JP6048730B2 - Preform manufacturing method - Google Patents

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JP6048730B2
JP6048730B2 JP2012198819A JP2012198819A JP6048730B2 JP 6048730 B2 JP6048730 B2 JP 6048730B2 JP 2012198819 A JP2012198819 A JP 2012198819A JP 2012198819 A JP2012198819 A JP 2012198819A JP 6048730 B2 JP6048730 B2 JP 6048730B2
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prepreg
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JP2014051077A (en
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佳秀 柿本
佳秀 柿本
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三菱レイヨン株式会社
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本発明は、所望の立体形状を有する繊維強化樹脂成形品を得るべく、その本成形に先立って、シート状のプリプレグを雄雌型の間でプレスすることにより、プリフォームとするプリフォームの製造方法に関する。   In order to obtain a fiber-reinforced resin molded article having a desired three-dimensional shape, the present invention manufactures a preform to be a preform by pressing a sheet-like prepreg between male and female molds prior to the main molding. Regarding the method.
従来、例えば強化繊維に未硬化の熱硬化性樹脂を含浸させてなるシート状のプリプレグを成形型内で加熱、加圧することで、所定形状の繊維強化樹脂成形品を得る技術が知られている(例えば、特許文献1参照。)。   Conventionally, for example, a technique for obtaining a fiber-reinforced resin molded product having a predetermined shape by heating and pressing a sheet-like prepreg formed by impregnating a reinforcing fiber with an uncured thermosetting resin in a molding die is known. (For example, refer to Patent Document 1).
また、曲面を含む三次元形状を有するような繊維強化樹脂成形品を製造する場合には、シート状のプリプレグから最終成形品の形状を考慮した所定形状のプリフォームを、本成形に先立って予め賦形する技術も知られている。このような、プリフォームの賦形方法としては、例えば、シワの発生を抑制するために、部分的に延長させたプリプレグを複数枚積層し、その延長させた部分を成形機に設置した張力付与手段により張力を付与させながら雄雌型でプレスすることにより賦形させて、賦形後にその延長部分を切除して所望のプリフォームを得る方法も知られている(例えば、特許文献2参照)。   In addition, when manufacturing a fiber reinforced resin molded product having a three-dimensional shape including a curved surface, a preform having a predetermined shape considering the shape of the final molded product from a sheet-like prepreg is preliminarily formed prior to the main molding. Techniques for shaping are also known. As such a preform shaping method, for example, in order to suppress the generation of wrinkles, a plurality of partially extended prepregs are laminated, and the extended portion is installed in a molding machine. There is also known a method in which a desired preform is obtained by shaping by pressing with a male and female mold while applying tension by means, and then cutting out the extension after shaping (see, for example, Patent Document 2). .
国際公開第2004/018186号International Publication No. 2004/018186 特開2011−110899号公報JP 2011-110899 A
しかしながら、深絞り等複雑形状の賦形を行う場合、張力付与手段が固定されていることで、張力付与手段の位置でプリプレグが拘束され、張力のかかる方向がプレスしている間で大きく変動してしまうため、プリフォームの表面にシワができたり、所望の形状までプリプレグを賦形させることができなかったりする問題があった。   However, when shaping complex shapes such as deep drawing, the tension applying means is fixed, so that the prepreg is constrained at the position of the tension applying means, and the direction in which the tension is applied varies greatly during pressing. Therefore, there is a problem that the surface of the preform is wrinkled or the prepreg cannot be shaped to a desired shape.
また、上記の影響が出ないように、プリプレグの余剰部分を大きく延長させた場合は、シワの回避が困難であり、シワ回避が可能となるまで張力を加えるためには、より大きな荷重で張力を加えることが必要となり、その結果、装置が大型化することや、それに伴って高価な装置となる問題があった。また、プリプレグの余剰部分はロスとなるので、ロスが多くなりコストアップの要因となった。   Also, if the excess part of the prepreg is greatly extended so that the above effect does not occur, it is difficult to avoid wrinkles, and in order to apply tension until it is possible to avoid wrinkles, As a result, there has been a problem that the apparatus becomes larger and accordingly the apparatus becomes expensive. In addition, since the surplus portion of the prepreg becomes a loss, the loss increases and causes a cost increase.
本発明は、前記事情を鑑みてなされたものであり、プリフォームのシワ回避と所望形状への賦形の両立が可能となるプリフォームの製造方法を提供することを目的とする。   The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a preform capable of avoiding wrinkling of the preform and shaping the preform into a desired shape.
