JP5786352B2 - Manufacturing method of fiber reinforced resin sheet - Google Patents

Description

  The present invention relates to a method for producing a fiber-reinforced resin plate provided with a metal member (reinforcing material).

  For a door of a railway vehicle, a seat back, or the like, a substantially plate-shaped molded product made of a fiber reinforced resin, that is, a fiber reinforced resin plate material may be used as a core material. Thus, when using a fiber reinforced resin board | plate material for a core material, in order to provide high rigidity with a core material, a rib is often formed or an unevenness | corrugation is formed. For example, Patent Document 1 discloses a fiber-reinforced resin plate material in which a plurality of concave stripes extending in the vertical direction are formed as a door core material. Patent Document 2 describes a backrest skeleton material in which ridges (side reinforcing portions) extending in the vertical direction are formed on both side portions of a fiber reinforced resin plate material. In addition, a method of increasing the rigidity of the core material by bonding a corrugated reinforcing material to the back surface of the core material by post-processing is also known.

JP 2004-339778 A JP-A-2005-194

  However, the rib formation requires composite molding using a short fiber material such as SMC (Sheet Molding Compound), which increases the number of molding steps and has difficulty in obtaining sufficient rigidity. In addition, there are many cases where satisfactory rigidity cannot be obtained even by the method of forming irregularities. Further, in the method of bonding a corrugated reinforcing material to the back surface of the core material by post-processing, the number of processes increases by the number of bonding processes, which is problematic in terms of productivity.

  This invention is made | formed in view of the said situation, and it aims at manufacturing the fiber reinforced resin board | plate material provided with high rigidity, without increasing the number of processes.

In the method for producing a fiber-reinforced resin plate material of the present invention, a metal member is disposed on at least a part of a sheet-like material comprising a prepreg in which a long fiber is impregnated with a thermosetting resin, and the sheet-like material and the metal-made material are produced. This is a method for producing a fiber-reinforced resin plate material, in which a member is compressed and integrated with a mold.
The sheet-like material is composed of two or more layers, and it is preferable that the resin content of the layer in contact with the metal member of the sheet-like material is larger than the resin content of the other layers.
The cavity of the mold may be formed in advance in a shape that counteracts the warp deformation of the fiber reinforced resin plate material caused by the difference in coefficient of linear expansion between the fiber reinforced resin obtained by curing the sheet-like material and the metal member. Is preferred.

  According to the present invention, a fiber-reinforced resin plate having high rigidity can be manufactured without increasing the number of steps.

It is the (a) perspective view and (b) sectional view showing an example of the fiber reinforced resin board manufactured by the manufacturing method of the present invention. In the manufacturing process of the fiber reinforced resin sheet of FIG. 1, (a) a perspective view showing a state in which a square pipe is arranged on one side of a sheet-like material, and (b) a preform obtained by coating the square pipe with a sheet-like material. It is a perspective view. It is a perspective view which shows an example of the metal mold | die used for manufacture of the fiber reinforced resin board | plate material of FIG. In the fiber reinforced resin board | plate material of FIG. 1, it is typical sectional drawing which shows the principal part when curvature deformation arises. It is sectional drawing which shows the other example of the metal mold | die used for manufacture of the fiber reinforced resin board | plate material of FIG. It is a perspective view which shows the other example of the fiber reinforced resin board manufactured by the manufacturing method of this invention. It is a perspective view which shows the other example of the fiber reinforced resin board manufactured by the manufacturing method of this invention. It is a perspective view which shows the other example of the fiber reinforced resin board manufactured by the manufacturing method of this invention. It is the (a) perspective view and (b) sectional view which show an example of the fiber reinforced resin board manufactured by the manufacturing method of the present invention. It is a perspective view which shows an example of the metal mold | die used for manufacture of the fiber reinforced resin board | plate material of FIG. FIG. 10 is a perspective view showing a state when warpage deformation occurs in the fiber-reinforced resin plate material of FIG. 9. It is an image figure which shows the other example of the metal mold | die used for manufacture of the fiber reinforced resin board | plate material of FIG.

