JP5786616B2 - Method and apparatus for molding fiber reinforced plastic structure - Google Patents

Description

  The present invention is directed to a fiber reinforced plastic manufactured using a resin transfer molding process assisted by vacuum decompression (hereinafter, fiber reinforced plastic may be referred to as FRP) having a plurality of different thickness portions. The present invention relates to an automatic molding method by remote control and an automatic molding apparatus using the same.

  The adoption of FRP is advancing as a new material for manufacturing large structures such as wing members in aircraft. The outer skin portion and the girders of the wing member have a shape in which the thickness is gradually reduced toward the tip of the wing in order to achieve both the rigidity of the entire structure and the weight reduction. As described above, establishment of an FRP molding technique for a large member in which a plurality of regions having different thicknesses exist in one member is required.

  Conventionally, as a molding method for large FRP structural members such as aircraft members, a sheet-shaped prepreg, which is obtained by impregnating reinforcing fibers with a semi-cured matrix resin, is repeatedly laminated and then shaped into a desired shape. In general, a method of applying heat and pressure simultaneously with an apparatus called an autoclave to cure the same. However, since the autoclave is a facility with high operational costs, in recent years, as an FRP molding method with a lower cost, it can be laminated in a cavity formed by a molding die and a film material via a sealing material as needed. By encapsulating an aggregate of reinforcing fiber woven fabrics that have been shaped (hereinafter also referred to as “preform”), injecting and impregnating a liquid matrix resin into the enclosed woven fabric, and then curing it. A method of forming an FRP structure is also used. In this method, when the resin injected into the reinforcing fiber woven fabric is a thermosetting resin, FRP is obtained by promoting chemical curing reaction by heating, and the resin injected into the reinforcing fiber woven fabric is thermoplastic. In the case of a resin, FRP can be obtained by solidifying a resin impregnated in a fluidized state by heating by a cooling treatment, and thus has an advantage that it is not limited to the type of matrix resin to be used.

  The above FRP molding method employs a method of injecting resin using a differential pressure with respect to atmospheric pressure as a mechanism for injecting resin into the preform. In particular, it is called resin transfer molding (hereinafter also referred to as VaRTM molding) with the aid of vacuum decompression. In VaRTM molding, the opposite surface of the mold is covered with a highly conformable film material, so even a member with a complex shape has the cost advantage of requiring only one mold for processing with high accuracy. Have. On the other hand, in VaRTM molding, the thickness of the preform changes in the process from the injection of the matrix resin to the curing, so that there is a problem that the dimensional variation in the thickness direction of the FRP after curing becomes large.

  Changes in the preform thickness in VaRTM molding occur in the following three processes. The first is the thickness change in the process of impregnating the preform with a liquid resin (hereinafter referred to as the resin impregnation process). The second is the process of removing excess resin from the preform by suction after the resin is impregnated. The third is a thickness change in the process of curing the resin impregnated in the preform (hereinafter referred to as a resin curing process).

  The thickness change in the above three processes becomes a greater thickness change when a structure is formed in which a gap serving as a resin flow path is formed between layers or layers of the reinforcing fiber woven fabric. For example, when the surface of the reinforcing fiber woven fabric is dispersed with particles mainly composed of a thermoplastic resin, or a woven fabric or film mainly composed of a thermoplastic resin is applied between the layers of the reinforcing fiber woven fabric. In this case, the reinforcing fiber woven fabric has a three-dimensional knitted structure or a three-dimensional braided structure.

  The thickness change in the resin impregnation process is a change in the thickness increasing direction. This is because when the liquid resin is impregnated inside the preform, the pressure inside the preform rises in proportion to the amount of the resin flowing in, and the differential pressure from the atmospheric pressure becomes small. This is because the preform expands in volume from the state before resin injection. This increase in thickness increases as the number of laminated reinforcing fiber woven fabrics increases. As disclosed in Patent Document 1, for the purpose of facilitating resin impregnation, the thickness of the preform is designed to be larger than the thickness of the FRP after curing. If left unattended, the thickness of the FRP after curing will greatly deviate from the design value to the plus side. In order to prevent this, it is necessary to suppress an increase in the thickness of the preform during the resin impregnation process. In particular, when molding FRP with multiple parts with different number of layers, excess resin is supplied to the thin part until the thin part is impregnated first and the thick part is impregnated with resin. Therefore, although the dimensional accuracy of the thick part is good, there is a problem that the dimension of the thin part increases the risk of causing a tolerance deviation on the plus side with respect to the design thickness. Further, as described above, after the portion with the small thickness is impregnated before the portion with the large thickness, the resin flows from the portion with the small thickness toward the portion with the large thickness. There was also a problem of disturbing and causing no impregnation.

  As disclosed in Patent Document 1 and the like, the resin suction process is performed by switching the resin injection path to the vacuum suction path after the resin impregnation into the preform is completed. The thickness change in the resin suction process is a change in the direction in which the thickness decreases. This is because once the resin injection path is switched to the vacuum suction path, the resin once impregnated by the differential pressure between the resin injection path that has become vacuum and the inside of the preform that has become close to atmospheric pressure due to resin impregnation. This is because the preform shrinks in volume from the state immediately after impregnation with the resin by being discharged out of the preform. If this change in thickness is converted into the amount of decrease in thickness per number of laminated sheets, the amount of decrease decreases as the number of laminated reinforcing fiber woven fabrics increases. The reason for this is that as the number of laminated reinforcing fiber woven fabrics increases, the resin impregnated inside the preform receives more flow resistance before being discharged out of the preform. Originally, the decrease in thickness in the resin suction process is indispensable to offset the increase in thickness in the resin impregnation process and bring the preform thickness closer to the FRP design value. If the thickness of the reform is excessively reduced, the tolerance on the minus side is deviated from the designed thickness value of the FRP after curing. In order to prevent this, it is necessary to appropriately control the thickness reduction of the preform in the resin suction process. In particular, when forming an FRP having a plurality of portions having different numbers of laminated layers, the thickness is reduced until the portion having the smaller thickness reaches the target thickness first and the portion having the larger thickness reaches the target thickness. However, there is a risk that the dimension of the thick part will be out of tolerance on the minus side of the thickness design value. There was a problem of raising it.