本発明は、立体形状を有する繊維強化樹脂成形品を得るべく、強化繊維とマトリックス樹脂を含むシート状のプリプレグを雄雌型の間でプレスすることで、プリフォームとするプリフォームの製造方法であって、
前記シート状のプリプレグを雄雌型のプレスする際に、シート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を加えながらシート状のプリプレグを雄雌型でプレスすることで賦形するプリフォームの製造方法にある。
The present invention is a method for producing a preform, which is a preform by pressing a sheet-like prepreg containing reinforcing fibers and a matrix resin between male and female molds in order to obtain a three-dimensional fiber reinforced resin molded product. There,
When the male and female prepregs are pressed on the sheet-like prepreg, the sheet-like prepreg is pressed while applying tension in the direction perpendicular to the male and female dies to be pressed from the center to the outer edge. It is in the manufacturing method of the preform which shape | molds by pressing a prepreg with a male-female type | mold.
本発明のプリフォームの製造方法によれば、プリフォームのシワ回避と所望形状への賦形の両立が可能となる。   According to the preform manufacturing method of the present invention, it is possible to achieve both avoidance of wrinkling of the preform and shaping to a desired shape.
本発明のプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows one process in one Embodiment of the manufacturing method of the preform of this invention. 本発明のプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows one process in one Embodiment of the manufacturing method of the preform of this invention. 本発明とは異なるプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows 1 process in one Embodiment of the manufacturing method of the preform different from this invention. 本発明とは異なるプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows 1 process in one Embodiment of the manufacturing method of the preform different from this invention. 本発明とは異なるプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows 1 process in one Embodiment of the manufacturing method of the preform different from this invention. 本発明のプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows one process in one Embodiment of the manufacturing method of the preform of this invention. 本発明のプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows one process in one Embodiment of the manufacturing method of the preform of this invention. 本発明のプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows one process in one Embodiment of the manufacturing method of the preform of this invention. 本発明のプリフォームの製造方法の一実施形態例における一工程を示す図である。It is a figure which shows one process in one Embodiment of the manufacturing method of the preform of this invention.
本発明のプリフォームの製造方法における第一の実施形態例について説明する。以下の工程(1)〜(5)を順次経てプリフォームを製造する。
(1)雌雄型の間に強化繊維とマトリックス樹脂を含むシート状のプリプレグを配置する。
(2)シート状のプリプレグの外延部の必要箇所をクランプで把持して、シート状のプリプレグに張力を付与させる。
(3)シート状のプリプレグに張力を付与したまま、加熱する。
(4)クランプの位置をプリフォーム型(雄雌型)がプレスする際に移動する方向に可動するようにしたのち、加熱したプリプレグをプリフォーム型でプレスして賦形させる。
(5)張力を除去し、クランプを外した後、プリフォーム型を開き、プリフォームを取り出す。
具体的にはまず、図1に示すようにプリフォーム型(雌型10及び雄型20)にプリプレグ30を配置する。
A first embodiment of the preform manufacturing method of the present invention will be described. A preform is manufactured through the following steps (1) to (5).
(1) A sheet-like prepreg containing reinforcing fibers and a matrix resin is placed between the male and female molds.
(2) A necessary portion of the outer extension portion of the sheet-like prepreg is held by a clamp, and tension is applied to the sheet-like prepreg.
(3) Heat the sheet-like prepreg while applying tension.
(4) After the position of the clamp is made to move in the direction of movement when the preform mold (male and female mold) is pressed, the heated prepreg is pressed with the preform mold and shaped.
(5) After removing the tension and removing the clamp, the preform mold is opened and the preform is taken out.
Specifically, first, as shown in FIG. 1, the prepreg 30 is arranged in a preform mold (female mold 10 and male mold 20).
(プリフォーム型)
本実施形態例におけるプリフォーム型は、型を挟圧させたときにプリプレグ30を所望の形状に賦形できるようなプリフォーム型であれば、本発明のプリフォームの製造方法に用いることができる。
図1では、上型に雌型10、下型に雄型20を用いているが、それが反対になっていても構わないし、また、どちらか一方が固定型でもう一方が可動型であっても構わない。
プリフォーム型の材質は金属、ケミカルウッドなどプリプレグを賦形させることができるものであれば特に制限はないが、材料が安価であること、加工が容易であることからケミカルウッドであることが好ましい。
(Preform type)
The preform mold in this embodiment can be used in the preform manufacturing method of the present invention as long as the preform mold can shape the prepreg 30 into a desired shape when the mold is clamped. .