Hereinafter, the present invention will be described in detail.
FIG. 1A is a perspective view and FIG. 1B is a cross-sectional view showing an example of a fiber reinforced resin plate produced by the production method of the present invention.
1A is a rectangular flat plate-shaped FRP plate body 11 made of fiber reinforced resin (hereinafter sometimes referred to as FRP), and both end portions in the longitudinal direction on one side of the FPR plate body 11. , And two metal square pipes (metal members) 12 that reinforce the FRP plate body 11. The FRP plate member 10 </ b> A in this example is obtained by integrating the FRP plate member main body 11 and the square pipe 12 in a state in which the outer periphery of the two square pipes 12 is covered with both end portions of the FRP plate member main body 11.

FRP which comprises the FRP board | plate material main body 11 contains the long fiber as a reinforced fiber, and the thermosetting resin as a matrix resin.
The long fiber means an unbroken continuous fiber in the FRP plate body 11, and examples thereof include carbon fiber, aramid fiber, boron fiber, steel fiber, PBO fiber, high-strength polyethylene fiber, and glass fiber. One or more of these can be used. Among these, when carbon fiber is used, it is possible to manufacture an FRP plate material 10A that has higher rigidity and is suitable, for example, as a core material for the back of a door or seat of a railway vehicle.

Examples of the thermosetting resin include an epoxy resin, an unsaturated polyester resin, a vinyl ester resin, a phenol resin, and a benzoxazine resin. Among these, an epoxy resin is preferable because it has excellent adhesion to long fibers and adhesion to a metal member that is a reinforcing material.
Examples of the material (metal) of the metal member include aluminum, iron, stainless steel, and various alloys. Among these, general-purpose steel materials such as SS400 (JIS standard) are preferable when cost is important, and aluminum is preferable when weight is important.

The FRP plate 10A of FIG. 1 can be manufactured as follows.
First, in order to form the FRP plate body 11, a sheet-like material is prepared that includes a prepreg impregnated with a thermosetting resin into long fibers oriented in one direction.
The sheet-like material may be one provided with at least one prepreg, and in some cases, one surface of the sheet-like material may be provided with a resin layer not containing long fibers. In this example, so-called 5 ply (0/90/0/90/0), in which prepregs are laminated such that five layers of layers having an orientation angle of long fibers of 0 ° and 90 ° are alternately laminated. The prepreg laminate is used as a sheet.

Next, as shown in FIG. 2 (a), two square pipes 12 are arranged substantially in parallel on one side of the sheet-like material 13, and both end portions of the sheet-like material 13 are wound around the square pipe 12 to form the square pipe. The preform 14 shown in FIG.
In addition, at the time of manufacture of the preform 14, in order to improve the adhesion between the square pipe 12 and the sheet-like material 13, it is preferable to wipe the outer periphery of the square pipe 12 with an organic solvent such as acetone in advance and degrease it. . In addition, after the both end portions of the sheet-like material 13 are wound around the square pipe 12, a deaeration process is performed, and air between the sheet-like material 13 and the square pipe 12 or between the prepregs constituting the sheet-like material 13. It is preferable to release the air to improve the adhesion.

Next, as shown in FIG. 3, a mold 20 is prepared which comprises an upper mold 21 and a lower mold 22 and forms a cavity having substantially the same shape as the preform 14 of FIG. The cavity of the mold 20 includes an upper mold 21 having a convex portion having a width W ₁ , a length L ₁ , and a height H ₁ , and a lower mold having a concave portion having a width W ₂ , a length L ₁ , and a depth D _1. 22.
Next, the preform 14 is placed in the mold 20, the mold 20 is closed, and compression molding is performed. Compression conditions such as molding temperature (mold temperature), molding pressure, and molding time (curing time) can be appropriately determined according to the type of thermosetting resin that constitutes the prepreg of the sheet-like material 13. In addition, a necessary draft can be appropriately set for the mold.
Thus, by performing compression molding using the mold 20, the thermosetting resin contained in the sheet-like material 13 of the preform 14 is thermally cured, and the thermally-cured sheet-like material 13, that is, the FRP flat plate body 11 and The FRP plate 10A of FIG. 1 in which the square pipe 12 is integrated and the two square pipes 12 are provided on one side of the flat plate-like FRP plate main body 11 can be manufactured.

