying simultaneously the resin from both sides of the resin supply section allowed to proceed resin impregnation, characterized in that molding.

  Moreover, in the manufacturing method of the FRP structure of this invention, the deaeration bag which has the cloth which has a waterproof breathable film | membrane, and a ventilation means is used as a deaeration part.

  Further, a spiral tube having a spiral resin supply slit is used as the plurality of resin supply units.

  Further, the core material is abutted, and the deaeration portion is extended along the abutting portion to secure a path for releasing the air on the lower surface of the core material.

  In addition, a core material with a through hole is arranged in the deaeration part, and a path through which air on the lower surface of the core material is released by the through hole is secured.

An apparatus for manufacturing an FRP structure according to the present invention is a manufacturing apparatus for carrying out the above-described method for manufacturing an FRP structure,
Using the spiral tube having a spiral resin supply slit as the resin supply part disposed at the edge portions on both sides of the molded body,
As the deaeration part arranged along the intermediate line of the molded body, a deaeration bag having a cloth having a waterproof air permeable membrane and a ventilation means is used.

  In addition, the deaeration bag is formed in a bag shape surrounding the ventilation means with a cloth having a waterproof and breathable membrane.

  According to the present invention, since resin is simultaneously supplied from the edge portions on both sides while degassing from the center line of the molded body, the impregnation distance is shortened, so that the manufacturing time of the FRP structure can be greatly shortened. it can. In addition, by providing a degassing part made of a waterproof and breathable membrane that allows gas to pass but not liquid to pass along the center line of the molded body, it can be degassed from the center line, Generation of voids, impregnation deficient regions, etc. can be prevented.

It is a top view which shows schematic structure of the manufacturing apparatus of the FRP structure in Embodiment 1 of this invention. It is AA sectional drawing of FIG. 2 is an enlarged cross-sectional view of a deaeration unit according to Embodiment 1. FIG. It is sectional drawing which shows schematic structure of the manufacturing apparatus of the FRP structure in Embodiment 2 of this invention. 6 is an enlarged cross-sectional view of a deaeration unit according to Embodiment 2. FIG. It is a top view which shows schematic structure of the manufacturing apparatus of the conventional FRP structure. It is BB sectional drawing of FIG. It is a perspective view which shows an example of the core material with a groove | channel used for a FRP structure.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings.

Embodiment 1 FIG.
FIG. 1 is a top view showing a schematic configuration of an apparatus for manufacturing an FRP structure according to Embodiment 1 of the present invention, and FIG. 2 is a cross-sectional view taken along line AA of FIG. FIG. 3 is an enlarged cross-sectional view of the deaeration part. Here, a method for manufacturing a quadrilateral FRP sandwich panel will be described as an example.
In the figure, reference numeral 1 denotes a molding die having a flat surface (molding surface), such as a surface plate, and 2 denotes a molded object. For example, as shown in FIG. It is comprised from the core material (groove core material) 3 provided vertically and horizontally, and the 1 or several fiber reinforcement cloth 4a, 4b which faced the several grooved core material 3 and was piled up on the upper and lower surfaces. Note that the molding surface of the mold 1 is not limited to a flat shape, and may be a curved surface.

  The molded body 2 configured as described above is placed on the mold 1. And this to-be-molded body 2 is covered with the peel ply 5 (release sheet), the deaeration part 9 is arrange | positioned along the centerline of the to-be-molded body 2, and the edge part of the side which the to-be-molded body 2 opposes The resin supply unit 10 is disposed substantially parallel to the sides of the resin supply unit 10. Here, the resin supply unit 10 includes spiral tubes 10a and 10b. The spiral tubes 10a and 10b are connected to a resin tank 6 storing a liquid resin via a resin supply hose 7 and an on-off valve 8. As the resin, a thermosetting resin such as an unsaturated polyester resin, a vinyl ester resin, or an epoxy resin is used. These resins are liquid at room temperature, and are hardened by adding a curing agent or the like for initiating polymerization to gel for a predetermined time.

  On the other hand, the deaeration part 9 is arrange | positioned on the centerline of the to-be-molded body 2 in the shape of a line or a strip | belt. In the first embodiment, the deaeration unit 9 is installed with its periphery sealed on the upper surface of the peel ply 5, and in the second embodiment, a deaeration bag 9 a is installed. The deaeration bag 9a is connected to a vacuum pump (both not shown) through a resin trap via a vacuum hose 11.