  The resin curing process refers to a process in which the resin is cured in a state where the resin injection path and the vacuum suction path are all closed and the volume inside the bag is determined. The above path is closed in order to prevent the resin from entering and exiting from the inside of the preform as much as possible. In practice, however, the resin flows due to the resin shrinkage and the resin flow accompanying the uniform pressure inside the preform. There was a problem that variation occurred in the thickness change during the curing process. Therefore, when building a system that controls the thickness of the FRP until the resin is cured, the track record of the difference between the preform thickness until the resin curing process and the final FRP thickness is achieved. It is necessary to accumulate the value and feed it back to the target value of the preform thickness up to the resin curing process.

  The technical problems resulting from the above three thickness changes are unique to VaRTM molding, and in particular, when manufacturing FRP having at least two regions with different number of layers, a special invention is required. there were. For example, in manufacturing the FRP as described above, when the reinforcing fiber plastic panel manufacturing apparatus of Patent Document 2 is used, it is possible to prevent unimpregnation of the resin. Thus, it is impossible to solve the plus-side thickness tolerance deviation caused by the resin impregnation process and the minus-side thickness tolerance deviation caused by the resin suction process.

  Moreover, even when the manufacturing apparatus of Patent Document 3 is used, in addition to the impregnation determination as in Patent Document 2, there is a process of continuing the suction of the resin until the target thickness is reached, but the plurality of different thicknesses are present. Since the thickness control is uniform over the entire area including the region, problems such as the above-described partial deviation in thickness tolerance, and disturbance of the impregnation path due to the entry / exit of the resin between regions having different thicknesses cannot be solved.

JP 2004-130598 A JP 2010-125666 A US Publication No. 2002-0155186

The above technical issues can be summarized as follows. That is, in manufacturing an FRP having at least two regions having different numbers of stacked layers by VaRTM molding,
(1) In the resin impregnation process, a molding apparatus and a control system thereof that suppress an increase in the thickness of the preform in a small thickness portion until the resin impregnation of the entire FRP is completed,
(2) In the resin impregnation process, a molding apparatus that suppresses resin inflow from the small thickness portion to the thick thickness portion and the control system thereof until the resin impregnation of the entire FRP is completed,
(3) In the resin suction process, a molding apparatus and a control system therefor that suppress excessive thickness reduction in a small thickness portion until the entire thickness of the FRP reaches a predetermined thickness, and (4) resin A molding apparatus that is not affected by variations in thickness change during the curing process, and a control system thereof;
It is.

  The present invention is a molding apparatus and a control system for solving some or all of the above problems, and the thickness dimension of FRP as a result of accumulating these problems can be obtained with high accuracy regardless of the number of regions having different numbers of layers. The goal is to achieve.

  In order to solve the above problems, an automatic fiber reinforced plastic molding system according to the present invention encloses a plurality of reinforced fiber woven fabrics in a gap formed by a mold and a film material via a sealing material. The liquid resin is injected into the gap using the differential pressure from the atmospheric pressure while the entire area of the gap is evacuated, and then the liquid resin is cured using a resin curing controller. In the molding of the fiber reinforced plastic that undergoes the process, the reinforced fiber woven fabric has at least two regions with different numbers of layers, and resin injection into at least two of the regions with different numbers of layers A thickness sensor capable of measuring the thickness of the reinforcing fiber woven fabric and a resin impregnated sensor capable of quantifying the resin impregnated state inside the reinforcing fiber woven fabric, and each of the regions having different numbers of laminated layers. A valve for individually opening and closing the resin injection path and the vacuum suction path that communicates with each other, confirming the measurement value of the thickness sensor, sending a control signal based on it, confirming the measurement value of the resin impregnation sensor, Transmission of control signals based on that and transmission of opening / closing control signals of all valves can be performed remotely from one terminal.

  In the automatic molding system according to the present invention, at least a region where the resin injection paths are not in contact with each other and the resin suction paths are not in contact with each other in the gap formed by the molding die and the film material via the sealing material. One form may exist.

  Alternatively, a thickness sensor capable of measuring the thickness of the reinforcing fiber woven fabric during resin injection and a resin impregnation capable of quantifying the resin impregnated state inside the reinforcing fiber woven fabric at least one place in each of the regions having different numbers of laminated layers. The structure provided with a sensor may be sufficient.

  A first configuration that suitably realizes the present invention is that, among the resin impregnation sensors in the system, one of the resin impregnation sensors detects that the impregnation is completed first, and then the last resin impregnation sensor is impregnated. A mechanism for controlling the thickness of the reinforcing fiber woven fabric in each of the impregnated regions to a predetermined thickness range based on the measurement value of the thickness sensor of the region in which the impregnation is detected. Is to have.

  A second configuration that preferably realizes the present invention is that, among the resin impregnation sensors in the system, one of the resin impregnation sensors detects that the first impregnation is completed first, and then the last resin impregnation sensor completes the impregnation. In order from the area where the completion of impregnation is detected, the vacuum suction path directly connected to the area where the completion of impregnation is closed by remote control and the area where the completion of impregnation is detected. Based on the measurement value of the thickness sensor installed in the resin, in the resin injection path directly connected to the impregnated region, there is a mechanism for controlling the thickness of the reinforcing fiber woven fabric in each of the impregnated region to a predetermined thickness range That is.

  After the thickness of the reinforcing fiber woven fabric is controlled within the predetermined thickness range by the first configuration or the second configuration, the resin injection path is switched to the vacuum suction path, and the vacuum suction is performed on all areas having different numbers of layers. The present invention can also be suitably realized by including a step of opening the path, and then closing all the vacuum suction paths by remote control after a predetermined time has elapsed.

  According to a third configuration that preferably realizes the present invention, after all the resin impregnation sensors in the system detect the impregnation, the resin injection path is switched to the vacuum suction path, and the vacuum in all the regions where the number of stacked layers is different. All the vacuum suction that communicates with the area in order from the area where the thickness sensor installed in each area where the number of stacked layers has reached has reached the predetermined thickness range. The route is to be closed remotely.