Since the FRP plate material 10A manufactured in this way is provided with a metal member, for example, after using a plate material in which irregularities are formed on the FRP plate material itself and rigidity is provided, or a short fiber material is used. Compared to a plate material on which ribs are formed by processing, it has higher rigidity. Therefore, it is suitably used for applications that require high rigidity, such as railcar doors and seat back cores.
Moreover, the manufacturing method of FRP board | plate material 10A demonstrated above arrange | positions a metal member on the single side | surface of the sheet-like material 13 which comprises a prepreg, and compression-molds the sheet-like material 13 and a metal member with the metal mold | die 20. This is a method of integration, and does not require post-processing such as a bonding step of bonding the reinforcing material to the FRP plate body and formation of a rib using a short fiber material. Therefore, FRP board material 10A provided with high rigidity can be manufactured, without increasing the number of processes.

When the metal member and the FRP plate body 11 are integrated by such compression molding, since the metal has a larger linear expansion coefficient than FRP, the FRP plate material 10A obtained by compression molding has such a Warpage deformation due to the difference in coefficient of linear expansion between metal and FRP tends to occur. Specifically, the metal square pipe 12 has a larger linear expansion coefficient than the FRP plate body 11 and has a larger shrinkage due to cooling after compression molding. Therefore, as shown in FIG. In the obtained FRP plate member 10A, the surface portions corresponding to the four surfaces of the square pipe 12 are likely to warp convexly on the outer side (FRP main body side) indicated by arrows.
Therefore, in order to suppress such warp deformation, a mold whose cavity is formed in advance in a shape that cancels such warp deformation of the molded FRP plate 10A is used as a mold used for compression molding. Is preferred. Specifically, as shown in FIG. 5, in the upper mold 21 ′ and the lower mold 22 ′, the cavity shapes of the surface portions P corresponding to the respective surfaces of the square pipe 12 are respectively convex on the inner side (metal member side). A mold 20 ′ formed in a shape opposite to the warp deformation is used. As described above, when the cavity is formed in advance so as to cancel the warp deformation of the FRP plate 10A caused by the difference in the linear expansion coefficient between the FRP and the metal member, the metal member is greatly contracted by cooling after the compression molding. However, the FRP plate material 10A in which warpage deformation is suppressed can be obtained.
Note that the degree of convexity of the cavity shape toward the metal member side depends on the dimensional accuracy required for the FRP plate 10A, the material of the metal member and the FRP (the degree of difference in linear expansion coefficient between the two), and the like. Can be set.

Moreover, as a method of suppressing such warpage deformation, the sheet-like material forming the FRP plate body 11 is made into two or more layers, and the resin content of the layer in contact with the metal member is determined from the resin content of the other layers. A method of increasing the size is also mentioned. The magnitude of the linear expansion coefficient of metal, thermosetting resin, and FRP is in the order of metal> thermosetting resin> FRP. Therefore, by increasing the resin content of the layer in contact with the metal member and increasing the linear expansion coefficient of the layer so as to approach the linear expansion coefficient of the metal member, warping deformation caused by the difference in the linear expansion coefficient is reduced. Can be suppressed. In this case, the layer in contact with the metal member may be a resin layer having a resin content of 100% by mass, which is made of only resin without containing long fibers.
In addition, when a sheet-like object is three or more layers, the resin content of the layer which contact | connects a metal member should just be larger than the average resin content of the other two or more layers.
Moreover, while making a sheet-like object into such a structure, according to the method using metal mold | die 20 'as shown in FIG. 5 at the time of compression molding, curvature deformation can be suppressed more.

In the FRP plate member 10A of FIG. 1 described above, the square pipes 12 that are metal members are arranged on both side ends of one side of the FPR plate member main body 11, but the number of arrangement and the arrangement pattern are the uses of the FRP plate member, It can be set as appropriate according to the required rigidity and is not particularly limited.
For example, as shown in FIG. 6, in addition to the both side ends of the FRP plate body 11, a U-shaped arrangement that is also arranged at one end in the longitudinal direction, or both side ends as shown in FIG. In addition to the outer peripheral edge of the FRP plate main body 11 such as a square-shaped arrangement which is also arranged at both ends in the longitudinal direction, that is, arranged in a frame shape over the entire outer peripheral edge of the FRP plate main body 11. Various forms arranged at least in part can be exemplified.
Further, as shown in FIG. 8, in addition to the entire outer peripheral edge portion of the FRP plate body 11, a ladder-like arrangement form that further includes one or more square pipes 12 that connect the square pipes 12 at both ends. It can be illustrated. In any of these arrangement patterns, it is preferable that the outer periphery of the square pipe 12 is covered with the FRP plate body 11. When covering the square pipe 12, it is possible to cover the entire outer periphery of the square pipe 12 by cutting the sheet-like material according to the arrangement pattern of the square pipe 12 when manufacturing the preform. Good.