In FIG. 1, the female mold 10 is used for the upper mold and the male mold 20 is used for the lower mold, but they may be reversed, and either one is a fixed mold and the other is a movable mold. It doesn't matter.
The preform material is not particularly limited as long as it can shape the prepreg such as metal and chemical wood, but is preferably chemical wood because the material is inexpensive and easy to process. .
(プリプレグ)
本発明のプリフォームの製造方法に用いることができるプリプレグ30の大きさは必要箇所をクランプできる程度に賦形後に得たい形状より大きければよい。また、プリプレグ30の形態は、強化繊維が一方向に引き揃えられたUDプリプレグであってもよいし、強化繊維が製織された織物プリプレグであってもよい。さらに、プリプレグ30の形状としては、例えば、三角形状、矩形状、菱形状等の多角形状、円形状、楕円形状、扇形状などが挙げられるが、所望の成形品に応じて適宜選択すればよい。
(Prepreg)
The size of the prepreg 30 that can be used in the preform manufacturing method of the present invention may be larger than the shape that is desired to be obtained after shaping to such an extent that necessary portions can be clamped. The form of the prepreg 30 may be a UD prepreg in which reinforcing fibers are aligned in one direction, or a woven prepreg in which reinforcing fibers are woven. Furthermore, examples of the shape of the prepreg 30 include a triangular shape, a rectangular shape, a polygonal shape such as a rhombus shape, a circular shape, an elliptical shape, and a fan shape, and may be appropriately selected depending on a desired molded product. .
本発明のプリフォームの製造方法に用いることができるプリプレグ30に含まれる強化繊維としては、例えば、炭素繊維、ガラス繊維、アラミド繊維、高強度ポリエステル繊維、ボロン繊維、アルミナ繊維、窒化珪素繊維、ナイロン繊維などが挙げられる。これらの中でも比強度および比弾性に優れることから、炭素繊維が好ましい。   Examples of the reinforcing fiber included in the prepreg 30 that can be used in the method for manufacturing a preform of the present invention include carbon fiber, glass fiber, aramid fiber, high-strength polyester fiber, boron fiber, alumina fiber, silicon nitride fiber, and nylon. Examples include fibers. Among these, carbon fiber is preferable because it is excellent in specific strength and specific elasticity.
本発明のプリフォームの製造方法に用いることができるプリプレグ30に含まれるマトリックス樹脂としては、熱硬化性樹脂が好ましい。熱硬化性樹脂としては、例えば、エポキシ樹脂、不飽和ポリエステル樹脂、アクリル樹脂、ビニルエステル樹脂、フェノール樹脂、ベンゾオキサジン樹脂などが挙げられる。これらの中でも、硬化後の強度を高くできることから、エポキシ樹脂であることがさらに好ましい。
プリプレグ30に含まれるマトリックス樹脂中には、硬化剤、離型剤、脱泡剤、紫外線吸収剤、充填材などの各種添加剤などが含まれてもよい。
As the matrix resin contained in the prepreg 30 that can be used in the preform manufacturing method of the present invention, a thermosetting resin is preferable. Examples of the thermosetting resin include an epoxy resin, an unsaturated polyester resin, an acrylic resin, a vinyl ester resin, a phenol resin, and a benzoxazine resin. Among these, an epoxy resin is more preferable because the strength after curing can be increased.
The matrix resin contained in the prepreg 30 may contain various additives such as a curing agent, a release agent, a defoaming agent, an ultraviolet absorber, and a filler.
本発明のプリフォームの製造方法に用いることができるプリプレグ30は、2〜30枚積層して積層体として用いることが好ましい。プリプレグ30の積層枚数が2枚以上であれば、充分な強度の成形品を得ることができ、30枚以下であれば、積層のコストを抑えることができるので好ましい。   It is preferable that 2 to 30 prepregs 30 that can be used in the preform manufacturing method of the present invention are laminated and used as a laminate. If the number of laminated prepregs 30 is two or more, a sufficiently strong molded product can be obtained, and if it is 30 or less, the cost of lamination can be suppressed, which is preferable.