  According to a fourth configuration that preferably realizes the present invention, after all of the resin impregnation sensors in the system detect the impregnation, the resin injection path is switched to the vacuum suction path, and the vacuums of all the regions where the number of stacked layers are different are set. In the vacuum suction path that communicates with each of the regions having different numbers of layers, the thickness of the reinforcing fiber woven fabric in the region is within a predetermined thickness range until the resin is cured after the step of opening the suction route. It has a mechanism to control.

  Even after performing the thickness control of the reinforcing fiber woven fabric according to either the third configuration or the fourth configuration, following the thickness control of the reinforcing fiber woven fabric according to either the first configuration or the second configuration, The present invention can be suitably realized.

  As a mechanism for controlling the thickness of the reinforcing fiber woven fabric to a predetermined thickness range described in the first configuration, the second configuration, or the fourth configuration, a resin injection path or a vacuum suction path directly connected to the region is used. You may use the system which repeats opening and closing of the connected valve.

  Further, as a mechanism for controlling the thickness of the reinforcing fiber woven fabric to a predetermined thickness range described in the first configuration, the second configuration, or the fourth configuration, a resin injection path or vacuum suction directly connected to the region You may use the system which controls the magnitude of the internal diameter of the valve connected with the path | route.

  As a mechanism for controlling the thickness of the reinforcing fiber woven fabric to a predetermined thickness range as described in the second configuration or the fourth configuration, the resin temperature in the resin injection path or vacuum suction path directly connected to the region is changed to resin A method of increasing / decreasing using a curing control apparatus may be used.

  Alternatively, as a mechanism for controlling the thickness of the reinforcing fiber woven fabric to a predetermined thickness range described in the fourth configuration, a method of increasing or decreasing the degree of vacuum in the resin injection path or the vacuum suction path directly connected to the area is used. May be.

  The predetermined thickness range when controlling the thickness of the reinforcing fiber woven fabric in the region where the number of laminated layers is different is desirably 1 to 1.05 times the target thickness of the fiber reinforced plastic after resin curing.

  Or, if there is an error between the target thickness of fiber reinforced plastic after resin curing and the actual thickness of fiber reinforced plastic after resin curing, the reinforced fiber in the area where the number of layers will be different at the next molding It is desirable to have a system that adds the magnitude of the error to a predetermined thickness when controlling the thickness of the woven fabric.

  Moreover, it is desirable that the difference in thickness between the region having the maximum thickness and the region having the minimum thickness is 4 mm or more among the regions in which the number of laminated reinforcing fiber woven fabrics is different.

  Furthermore, the particle | grains which have a thermoplastic resin as a main component may be sprayed on the surface of the said reinforced fiber woven fabric.

  Also, detection of completion of impregnation by the resin impregnation sensor may be determined based on the measurement results of two or more types of resin impregnation sensors.

  According to the method of the present invention, VaRTM molding, which is low in cost as compared with a prepreg but is forced to undergo a large thickness fluctuation of the product during the manufacturing process, is applied to a molded product having a plurality of regions having different thicknesses. When applied, it is possible to improve the dimensional accuracy of the molded product due to the fluctuation, in particular, to improve the dimensional accuracy in the thickness direction, and to suppress variation in dimensional accuracy between the thick part and the thin part. Become.

It is the schematic diagram which showed the one aspect | mode of the VaRTM shaping | molding apparatus structure used in order to implement this invention. It is the figure which showed typically the XX 'cross section of FIG. It is the figure which showed the example of the control flowchart of a vacuum suction path | route. It is the figure which showed the example of the control flowchart of the resin injection | pouring path | route. It is the figure which showed the example of the control flowchart of a resin suction path | route.

  Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In addition, this invention is not limited to the aspect described in drawing.

  FIG. 1 and FIG. 2 illustrate an apparatus configuration for suitably realizing the automatic molding system of the present invention. A plurality of reinforced fiber woven fabrics 101 are stacked on the mold 100, and molding auxiliary materials such as peel ply 102 and resin path media are disposed at necessary positions above and below the woven fabric 101. The peel ply 102 is a release material that prevents adhesion between the fiber reinforced plastic and the resin pass media after the resin is cured, and the resin pass media is a mesh material or a non-woven fabric that serves as a flow path of the liquid resin 104. The resin injection medium 103 on the resin injection side communicates with the resin injection pipe 105, and the resin path medium 106 on the vacuum suction side communicates with the vacuum suction pipe 107. In the present invention, unless otherwise specified, the resin injection medium 103 on the resin injection side and the resin injection pipe 105 are referred to as a resin injection path. Similarly, the vacuum suction path is referred to as a vacuum suction path with the resin path medium 106 and the vacuum suction pipe 107 on the vacuum suction side as one body. The whole of the above is covered with a film material 109 through a sealing material 108. The resin injection path is connected to the resin container 110, the vacuum suction path is connected to the vacuum pump 111, and the inside of the film material 109 is kept in vacuum using the vacuum pump 111. As a result, the reinforced fiber woven fabric 101 enclosed in the gap formed by the mold 100 and the film material 109 via the sealing material 108 is in a liquid state stored in the resin container 110 due to a differential pressure from the atmospheric pressure. Resin 104 can be injected and impregnated. By curing the resin after the impregnation is completed using a curing control device, a fiber reinforced plastic is obtained.

  The number and form of the reinforcing fiber woven fabric 101 are arbitrarily set within a range that satisfies the mechanical properties expected of the FRP structure after molding. The type of reinforcing fiber to be used is not limited, and examples thereof include glass fiber, carbon fiber, aramid fiber, or reinforcing fiber using these in combination, and among them, the point of achieving both mechanical strength and weight reduction. Is considered, carbon fiber is preferably used. Moreover, the particle | grains which have a thermoplastic resin as a main component may be sprayed on the surface of this reinforced fiber woven fabric.

  The type of the liquid resin 104 to be injected is not limited and can be arbitrarily applied as long as it satisfies the mechanical properties expected of the FRP structure after molding. For example, thermosetting resins such as epoxy resins, unsaturated polyester resins, and phenol resins, thermoplastic resins such as polyester, polyolefin, and polyamide resins, and mixed resins thereof can be used. In the present invention, the curing step is a step of curing the thermosetting resin when the resin used is a thermosetting resin, and a heated thermoplastic resin when the resin used is a thermoplastic resin. When the monomer or oligomer is used as the step of cooling or the thermoplastic resin to be injected, it means the step of polymerizing and cooling the monomer or oligomer.