Further, in this example, the square pipe 12 having a rectangular cross section is used as the metal member, but depending on the use of the FRP plate material, required rigidity, etc., a circle, a polygon other than a rectangle, an irregular shape, etc. A hollow pipe with any cross-sectional shape can be used. Further, as the metal member, a member having a part of the outer periphery opened and having a cross-sectional shape of, for example, a U shape, a solid member that is not hollow, or the like may be used instead of the pipe. However, the pipe is suitable in that it can give higher rigidity than a member having a part of the outer periphery opened, for example, a U-shaped cross section, and is lighter than a solid member.
Further, the shape of the FRP plate material is not limited to a quadrangle (rectangular shape) as shown in the illustrated example, and can be various shapes depending on the purpose as long as it is a substantially flat plate shape.

Further, the sheet-like material constituting the FRP plate material main body 11 only needs to have at least one layer of prepreg, and as described above, even one layer of prepreg is laminated with two or more layers of prepreg. However, the outermost layer on one side may be provided with a resin layer made of only a thermosetting resin not containing long fibers.
Moreover, when a sheet-like material is provided with two or more layers of prepregs, the types of thermosetting resins contained in each prepreg may be different, but from the viewpoint of mutual adhesion, they are the same thermosetting resin. It is preferable. Moreover, the kind of long fiber contained in each prepreg may be the same or different.

FIG. 9 is a perspective view showing another example of the FRP plate material manufactured by the manufacturing method of the present invention.
The FRP plate member 10B of FIG. 9 is arranged along the longitudinal direction at the center in the short direction on one side of the rectangular substantially flat plate-like FRP plate member main body 11 made of FRP and the FPR plate member main body 11, and the FRP plate member main body 11 The FRP plate material main body 11 and the metal plate 15 are integrated by compression molding with a metal mold. Both end portions of the FRP plate material 10B of this example are rising portions 11a and 11b that rise toward the side where the metal plate 15 is disposed, and the metal plate 15 extends in the longitudinal direction at portions other than the rising portions 11a and 11b. Are arranged along.

The FRP plate 10B of FIG. 9 can be manufactured as follows.
First, as shown in FIG. 10, a mold 30 is prepared which includes an upper mold 31 and a lower mold 32 and forms a cavity having a shape along the FRP plate material 10B. Specifically, the cavity of the mold 30, the rising portion 11a, a width _{W 3} which portion is also included which corresponds to 11b, a length _{L 2,} a predetermined aperture amount (the depth of the FRP plate 10B ). Further, among the gaps formed between the upper mold 31 and the lower mold 32 when the mold is closed, the gap corresponding to the portion with the metal plate (metal plate insert portion) and the portion without the metal plate are supported. Each gap is set to an appropriate range.

  On the other hand, as a sheet-like material for forming the FRP plate body 11, a rectangular sheet-like material comprising a prepreg in which long fibers oriented in one direction are impregnated with a thermosetting resin is prepared. The sheet-like material used in this example may also have at least one prepreg, but in this example, a long fiber orientation angle of 0 °, −45 °, + 45 °, and A so-called 5ply (0 / + 45/0 / −45 / 0) sheet-like material in which prepregs are laminated so as to have a structure in which five layers are laminated is used.

Next, the sheet 30 and the metal plate are sequentially arranged from the lower side in the mold 30 shown in FIG. 10, and the mold 30 is closed and compression molded. Compression conditions such as molding temperature (mold temperature), molding pressure, and molding time (curing time) can be appropriately determined according to the type of thermosetting resin constituting the prepreg.
By performing compression molding in this manner, the thermosetting resin contained in the sheet-like material is thermoset, and the thermally-cured sheet-like material (FRP plate body 11) and the metal plate 15 are integrated to form a flat plate-like FRP. The FRP plate 10B of FIG. 9 in which the plate main body 11 and the metal plate 15 arranged on one side thereof are integrated can be manufactured.