(張力付与手段)
本発明のプリフォームの製造方法では、シート状のプリプレグを雄雌型のプレスする際に、シート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を付与させることが必要である。図2にその一例を示す。
本発明のプリフォームの製造方法では、シート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を付与させる際に、シート状のプリプレグの外延部を把持するクランプ41と、雄雌型のプレスする際にシート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を付与する張力付与機構42と、クランプの把持する位置をプレスする方向に可動できる位置可動機構43とを有する張力付与手段40を有することが好ましい。
(Tensioning means)
In the preform manufacturing method of the present invention, when a sheet-like prepreg is male-female pressed, it is perpendicular to the direction in which the male-female mold is pressed from the center of the sheet-like prepreg toward the outer edge. It is necessary to apply tension in the direction. An example is shown in FIG.
In the preform manufacturing method of the present invention, when applying tension in the direction perpendicular to the direction of pressing with the male and female dies, from the center of the sheet-shaped prepreg toward the outer edge, the sheet-shaped prepreg Clamp 41 that grips the outer extension, and tension that applies tension in a direction perpendicular to the direction of pressing by the male and female dies from the center of the sheet-like prepreg toward the outer edge when the male and female dies are pressed. It is preferable to have tension applying means 40 having an applying mechanism 42 and a position movable mechanism 43 that can move in the direction of pressing the position held by the clamp.
クランプ41の材質としては、プリフォームを成形する温度では変形せず、また、加熱して軟化したプリプレグを十分把持できるものであれば特に制限はないが、加工性や入手のしやすさからプラスチック製品であることが好ましい。また、クランプする方式としては、バネ式やエアシリンダー式などが挙げられるが、荷重を大きくする際の作業性からエアシリンダー式であることが好ましい。また、プリプレグをクランプで把持する位置は、実際に賦形させてシワ回避の状況を確認しながらトライアンドエラーで決めても構わないし、必要があれば、賦形させたい形状の賦形性解析を行い、シワが混入しやすいと思われる位置をクランプで把持しても構わない。
プリプレグ30をクランプ41で把持させた後、雄雌型でプレスする際に、張力付与機構42を用いて、シート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を付与することが望ましい。
The material of the clamp 41 is not particularly limited as long as it does not deform at the temperature at which the preform is molded and can sufficiently hold the prepreg heated and softened. A product is preferred. In addition, examples of the clamping method include a spring type and an air cylinder type, but an air cylinder type is preferable from the viewpoint of workability when increasing the load. In addition, the position where the prepreg is gripped by the clamp may be determined by trial and error while actually shaping and checking the state of wrinkle avoidance, and if necessary, the shapeability analysis of the shape to be shaped The position where wrinkles are likely to be mixed may be gripped with a clamp.
When the male and female molds are pressed after the prepreg 30 is held by the clamp 41, the tension applying mechanism 42 is used to press the male and female molds from the center of the sheet-like prepreg toward the outer edge. It is desirable to apply tension in a direction perpendicular to the direction.
図3に示すように、垂直方向より上方向に張力を付与する場合は、プリプレグ30が上方向に移動するため、雄雌型でプレスする際に、雄雌型の移動を妨げる方向に荷重が加わることで、所望の形状にプリプレグを賦形させることが困難となる。
また図4に示すように、垂直方向より下方向に張力を付与する場合は、プリプレグ30が下方向に移動するため、賦形させたい形状によっては、雄雌型でプレスするために型で挟み込む前に、プリプレグと型が接触してしまう。その状態でプレスを行うと、形状が乱れてしまう恐れがある。
張力を付与する方式としては、エアシリンダー方式や巻きバネ方式などが挙げられるが、荷重を受けた際にスムーズに可動できる点から巻きバネ方式が望ましい。また、張力付与機構42により、プリプレグ30に付与する張力としては、0.1〜5.0kgであることが好ましい。
As shown in FIG. 3, when tension is applied upward from the vertical direction, since the prepreg 30 moves upward, when pressing with a male and female mold, a load is applied in a direction that hinders the movement of the male and female molds. By adding, it becomes difficult to shape the prepreg into a desired shape.
Also, as shown in FIG. 4, when tension is applied downward from the vertical direction, the prepreg 30 moves downward, so that depending on the shape to be shaped, it is sandwiched by a mold for pressing with a male and female mold. Before, the prepreg and the mold come into contact. If pressing is performed in this state, the shape may be disturbed.
Examples of a method for applying tension include an air cylinder method and a winding spring method, but the winding spring method is desirable because it can move smoothly when a load is applied. The tension applied to the prepreg 30 by the tension applying mechanism 42 is preferably 0.1 to 5.0 kg.