  The reinforced fiber woven fabric preform 112 has at least two regions where the number of laminated layers is different from each other. These regions can be rephrased as regions having different thicknesses. In FIG. 2, as an example, a region with the smallest thickness is a region A (117), and a region with the largest thickness is a region B (124). As the difference in thickness between the region A and the region B is larger, the liquid resin 104 impregnated in the region A first flows out into the region B and disturbs the resin impregnation route in the region B. Impregnation occurs and causes a decrease in strength of the fiber reinforced plastic. Such a phenomenon of resin outflow becomes remarkable in a range where the difference in thickness between the region B and the region A is 4 mm or more, and the present invention is effective in this range. If the difference in thickness between the region A and the region B is noted as the number of reinforcing fiber woven fabrics used in a general resin transfer molding process, the number of reinforcing fiber woven fabrics laminated in the region A and the region B The difference from the number of laminated reinforcing fiber woven fabrics is preferably 4 or more. Furthermore, when using the unidirectional reinforcing fiber woven fabric in which the thickness of the reinforcing fiber woven fabric per sheet is about 0.2 mm, the number of reinforcing fiber woven fabrics laminated in the region A and the reinforcement in the region B are used. The difference from the number of laminated fiber woven fabrics is more preferably 20 or more. The thinner the reinforcing fiber woven fabric per sheet, the lower the resin impregnation resistance in the thickness direction, and the more uniform resin impregnation can be realized. In addition, the thickness of the region A or the region B in the present invention is a strengthened state in each region before the resin is injected and in a state where the thickness of the peel ply, the resin pass media, or the like is removed. The thickness of the fiber woven fabric preform.

  It is desirable that an independent resin injection path and a vacuum suction path are provided in regions where the number of stacked layers is different. However, when there are many regions with different numbers of layers, in order to prevent the piping work for injection and suction from becoming complicated, a plurality of regions whose numbers of layers are close to each other are grouped, one for each group. It is good also as a form which installs each independent resin injection | pouring path | route and a vacuum suction path | route. Of the regions or groups having different numbers of layers, it is desirable that the resin injection path and the vacuum suction path are not in contact with each other in the areas or groups adjacent to each other. This is to prevent the resin from flowing out more than expected from the region where the number of stacked layers is large to the region where the number of stacked layers is large between adjacent regions or groups. For the purpose of preventing the arrangement work from being complicated, they may be in contact with each other as long as the phenomenon of resin outflow can be suppressed. Hereinafter, unless otherwise specified, the regions having different numbers of layers refer to regions where the resin injection path and the vacuum suction path are not in contact with each other.

  It is desirable that the thickness sensor 113 and the resin impregnation sensor 114 are installed in pairs in areas where the number of stacked layers is different. A plurality of sets of sensors may be arranged in one area where the number of stacked layers is different, or there may be an area where no sensors are arranged at all. However, ideally, it is desirable that at least one set of sensors is arranged in each of the regions where the number of laminated layers is different. Even when this is not possible, the number of laminated layers is different when viewed from the entire reinforced fiber woven fabric. Of the two regions, it is essential that at least one set of sensors be arranged only in the two regions having the largest difference in thickness. It should be noted that the number of thickness sensors and impregnation sensors in the present invention is not necessarily the same, and either sensor may exceed the number of the other sensor.

  As the thickness sensor 113, any thickness measuring method can be used as long as it measures the thickness of the reinforced fiber woven fabric during resin injection and can sequentially output the result. For example, a mechanical system such as a dial gauge, a differential transformer system, an electrostatic capacity system, an eddy current system, an ultrasonic system, or an optical laser system displacement meter can be used. It is desirable that the thickness sensor 113 be repeatedly installed in each region where the thickness sensor is installed, and be installed at a location that exhibits an average thickness variation behavior of the entire region. The measurement accuracy of the thickness sensor 113 is desirably a measurement accuracy of 0.5% or less of the target thickness after curing, assuming the smallest thickness portion of the entire FRP. When heating is required at the time of resin injection, it is desirable that the sensor has a corresponding heat resistance. In addition, a method of embedding sensor electrodes inside the film material 109 can be used for the purpose of reliably sensing the thickness variation of the reinforcing fiber woven fabric during the resin injection, but there is a risk of air bubbles mixing or non-impregnation due to vacuum leak. In consideration, it is more preferable to use a thickness sensor of a type that can be installed outside the gap formed by the mold 100 and the film material 109 via the seal material 108. In FIG. 1, the thickness sensor 113 is installed outside the gap formed by the mold 100 and the film material 109, but the thickness sensor 113 is installed inside the gap formed by the mold 100 and the film material 109. Alternatively, it may be disposed outside the gap formed by the mold 100 and the film material 109 and arranged in a direction facing each other on both the surface of the film material 109 and the surface of the mold 100. Good.

  The resin impregnation sensor 114 can be of any measurement method as long as the resin impregnation state inside the reinforced fiber woven fabric is quantified and the result can be sequentially output. For example, a resin impregnation sensor such as a photoelectric sensor, an ultrasonic sensor, or an electric resistance sensor can be used. It is desirable that the resin impregnation sensor is repeatedly stable in each region where the resin impregnation sensor is installed, and is installed at a location where the resin impregnation is slowest in the entire region. The measurement accuracy of the impregnation sensor 114 is not particularly defined as long as the completion of impregnation can be determined, but when impregnation completion determination is not reliable only by the measurement result of one sensor, two or more types of resin impregnation are performed. The measurement result of the sensor may be used. When heating is required at the time of resin injection, it is desirable that the sensor has a corresponding heat resistance. In addition, for the purpose of reliably sensing the impregnation fluctuation in the reinforcing fiber woven fabric during resin injection, a method of embedding a sensor inside the reinforced fiber woven fabric can also be used, but due to a vacuum leak through the sensor lead wire In consideration of the risk of air bubbles and non-impregnation, it is more preferable to use a resin-impregnated sensor of a type that can be installed outside the gap formed by the mold 100 and the film material 109 via the sealing material 108. In FIG. 1, the resin impregnation sensor 114 is installed outside the gap formed by the mold 100 and the film material 109, but the resin impregnation sensor 114 is disposed inside the gap formed by the mold 100 and the film material 109. May be installed outside the gap formed by the mold 100 and the film material 109, and arranged in a direction facing each other on both the surface of the film material 109 and the surface of the mold 100. May be.