Also in the FRP plate member 10B of the example of FIG. 9, warp deformation is likely to occur due to the difference in the linear expansion coefficient between the metal and the FRP. Specifically, as shown in FIG. 11, the metal plate 15 has a larger coefficient of linear expansion than the FRP plate material body 11 and contracts more easily, so that the metal plate 15 is likely to warp convex toward the FRP plate material body 11 side. Further, as in this example, in the case of the long FRP plate material 10B, the warpage in the longitudinal direction becomes more remarkable than the short direction, and the warp shape is mainly curved in the longitudinal direction.
Therefore, also in this example, in order to suppress warping deformation, as a mold used for compression molding, a mold whose cavity is formed in advance in a shape that cancels such warping deformation of the molded FRP plate material. Is preferably used. Specifically, as shown in the image diagram of FIG. 12, the shape of the cavity C in the longitudinal direction is convex toward the side where the metal plate 15 is disposed (upper side in FIG. 12) with a predetermined curvature corresponding to warp deformation. A curved mold is used. In the mold shown in FIG. 12, due to such a curvature, the length L ₂ ′ on the upper mold side of the cavity C is slightly longer than the length L ₂ ″ on the lower mold side.
Thereby, even if the metal plate 15 which is a metal member contracts greatly after compression molding, the FRP plate material 10B in which warpage deformation in the longitudinal direction is suppressed can be obtained.
In addition, when it is necessary to suppress the warpage in the short direction, a mold that is convexly curved toward the metal plate 15 may be used for the cavity shape in the short direction. Further, the degree of convexity of the cavity shape toward the metal member side is appropriately determined according to the dimensional accuracy required for the FRP plate 10B, the material of the metal member and the FRP (the degree of difference in linear expansion coefficient between the two), and the like. Can be set.

  Also in this example, the sheet-like material is composed of two or more layers, and the resin content of the layer in contact with the metal plate 15 is made larger than the resin content of the other layers as described above. Warpage deformation due to the difference in linear expansion coefficient can be suppressed. In addition, it is also preferable to use a sheet-like material whose resin content is adjusted as described above and a mold in which a cavity is formed in advance so as to cancel the warp deformation of the molded FRP plate.

  There is no particular limitation on the use of the FRP plate members 10A and 10B manufactured by the manufacturing method described above. For example, a core material of a backrest of a door or seat of a railway vehicle, an automobile member, a railcar outer surface member, a marine member, an industry It can be suitably used as a machine member.

Hereinafter, the present invention will be specifically described with reference to examples.
[Example 1]
As shown in FIG. 1, a rectangular flat plate-shaped FRP plate material main body 11 and two metal square pipes 12 arranged on both sides in the longitudinal direction on one side of the FPR plate material main body 11 are provided. The FRP plate material 10A was manufactured as follows.
First, a unidirectional prepreg (resin content: 30% by mass, thickness 0.2 mm, manufactured by Mitsubishi Rayon Co., Ltd.) “TR391E250S” in which long fibers (carbon fibers) oriented in one direction are impregnated with a thermosetting resin (epoxy resin). )), And the prepreg is laminated so that a layer in which the orientation angle of the long fiber is 0 ° and 90 ° is laminated, and 5 ply (0/90/0/90/0) A sheet-like material (300 mm × 300 mm) was prepared.
Next, as shown in FIG. 2, the square pipe 12 is arranged substantially in parallel on one side of the sheet-like material 13, and both end portions of the sheet-like material 13 are wound around the square pipe 12 to cover the outer periphery of the square pipe 12. A preform 14 was manufactured.
As the square pipe 12, a square pipe made of steel (SS400) having a square cross section of 28 mm × 28 mm, a length of 300 mm, and a thickness of 2 mm was used.
Further, when the preform 14 was manufactured, a degreasing process was performed in which the outer periphery of the square pipe 12 was wiped with acetone in advance in order to improve the adhesion between the square pipe 12 and the sheet-like material 13. And after winding the both ends of the sheet-like material 13 around the square pipe 12, the both ends of the square pipe 12 are plugged with rubber material, and then deaeration treatment (debulk) is performed. 12 and the air between the layers of the sheet-like material 13 were removed to improve the adhesion.
Next, the mold 20 shown in FIG. 3 was prepared, the preform 14 was placed in the mold 20, the mold 20 was closed, and compression molding was performed. Thereafter, the mold 20 was opened to obtain the FRP plate material 10A shown in FIG.