本発明のプリフォームの製造方法では、プリプレグ30に張力を付与したまま所定の温度まで加熱した後、位置可動機構43で、クランプで把持する位置を型のプレス方向に可動できるようにすることがさらに好ましい。
図5に示すように、クランプで把持する位置が固定されてしまう場合は、型でプレスする時にその位置でプリプレグが拘束されてしまうため、所望の形状までプリプレグを賦形させることができない。
クランプで把持する位置を可動させる方法としては、エアシリンダー方式や巻きバネ方式などが挙げられるが、荷重を受けた際にスムーズに可動できる点から巻きバネ方式が望ましい。図2では、張力付与手段40の自重を支えるよう巻きバネが配置さえており、雄雌型でプレスする時に受けた荷重に合わせてチャック位置が可動できるようになっている。
In the preform manufacturing method of the present invention, after the prepreg 30 is heated to a predetermined temperature while tension is applied, the position movable mechanism 43 can move the position held by the clamp in the press direction of the mold. Further preferred.
As shown in FIG. 5, when the position gripped by the clamp is fixed, the prepreg is constrained at that position when pressing with a mold, so that the prepreg cannot be shaped to a desired shape.
Examples of the method for moving the position held by the clamp include an air cylinder method and a winding spring method, but the winding spring method is desirable because it can move smoothly when a load is applied. In FIG. 2, a winding spring is even arranged to support the own weight of the tension applying means 40, and the chuck position can be moved according to the load received when pressing with the male and female dies.
(加熱機)
本発明のプリフォームの製造方法では、図6に示すように、プリプレグ30を加熱機50で加熱させることが好ましい。加熱機50は、賦形前にプリプレグ30を軟化させるために加熱するものである。加熱方式としては、例えば、熱風式、赤外線式などが挙げられるが、加熱時間を短縮できる点から赤外線式が好ましい。
(Heating machine)
In the preform manufacturing method of the present invention, the prepreg 30 is preferably heated by a heater 50 as shown in FIG. The heater 50 heats the prepreg 30 before softening. Examples of the heating method include a hot air type and an infrared type, but an infrared type is preferable because the heating time can be shortened.
また、この加熱機50は、加熱するときのみプリプレグ30の上部に位置し、それ以外のときは型の動作の妨げにならないように場所に位置している。また、プリプレグ30の加熱温度は40〜80℃であることが好ましい。加熱温度を40℃以上にすれば、所定のプリフォームの形状に容易に成形でき、80℃以下にすれば、プリフォーム製造時の熱硬化性樹脂の硬化を防ぐことができる。その後、図7で示すように、雌型10を下降させて、雄型20と雌型10とでプレスしてプリプレグ30を賦形させる。その際、張力付与機構42にて雄雌型でプレスする方向に対して垂直方向に適切な張力を付与しながら、雄雌型でプレスするのに合わせてプリプレグが引き込まれている。また、位置可動機構43にて雄雌型でのプレスの進行状況に合わせてクランプの把持する位置が可動している。   The heater 50 is located above the prepreg 30 only when it is heated, and at other times it is located so as not to hinder the operation of the mold. Moreover, it is preferable that the heating temperature of the prepreg 30 is 40-80 degreeC. If the heating temperature is 40 ° C. or higher, it can be easily molded into a predetermined preform shape, and if it is 80 ° C. or lower, the thermosetting resin can be prevented from being cured during the manufacture of the preform. Thereafter, as shown in FIG. 7, the female mold 10 is lowered and pressed by the male mold 20 and the female mold 10 to shape the prepreg 30. At this time, the prepreg is pulled in along with the pressing with the male and female dies while applying an appropriate tension perpendicular to the direction of pressing with the male and female dies by the tension applying mechanism 42. Further, the position held by the clamp is moved by the position moving mechanism 43 in accordance with the progress of the press in the male and female dies.
また、雄雌型でプレスする時の圧力は0.01〜0.1MPaであることが好ましい。圧力を0.01MPa以上にすれば、所定のプリフォームの形状に容易に成形でき、0.1MPa以下にすれば、プリフォームの製造装置を単純化することができる。
ついで図8で示すように、張力を除去してクランプ41を外した後、雌型10を上昇させて、図9に示すように、雄型20から賦形されたプリプレグ30を取り出す。
Moreover, it is preferable that the pressure at the time of pressing with a male-female type | mold is 0.01-0.1 MPa. If the pressure is 0.01 MPa or more, it can be easily formed into a predetermined preform shape, and if it is 0.1 MPa or less, the preform manufacturing apparatus can be simplified.
Then, as shown in FIG. 8, after removing the clamp 41 by removing the tension, the female mold 10 is raised, and the prepreg 30 shaped from the male mold 20 is taken out as shown in FIG.