  Thickness sensor 113 and resin impregnation sensor 114 are all connected to one control terminal 115. It is essential that the control terminal 115 includes a storage device and a control device. Further, in addition to being connected to all sensors, the control terminal 115 individually opens and closes all the resin injection paths and all the vacuum suction paths communicating with the different number of laminated layers by remote control. It is essential to be able to transmit an open / close control signal to each valve. It is desirable that the control signal can be transmitted either automatically or manually. Further, the control terminal is also connected to the resin curing control device 131, and it is necessary to remotely control the curing control device to control the temperature of the entire mold including the reinforcing fiber woven fabric and the temperature of the injected liquid resin. There is. It is desirable that the control terminal 115 can sequentially receive and record measurement data of each sensor and temperature measurement data used for resin curing control. Further, it is necessary to have a function of automatically executing internal processing based on all measurement data and transmitting a specific control signal based on the determination result of the internal processing. It is desirable that the measurement data sequentially transmitted from the thickness sensor 113 and the resin impregnation sensor 114 can be displayed on the monitor of the control terminal 115 and confirmed. If the above functions can be satisfied, any specifications, forms, control signal transmission methods, and the like of the control terminal 115 and the signal transmission cable 132 can be used.

  The valve 116 is operated by remote operation in response to any or all of a signal automatically received from the control terminal 115, a signal manually transmitted from the control terminal 115, and a signal transmitted at an arbitrary timing from a manual switch. Need to be possible. As long as the function of the operation by the remote operation is satisfied, any form of the valve 116 or the driving force of the opening / closing mechanism can be used. The valve 116 may be directly connected to the resin injection path so that the liquid resin 104 can pass therethrough. However, the resin serving as the resin injection path is considered in consideration of ease of mounting and the time for cleaning after the resin injection. It is desirable that the structure be attached to the manufactured tube from the outside. When heating is required at the time of resin injection, it is desirable that the valve has a corresponding heat resistance.

  In addition to the valve 116 performing only the opening / closing operation based on the control signal, the valve 116 can arbitrarily adjust and control the inner diameter of the resin injection path and the vacuum suction path based on the control signal, and the vacuum suction path based on the control signal Those that can arbitrarily adjust and control the degree of internal vacuum, those that can arbitrarily adjust and control the resin temperature inside the resin injection path and vacuum suction path based on the control signal, or a function that combines the above. Also good. For example, an electrically controlled on-off valve, a pneumatic control on-off valve, a vacuum regulator, a cartridge heater, or a combination of these functions may be provided.

  The resin curing control device 131 only needs to be capable of temperature control for temperature increase, temperature decrease, and isothermal holding based on a signal from the control terminal 115. Specifically, a heating / cooling control device using hot air and room temperature air, or hot air and cold air can be used. In addition, heating / cooling control devices that transfer heat via water or oil heating media, heating control devices using radiant heat, heating control devices using electric heaters, heating devices using chemical reactions, or heating control using electromagnetic heating systems An apparatus can also be used. The curing control device is required to act on the preform 112, but in addition, the resin injection container 104, the resin injection path, the vacuum suction path, or the valve 116 connected to the container or path. Alternatively, it may be a device that operates on a combination of the above-described containers, paths, and valves.

  The present invention has one of the three flowcharts of the vacuum suction path control flowchart 200, the resin injection path control flowchart 300, and the resin suction path control flowchart 400, or a combination thereof, under the apparatus configuration described above. It is essential to appropriately control the respective thickness portions of the preform 112 from the time the resin is impregnated until the resin is cured by the internal processing of the control terminal 115 based on the above. Below, each flowchart is described.

  FIG. 3 is a flowchart of a vacuum suction path control flowchart 200 in the internal processing of the control terminal 115. Region A refers to the region with the smallest thickness inside the preform 112, and region B refers to the region with the largest thickness within the preform 112. In addition, the basic configuration of the apparatus follows the configuration illustrated in FIGS. 1 and 2. In this internal processing, first, in a state (201) in which sensors are installed in each region from region A to region B, all the valves on all vacuum suction paths are opened by a control signal from the control terminal 115, and then all The valve on the resin injection path is opened and resin injection is started (202). From the time point (203) when the resin impregnation sensor in the region A first detects that the impregnation is completed, the resin injection path valve directly connected to the region A is closed by the control signal from the control terminal 115 (204). Stop the resin supply to. As a result, the surplus resin impregnated in the region A portion of the preform 112 is sucked and discharged through the vacuum suction path communicating with the region A, and the thickness of the region A starts to decrease (205). From here, until all the regions of the preform 112 reach a predetermined thickness (206), based on the measurement value of the thickness sensor in the region A, the control signal from the control terminal 115 and the response of the valve 116 thereto. Thus, the mechanism (207) for controlling the thickness of the region A to a predetermined thickness range works continuously. In the vacuum suction path control flowchart 200, a series of processes from when the resin impregnation sensor in each of the regions having different thicknesses detects impregnation until the mechanism for controlling the thickness of the region to a predetermined thickness range operates. The same flow 208 is applied to each of the regions having different thicknesses.

  A mechanism (207) for controlling the thickness of each of the regions having different thicknesses within a predetermined thickness range is a system that repeatedly opens and closes a valve connected to the vacuum suction path, and controls the size of the inner diameter of the valve connected to the vacuum suction path. Either a method, a method of increasing / decreasing the resin temperature in the vacuum suction path using a resin curing controller, a method of increasing / decreasing the degree of vacuum in the vacuum suction path, or a combination thereof can be used. These methods adjust the flow rate of the resin discharged from the regions having different thicknesses by increasing or decreasing the pressure loss in the vacuum suction path, thereby increasing the thickness reduction rate of the region proportional to the resin flow. It uses the principle of control.

  Thereafter, after detecting that the last resin impregnation sensor, that is, the resin impregnation sensor in the region B, has been completely impregnated (209), when all the regions having different thicknesses reach the predetermined thickness (206), the control terminal 115 According to the control signal, after the valves on all the resin injection paths are closed, the valves on all the vacuum suction paths are closed (210). And according to the control signal from the control terminal 115, the resin curing control device 131 works to cure the resin (211), thereby obtaining a fiber reinforced plastic.