The compression molding conditions and the size of the mold 20 used are as follows.
Molding temperature (mold temperature): upper mold 140 ° C, lower mold 140 ° C
Molding pressure: 3.6 MPa
Molding time (curing time): 600 seconds Upper convex portion: width W ₁ = 40 mm, length L ₁ = 300 mm, height H ₁ = 39 mm
Lower mold recess: width W ₂ = 100 mm, length L ₁ = 300 mm, depth D ₁ = 30 mm

[Example 2]
As shown in FIG. 9, a rectangular flat plate-shaped FRP plate material main body 11 and a single metal plate 15 arranged along the longitudinal direction at the central portion in the short direction on one side of the FPR plate material main body were provided. FRP board material 10B was manufactured as follows.
First, a unidirectional prepreg (resin content: 30% by mass, thickness 0.2 mm) in which a unidirectionally oriented long fiber (carbon fiber) is impregnated with a thermosetting resin (epoxy resin) is prepared. The prepreg is laminated so that five layers of a 0 ° layer, a −45 ° layer, and a + 45 ° layer are laminated, and a sheet shape of 5 ply (0 / + 45/0 / −45 / 0) is obtained. The thing (110 mm x 400 mm) was produced.
Next, a mold 30 shown in FIG. 10 was prepared.
Then, a sheet-like material and a metal plate (steel plate: 79 mm × 399 mm × 2 mm (t)) 15 were sequentially arranged on the lower mold, the mold 30 was closed, and compression molding was performed under the same conditions as in Example 1. Then, the metal mold | die 30 was opened and the FRP board | plate material 10B of FIG. 9 was obtained.
Note that the cavity formed by closing the mold 30 has the following size.
Width W ₃ = 100mm
Length L ₂ = 400mm
Aperture amount (depth) = 10 mm
The gap corresponding to the part with the metal plate (metal plate insert) = 4mm
The gap corresponding to the part where there is no metal plate = 2mm

[Example 3]
As a sheet-like material, only the layer constituting one surface (layer having an orientation angle of 0 °) has a resin content of the prepreg of 40% by mass, and the resin content of the other four layers of the prepreg is 30% by mass. The FRP plate 11B of FIG. 9 was obtained by compression molding in the same manner as in Example 2 except that a 5 ply sheet was used. In addition, these were arrange | positioned in the metal mold | die 30 so that the layer by which resin content was 40 mass% and the metal plate 15 contact | connected.

[Example 4]
As shown in FIG. 12, the FRP plate material 10B of FIG. 9 is obtained in the same manner as in Example 2 except that a mold that is curved so that the shape of the cavity C in the longitudinal direction is convex toward the metal plate side is used. It was. Specifically, a mold that was curved with such a curvature that the length L ₂ ′ on the upper mold side of the cavity C was 400.44 mm and the length L ₂ ″ on the lower mold side was 400.01 mm was used.

According to each of the above examples, an FRP plate having high rigidity could be manufactured without increasing the number of steps.
In particular, when the FRP plate materials obtained in Example 2 and Examples 3 and 4 were compared, the FRP plate material obtained in Example 2 was found to have a convex warpage deformation on the FRP plate material main body side. The FRP plate materials obtained in Examples 3 and 4 hardly show such warp deformation, and according to the methods of Examples 3 and 4, it was clear that the warp deformation of the FRP plate material can be suppressed. .

10A, 10B Fiber reinforced resin plate 12 Square pipe (metal member)
13 Sheet 15 Metal plate (metal member)
20, 30 Mold C Cavity

Claims (1)

A metal member is disposed on at least a part of a sheet-like material having a prepreg in which a long-fiber is impregnated with a thermosetting resin, and the sheet-like material and the metal member are compression-molded and integrated with a mold. A method for producing a fiber-reinforced resin plate ,
The said sheet-like material is comprised from two or more layers, The manufacturing method of the fiber reinforced resin board | plate material whose resin content of the layer which contact | connects the said metal members of the said sheet-like material is larger than the resin content of the other layer.

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