Here, as shown in FIG. 3, the deaeration unit 9 of Embodiment 1 is a waterproof and breathable cloth having a semipermeable membrane that allows gas such as air to pass but does not allow liquid (resin) such as water to pass. 9b, and a degassing spiral tube 9c as a ventilation means and a ventilation layer 9d on the upper surface of the waterproof breathable cloth 9b. As shown in FIG. 5, the deaeration unit 9 according to the second embodiment is configured by a deaeration bag 9a in which the entire air-permeable layer 9d and the spiral tube 9c are wrapped with a waterproof air-permeable cloth 9b to form a bag. . The deaeration spiral tube 9c is the same as the resin supply spiral tubes 10a and 10b. One end of the vacuum hose 11 is connected to the degassing spiral tube 9c.
As said waterproof breathable cloth 9b, the brand name "Gore-Tex" (trademark) used as cloths, such as rainwear, can be mention | raise | lifted, for example. In this deaeration bag 9a, a vacuum hose 11 penetrates the vacuum film 13 and is connected to a ventilation layer 9d on the waterproof breathable cloth 9b. Further, the waterproof breathable cloth 9b is peeled off with an adhesive tape 9f, for example. 5 is adhered and fixed.

The resin supply part 10 is a tube-shaped thing arrange | positioned so that it may extend in the direction orthogonal to the flow direction of resin, for example, spiral tube 10a, 10b can use it conveniently. The spiral tube is formed in a tube shape having a spiral slit by spirally winding a plastic band plate that is hard to some extent so that it does not easily become flat even under vacuum. When the resin is supplied into such a spiral tube, the resin flows out while diffusing in a plane through the spiral slit. In addition, as the resin supply part 10, what provided many holes, slits, etc. in the hard pipe | tube may be used.
Such a resin supply part 10 is installed in each edge part of the opposing side of the to-be-molded body 2 so that it may become substantially parallel to the side. And the whole to-be-molded body 2 is covered with the vacuum film 13, and the circumference | surroundings are sealed with the sealing member 14. FIG.

  When forming the FRP sandwich panel, the edge portions on both sides of the molded body 2 are evacuated from the center line of the molded body 2 through the degassing section 9 and the vacuum film 13 is evacuated. Resin is simultaneously supplied from the resin supply spiral tubes 10a and 10b provided in the slab. Then, the resin supplied from the spiral tubes 10a and 10b at the edge of the molded body 2 penetrates the fiber reinforced fabrics 4a and 4b through the resin flow grooves 3a of the grooved core material 3, and the center of the molded body 2 It flows toward the club. The tip line of the resin permeation part at that time is a line that is nearly parallel to the spiral tubes 10a and 10b.

  A deaeration unit 9 or a deaeration bag 9a is provided on the center line of the molded body 2, and the deaeration unit 9 or the deaeration bag 9a allows a gas such as air to pass therethrough but a liquid such as water as described above. Since the (resin) is a waterproof breathable cloth 9b configured not to pass through and a breathable layer 9d is provided on the upper surface of the waterproof breathable cloth 9b, the resin flowing from both sides of the molded body 2 Will meet on the centerline. However, because of the waterproof breathable cloth 9b of the deaeration part 9 or the deaeration bag 9a, only air is sucked and resin is not sucked. Therefore, unimpregnated regions, voids, and impregnation are formed on the lines where the resin from both sides meet. Insufficient areas do not occur. Moreover, since the deaeration part 9 thru | or the deaeration bag 9a are extended along the abutting part 3b of the some grooved core material 3, the resin which met on the lower surface centerline of the to-be-molded body 2 is the grooved core material 3 As described above, no unimpregnated region, void, insufficiently impregnated region, or the like is generated on the resin associating line on the lower surface.

As described above, the present embodiment has the following effects.
(1) For example, in the case of forming a large quadrilateral panel, resin impregnation is started simultaneously from both end edges of the opposing long sides, and a deaeration unit 9 or a deaeration bag is located in the vicinity of the middle line between these both ends. By arranging 9a, it is possible to prevent the generation of the unimpregnated region. As a result, the resin impregnation distance is about half that of the conventional method, and the time required for the impregnation is about ¼, so that the production time can be greatly shortened. Incidentally, in the conventional method, the impregnation distance is about 5 m, but in the present embodiment, the impregnation distance can be extended to at least 10 m, which is twice as much.
(2) As a result of shortening the impregnation time, a resin having a high viscosity or a resin having a short gelation time can be applied.
(3) Since air can be sucked through the abutting portion of the core material in the degassing line portion, an unimpregnated region, void, or insufficiently impregnated region does not occur on the lower surface of the molded body 2.