  In the example of FIG. 3, there are only two types of regions with different thicknesses, region A and region B, but there are regions with different thicknesses other than these two types, and a thickness sensor and a resin impregnation sensor are attached to these regions. If so, 208 flows corresponding to the number of the regions are appropriately inserted at the locations indicated by 212. Further, the effect of the present invention can be suitably achieved by replacing the portion after 213 with the portion after 405 in the control flowchart 400 of the resin suction path shown in FIG.

  FIG. 4 is a flowchart of the resin injection path control flowchart 200 in the internal processing of the control terminal 115. Region A refers to the region with the smallest thickness inside the preform 112, and region B refers to the region with the largest thickness within the preform 112. In addition, the basic configuration of the apparatus follows the configuration illustrated in FIGS. 1 and 2. In this internal processing, first, in a state (301) in which sensors are installed in each region from region A to region B, all the valves on all the vacuum suction paths are opened by a control signal from the control terminal 115, The valve on the resin injection path is opened and resin injection is started (302). From the time point (303) when the resin impregnation sensor in the region A first detects that the impregnation is completed (303), the valve of the vacuum suction path directly connected to the region A is closed by the control signal from the control terminal 115 (304). Stop discharging resin. As a result, surplus resin flows into the region A portion of the preform 112 via the resin injection path communicating with the region A, so that the thickness of the region A starts to increase (305). From here, until all the regions of the preform 112 reach a predetermined thickness (306), based on the measurement value of the thickness sensor in the region A, the control signal from the control terminal 115 and the response of the valve 116 thereto Thus, the mechanism (307) for controlling the thickness of the region A to a predetermined thickness range works continuously. In the flow chart 300 for controlling the resin injection path, a series of processes from when the resin impregnation sensor in each of the regions having different thicknesses detects the impregnation until the mechanism for controlling the thickness of the region to a predetermined thickness range operates. The same flow 308 is applied to each of the regions having different thicknesses.

  A mechanism (307) for controlling the thicknesses of the regions having different thicknesses within a predetermined thickness range is a system that repeatedly opens and closes the valve connected to the resin injection path, and controls the size of the inner diameter of the valve connected to the resin injection path. Either a method, a method of increasing / decreasing the resin temperature in the resin injection path using a resin curing control device, a method of increasing / decreasing the degree of vacuum in the resin injection path, or a combination thereof can be used. These methods increase or decrease the pressure loss of the resin injection path to adjust the flow rate of the surplus resin flowing into the regions having different thicknesses, thereby increasing the thickness increase rate of the region proportional to the inflow of the resin. It uses the principle of control.

  Thereafter, after detecting that the last resin impregnation sensor, that is, the resin impregnation sensor in the region B, has been impregnated (309), when all the regions having different thicknesses reach the predetermined thickness (306), the control terminal 115 According to the control signal, after the valves on all the resin injection paths are closed, the valves on all the vacuum suction paths are closed (310). Then, according to a control signal from the control terminal 115, the resin curing control device 131 works to cure the resin (311), thereby obtaining a fiber reinforced plastic.

  In the example of FIG. 4, there are only two types of regions with different thicknesses, region A and region B, but there are regions with different thicknesses other than these two types, and a thickness sensor and a resin impregnation sensor are attached to these regions. In such a case, 308 flows corresponding to the number of the regions are appropriately inserted at the locations indicated by 312. Further, the part after 313 is replaced with the part after 405 in the resin suction path control flowchart 400 shown in FIG. 5, or the part 313 is switched from the resin injection path to the vacuum suction path, so that all the numbers of laminated sheets are different. It is also possible to insert a process in which all vacuum suction paths are closed by remote operation in accordance with a control signal from the control terminal 115 after a predetermined time has elapsed after the vacuum suction path in the area is opened. An effect can be exhibited suitably.

  After passing through either the vacuum suction path control flowchart 200 or the resin injection path control flowchart 300, the step of switching the resin injection path to the vacuum suction path and opening the vacuum suction paths in all the regions with different numbers of layers. The effect of the present invention can also be suitably achieved by using a method in which all the vacuum suction paths are closed by remote control after a certain time has elapsed.

  FIG. 5 is a flowchart of the resin suction path control flowchart 400 in the internal processing of the control terminal 115. The resin suction path refers to the resin injection path that is switched to the vacuum suction path when the resin injection path is switched to the vacuum suction path after the resin impregnation of the preform 112 is completed. It is defined to refer to both the vacuum suction path that leads to the area. In the present invention, unless otherwise specified, the term “resin suction route” refers to the route defined above. Region A refers to the region with the smallest thickness inside the preform 112, and region B refers to the region with the largest thickness within the preform 112. In addition, the basic configuration of the apparatus follows the configuration illustrated in FIGS. 1 and 2. In this internal processing, first, in a state (401) in which sensors are installed in each region from region A to region B, the valves on all the vacuum suction paths are opened by the control signal from the control terminal 115, The valve on the resin injection path is opened and resin injection is started (402). Thereafter, the completion of impregnation starts from the resin impregnation sensor in the region A (403), and the completion of resin impregnation in the region B, which is the last resin impregnation region, is detected (404). Therefore, the resin injection path directly connected to all the areas having different thicknesses is switched to the vacuum suction path by the control signal from the control terminal 115 (406), and the respective thicknesses of the area A to the area B start to decrease simultaneously. (407). From this point, control is performed from the control terminal 115 based on the measured value of the thickness sensor in the region until all the regions of the preform 112 reach the predetermined thickness (410) in the regions having different thicknesses. A mechanism (408) for controlling the thickness of the region to a predetermined thickness range works continuously according to the signal and the response of the valve 116 to the signal. In the control flowchart 400 for the resin suction path, a series of processes from when the resin impregnation sensor in each of the regions having different thicknesses detects impregnation until the mechanism for controlling the thickness of the region to a predetermined thickness range operates. The same flow 409 is applied to each of the regions having different thicknesses.

  A mechanism (408) for controlling the thickness of each of the regions having different thicknesses to a predetermined thickness range is a system that repeatedly opens and closes the valve connected to the vacuum suction path, and controls the size of the inner diameter of the valve connected to the vacuum suction path. Either a method, a method of increasing / decreasing the resin temperature in the vacuum suction path using a resin curing controller, a method of increasing / decreasing the degree of vacuum in the vacuum suction path, or a combination thereof can be used. These methods adjust the flow rate of the excess resin discharged from the regions having different thicknesses by increasing / decreasing the pressure loss in the vacuum suction path, thereby reducing the thickness reduction rate of the region in proportion to the resin discharge. It utilizes the principle of controlling.

  Thereafter, when all the regions having different thicknesses reach a predetermined thickness (410), the valves on all the vacuum suction paths are closed according to the control signal from the control terminal 115 (411). Then, according to a control signal from the control terminal 115, the resin curing control device 131 works to cure the resin (412), thereby obtaining a fiber reinforced plastic.

  In the example of FIG. 5, there are only two types of regions with different thicknesses, region A and region B, but there are regions with different thicknesses other than these two types, and a thickness sensor and a resin impregnation sensor are attached to the regions. If so, the flow of impregnation completion detection corresponding to 403 or 404 is inserted at the position indicated by 413, and the flow of 409 corresponding to the number of regions is appropriately inserted at the position indicated by 415.

  As described above, the “predetermined thickness range” set in each of the regions having different thicknesses is desirably 1 to 1.05 times the target thickness of the fiber-reinforced plastic after resin curing. As described above, when the thickness of each of the regions having different thicknesses reaches a predetermined thickness range, all the resin injection paths and the vacuum suction paths are closed to block the entry and exit of the resin in the areas. This is because the thickness of the region decreases due to the effect of curing shrinkage or the like when the resin undergoes a curing reaction. If the predetermined thickness range is set to a thickness range exceeding 1.05 times the target thickness of the fiber reinforced plastic after resin curing, the thickness of the fiber reinforced plastic will have tolerance even if the thickness reduction during curing is taken into account. It is difficult to achieve the desired dimensional accuracy. Further, if the predetermined thickness range is set to a range below the target thickness of the fiber reinforced plastic after resin curing, the thickness of the fiber reinforced plastic falls below the tolerance due to the thickness reduction during the curing, and a desired dimension is obtained. There is an increased risk that it will be difficult to achieve accuracy. In this case, in particular, when the control flowchart 400 for the resin suction path in which vacuum suction is continued until immediately before curing, the curing reaction is started with the pressure inside the preform being reduced by vacuum suction. Since the thickness reduction during the curing becomes significant, it becomes more difficult to achieve dimensional accuracy.

  When the thickness control of the reinforcing fiber woven fabric is performed based on the flowchart of the present invention, there is an error between the target thickness of the fiber reinforced plastic after resin curing and the actual thickness of the fiber reinforced plastic after resin curing. If it occurs, it is desirable to have a function of adjusting the parameters of the internal processing of the control terminal by feeding back the result of this error at the next molding. Specifically, it is desirable to be able to execute a process of adding the magnitude of this error to a predetermined thickness when controlling the thickness of the reinforcing fiber woven fabric in the region where the number of laminated layers is different. This is because the thickness reduction during curing has variations due to differences in the curing rate inside the preform. Such a feedback function is not limited to the above-described addition process as long as it is an internal process capable of offsetting this variation.

  In addition, the present invention is more preferable if the impregnation detection of the resin impregnation sensor installed in each of the regions having different thicknesses in the flowchart of the present invention is determined using the measurement results of two or more types of resin impregnation sensors. The effect of can be demonstrated. This is because the measurement result of the resin impregnated sensor alone does not necessarily accurately represent the impregnation state of the entire region where the sensor is installed. This is because it is necessary to improve the reliability of the impregnation determination.

  In the industrial field that requires a large FRP structural member that is lightweight and requires high bending rigidity, the present invention realizes a reduction in manufacturing cost while achieving high dimensional accuracy of a molded product thickness. It contributes to the improvement of competitiveness. Specific applications include aircraft wing members, wind power rotor blades, hull structural members, and the like.

DESCRIPTION OF SYMBOLS 100 ... Mold 101 ... Reinforcement fiber woven fabric 102 ... Peel ply 103 ... Resin injection side resin 104 on resin injection side ... Liquid resin 105 ... Resin injection pipe 106 ... Vacuum suction Resin pass media 107 on the side ... Vacuum suction pipe 108 ... Sealing material 109 ... Film material 110 ... Resin container 111 ... Vacuum pump 112 ... Reinforced fiber woven preform 113 ... · Thickness sensor 114 ··· Resin impregnation sensor 115 ··· Control terminal 116 ··· Valve 117 ··· Region A
118... Resin path media on the resin injection side (communication to area A)
119: Resin injection pipe (communication to area A)
120 ・ ・ ・ Resin pass media on the vacuum suction side (communication to area A)
121 ・ ・ ・ Vacuum suction pipe (communication to area A)
122 ... Area A thickness sensor 123 ... Area A resin impregnation sensor 124 ... Area B
125 ・ ・ ・ Resin path media on the resin injection side (communication to area B)
126 ... Resin injection pipe (communication to area B)
127 ・ ・ ・ Resin path media on the vacuum suction side (communication to area B)
128 ・ ・ ・ Vacuum suction pipe (communication to area B)
129 ... Thickness sensor 130 in area B ... Resin impregnation sensor 131 in area B ... Resin curing control device 132 ... Signal transmission cable 200 ... Control flow chart 300 for vacuum suction path ... Resin Injection flow path control flowchart 400 ... Resin suction flow control flow chart

Claims (18)