Embodiment 2. FIG.
FIG. 4 is a cross-sectional view showing a schematic configuration of the FRP structure manufacturing apparatus according to Embodiment 2 of the present invention, and FIG. 5 is an enlarged cross-sectional view of a deaeration unit according to Embodiment 2.
In the second embodiment, a waterproof breathable membrane as described above is used as the deaeration unit 9 in that a through-hole 3c that vertically penetrates the core 3 is provided in the vicinity of the butted portion 3b of the grooved core 3. The only difference from Embodiment 1 is that the sealed bag-like deaeration bag 9a including the ventilation medium 9e is formed in the cloth (waterproof breathable cloth) 9b. The deaeration bag 9 a is placed on the through hole 3 c of the core material 3 along the butted portion 3 b of the grooved core material 3. Since other configurations are the same as those of the first embodiment, the same reference numerals are used.

  According to this second embodiment, in addition to having the same effect as the first embodiment, the core material 3 with the through-hole 3c is arranged in the portion where the waterproof breathable cloth 9b is arranged as the deaeration portion 9, so Since a sufficient passage path for air from the lower surface of the molded body 2 can be ensured, an effect of more reliably preventing an unimpregnated region, a void, and an insufficiently impregnated region can be obtained.

In the first and second embodiments described above, the example of manufacturing the FRP sandwich panel made of the core material 3 and the fiber reinforced fabrics 4a and 4b has been described. However, the present invention is not limited to the sandwich structure, but on one side of the core material. The present invention can be widely applied to an FRP structure provided with a fiber reinforced cloth. In this case, it is only necessary that the resin flow groove 3a is formed on at least one surface of the core material.
Further, the present invention can be applied not only to a flat surface but also to a curved shape that is convex or concave.

DESCRIPTION OF SYMBOLS 1 Mold 2 Molding object 3 Core material 3a Groove (resin distribution groove)
3b butt portion 3c through hole 4a, 4b fiber reinforced cloth 5 peel ply 6 resin tank 7 resin supply hose 8 on-off valve 9 deaeration part 9a deaeration bag 9b waterproof breathable cloth 9c deaeration spiral tube 9d ventilation layer 9e ventilation medium 9f Adhesive tape 10 Resin supply unit 10a, 10b Spiral tube 11 Vacuum hose 12a, 12b Degassing spiral tube 13 Vacuum film 14 Sealing member

Claims (8)

A core material provided with a plurality of resin flow grooves on at least one surface;
A molded object having a reinforcing fiber cloth placed on the resin flow groove side surface of the core material is hermetically covered with a vacuum film, and the molded object is impregnated with resin by a VARTM molding method to form an FRP structure. A method of manufacturing a body ,
A resin supply part is arranged in parallel with the side edge of each of the opposing sides of the molded body,
Waterproof and breathable along an intermediate line connecting intermediate points between the resin supply part disposed on one side of the molded body and the resin supply part disposed on the other side of the molded body A deaeration part having a cloth having a membrane and a ventilation means,
Wherein while degassing from the said intermediate line of the molded body by degassing unit, the FRP structure by supplying simultaneously the resin from both sides of the resin supply section allowed to proceed resin impregnation, characterized in that molded Production method.   The method for producing an FRP structure according to claim 1, wherein a deaeration bag having a cloth having a waterproof and air permeable membrane and a ventilation means is used as the deaeration part.   3. The method of manufacturing an FRP structure according to claim 1, wherein a spiral tube having a spiral resin supply slit is used as the plurality of resin supply portions. Butt the core, by extending the degassing unit along the butted portion, according to any one of claims 1 to 3, characterized in that to secure a path to escape the air in the lower surface of the core Manufacturing method of the FRP structure. The FRP according to any one of claims 1 to 3, wherein a core material with a through hole is arranged in the deaeration part, and a path for escaping air on the lower surface of the core material is secured by the through hole. Manufacturing method of structure.   When the molded body is hermetically covered with the vacuum film, the molded body is disposed so as to be sandwiched between a molding die and the vacuum film,
  The said deaeration part is arrange | positioned at the said vacuum film side of the said to-be-molded body, The manufacturing method of the FRP structure as described in any one of Claims 1-5 characterized by the above-mentioned. It is a manufacturing apparatus for enforcing the manufacturing method of the FRP structure as described in any one of Claims 1-6 ,
Using the spiral tube having a spiral resin supply slit as the resin supply part disposed at the edge portions on both sides of the molded body,
An apparatus for manufacturing an FRP structure, wherein a deaeration bag having a cloth having a waterproof air permeable membrane and a ventilation means is used as the deaeration part disposed along the intermediate line of the molded body. . 8. The FRP structure manufacturing apparatus according to claim 7 , wherein the deaeration bag is formed in a bag shape surrounding the ventilation means with a cloth having the waterproof and breathable membrane.

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