A plurality of reinforcing fiber woven fabrics are sealed in a gap formed by a mold and a film material via a sealing material, and a liquid resin is poured toward the gap while evacuating the entire gap. In the molding of fiber reinforced plastic, which is injected using a pressure difference from atmospheric pressure and then cured using a resin curing control device, the reinforced fiber woven fabric has a number of laminated layers. Thickness sensor and reinforcing fiber weave having at least two different regions, and capable of measuring the thickness of the reinforcing fiber woven fabric during resin injection in each of at least two or more regions out of the different number of layers It is equipped with a resin impregnation sensor that can quantify the resin impregnation state inside the cloth, and can individually open and close the resin injection path and the vacuum suction path that communicate with each of the different areas of the number of layers. Receiving the measurement value of the thickness sensor and transmitting the control signal based on the measurement value, receiving the measurement value of the resin impregnation sensor and transmitting the control signal based on the measurement value, and opening / closing control signals of all the valves An automatic molding system for fiber reinforced plastic having a control terminal configured to allow remote control of transmission. The thickness sensor which can measure the thickness of the reinforced fiber woven fabric during resin injection | pouring at least one place in each of the area | regions where the lamination | stacking number differs among the systems of Claim 1 and resin inside a reinforced fiber woven fabric An automatic molding system for fiber-reinforced plastic, comprising a set of a resin impregnation sensor capable of quantifying the impregnation state. In the system according to claim 1 or 2, the resin injection paths are not in contact with each other and the vacuum suction paths are also in contact with each other in the gap formed by the mold and the film material through the sealing material. An automatic molding system for fiber-reinforced plastic, characterized in that there are at least one set of non-existing regions. Among the resin impregnation sensors in the system according to any one of claims 1 to 3, after detecting that one of the resin impregnation sensors is initially impregnated, the measured values of all the thickness sensors are within a predetermined thickness range. Until it is detected that the impregnation is completed, in order from the region where the impregnation completion is detected, the valve connected to the resin injection path directly connected to the region where the impregnation completion is detected is remotely closed, and A fiber having a mechanism for controlling the thickness of the reinforcing fiber woven fabric in each of the impregnated regions to a predetermined thickness range based on the measurement value of the thickness sensor in the region where the impregnation is detected. Reinforced plastic automatic molding system. Among the resin impregnation sensors in the system according to any one of claims 1 to 3, after detecting that one of the resin impregnation sensors is initially impregnated, the measured values of all the thickness sensors are within a predetermined thickness range. Until it is detected that the impregnation is completed, in order from the region where the impregnation is detected, the valve connected to the vacuum suction path directly connected to the region where the impregnation is detected is remotely closed, and Based on the measured value of the thickness sensor installed in the area where the impregnation is detected, the thickness of the reinforcing fiber woven fabric in each of the impregnated areas is set to a predetermined thickness in the resin injection path directly connected to the impregnated areas. A fiber-reinforced plastic automatic molding system characterized by having a mechanism for controlling the range. After all of the resin impregnation sensors in the system according to claim 4 or 5 detect the impregnation, and the thickness of the reinforcing fiber woven fabric in the region where the impregnation is finally detected is controlled within a predetermined thickness range. , Switching the resin injection path to the vacuum suction path, and opening the valves connected to the vacuum suction paths of all the areas where the number of stacked layers is different. An automatic molding system for fiber-reinforced plastic, characterized in that a valve connected to the door is remotely closed. 4. After all of the resin impregnation sensors in the system according to claim 1 detect the impregnation, the resin injection path is switched to the vacuum suction path, and the vacuum suction paths in all the regions having different numbers of layers are opened. After that, the thickness sensors installed in each of the regions having different numbers of layers were connected to all the vacuum suction paths communicating with the region in order from the region where it was detected that the thickness sensor reached the predetermined thickness range. A fiber-reinforced plastic automatic molding system, characterized in that the valve is closed remotely. 4. After all of the resin impregnation sensors in the system according to claim 1 detect the impregnation, the resin injection path is switched to the vacuum suction path, and the vacuum suction paths in all the regions having different numbers of layers are opened. A mechanism for controlling the thickness of the reinforcing fiber woven fabric in the region to a predetermined thickness range in a vacuum suction path communicating with each of the regions having different numbers of layers until the resin is cured thereafter. An automatic molding system for fiber-reinforced plastic, comprising: The thickness control of the reinforced fiber woven fabric by the system according to claim 7 or 8 is performed following the thickness control of the reinforced fiber woven fabric by the system according to claim 4 or 5. Molding system. The system for repeatedly opening and closing a valve connected to a resin injection path or a vacuum suction path directly connected to the region as a mechanism for controlling the thickness of the reinforcing fiber woven fabric according to claim 4, 5 or 8 to a predetermined thickness range An automatic molding system for fiber-reinforced plastic, characterized in that As a mechanism for controlling the thickness of the reinforced fiber woven fabric according to claim 4, 5 or 8, the size of the inner diameter of a valve connected to a resin injection path or a vacuum suction path directly connected to the region is set. An automatic molding system for fiber-reinforced plastic, characterized by using a control method. As a mechanism for controlling the thickness of the reinforcing fiber woven fabric according to claim 5 or 8 to a predetermined thickness range, a method for controlling the temperature of a resin injection path or a vacuum suction path directly connected to the area is controlled. An automatic molding system for fiber-reinforced plastic, characterized by being used. The mechanism for controlling the thickness of the reinforcing fiber woven fabric according to claim 8 to a predetermined thickness range is characterized by using a method for increasing or decreasing the degree of vacuum in the resin injection path or vacuum suction path directly connected to the region. Automatic fiber reinforced plastic molding system. The predetermined thickness range when controlling the thickness of the reinforcing fiber woven fabric in the region where the number of layers is different is characterized by being 1-1.05 times the thickness of the target fiber-reinforced plastic after resin curing, An automatic molding system for fiber-reinforced plastic according to any one of claims 4 to 13. If there is an error between the target thickness of fiber reinforced plastic after resin curing and the actual thickness of fiber reinforced plastic after resin curing, the reinforced fiber woven fabric in the area where the number of layers will be different at the next molding The automatic molding system for fiber-reinforced plastic according to any one of claims 4 to 14, wherein a value of the error is added to a predetermined thickness when controlling the thickness of the fiber. The difference in thickness between the region having the largest thickness and the region having the smallest thickness among the regions where the number of laminated reinforcing fiber woven fabrics is different is 4 mm or more. The automatic molding system described. The automatic molding system according to any one of claims 1 to 16, wherein particles mainly composed of a thermoplastic resin are dispersed on a surface of the reinforced fiber woven fabric. 18. The automatic molding system according to claim 1, wherein detection of completion of impregnation by the resin impregnation sensor is determined based on measurement results of two or more types of resin impregnation sensors.

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