以上説明したプリフォームの製造方法では、プリフォーム型(雌型10と雄型20)に積層済みプリプレグ30を配置した後、プリプレグ30の外延部を張力付与手段40のクランプ41にて把持し、シート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を付与する。雌雄型でプレスしてプリプレグを賦形させる。
このように、シート状のプリプレグの中心部から外縁部に向かって張力を付与させて、クランプ位置を雄雌型のプレス方向に可動できるようにすることで、雄雌型を閉じるまでの間、プリプレグに、雄雌型でプレスする方向に対して垂直な方向に張力を加えることができる。その結果、プリフォームのシワ回避と所望形状への賦形の両立が可能となる。
In the preform manufacturing method described above, after placing the laminated prepreg 30 on the preform mold (female mold 10 and male mold 20), the outer extension of the prepreg 30 is gripped by the clamp 41 of the tension applying means 40, Tension is applied in a direction perpendicular to the direction of pressing with the male and female dies from the center of the sheet-shaped prepreg toward the outer edge. Press the male and female molds to shape the prepreg.
In this way, by applying tension from the center of the sheet-shaped prepreg toward the outer edge and allowing the clamp position to move in the male and female press direction, until the male and female molds are closed, Tension can be applied to the prepreg in a direction perpendicular to the direction in which the male and female dies are pressed. As a result, it is possible to avoid the wrinkle of the preform and shape the desired shape.
以下、実施例により本発明をより具体的に説明する。ただし、本発明は実施例に限定されるものではない。
(実施例1)
所望の成形機に対して、図1に示すように可動型として上型に雌型10を配置し、固定型として下型に雄型20を配置した。
次に、一方向に引き揃えた炭素繊維にエポキシ樹脂組成物を加熱含浸したUDプリプレグシートを所望の形状に裁断し、このプリプレグシートを炭素繊維の配向が0°と90°と交互になるように10枚積層してプリプレグ積層体を得た(以下、「プリプレグ積層体」のことも説明の便宜上、「プリプレグ」という。)のち、このプリプレグ30を雄型20の上に配置した。
その後、図2に示すように、プリプレグ30の外延部を張力付与手段40のクランプ41にて把持した。その後、張力付与機構42にてシート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を付与させた。このとき張力付与機構42に設置されている巻きバネを調整して、張力を2.0kgに設定した。
Hereinafter, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to the examples.
Example 1
For the desired molding machine, as shown in FIG. 1, a female mold 10 is disposed as an upper mold as a movable mold, and a male mold 20 is disposed as a fixed mold as a lower mold.
Next, a UD prepreg sheet obtained by heating and impregnating an epoxy resin composition into carbon fibers aligned in one direction is cut into a desired shape, and the orientation of the carbon fibers is alternated between 0 ° and 90 °. The prepreg laminate was obtained by laminating 10 sheets (hereinafter, the “prepreg laminate” is also referred to as “prepreg” for convenience of explanation), and then the prepreg 30 was disposed on the male mold 20.
Thereafter, as shown in FIG. 2, the outer extension portion of the prepreg 30 was held by the clamp 41 of the tension applying means 40. Thereafter, tension was applied in a direction perpendicular to the direction of pressing by the male and female dies from the center portion of the sheet-like prepreg toward the outer edge portion by the tension applying mechanism 42. At this time, the winding spring installed in the tension applying mechanism 42 was adjusted to set the tension to 2.0 kg.
赤外線ヒーター(加熱機50)をプリプレグ30の上部に配置し、プリプレグ30を約60℃になるまで加熱してプリプレグを軟化させた。その後、位置可動機構43にてクランプの把持する位置を、型でプレスする方向に可動できるようにした後、図7に示すように、雌型10を下降させて、雄型20と雌型10とでプレスしてプリプレグ30を賦形させた。   An infrared heater (heating machine 50) was placed on top of the prepreg 30 and the prepreg 30 was heated to about 60 ° C. to soften the prepreg. After that, the position held by the clamp is made movable in the pressing direction by the mold by the position movable mechanism 43, and then the female mold 10 is lowered as shown in FIG. And the prepreg 30 was shaped.
その後、図8に示すように、張力付与機構42の張力を除去してクランプ41を外したのち、雌型10を上昇させて、図9に示すように、雄型20からプリプレグ30を脱型した。脱型されたプリプレグ30は、シワなく所望の形状のプリフォームへ賦形されていた。このプリフォームを所定の温度まで加熱している圧縮成形用の下型に配置し、これを上型で挟み、加熱加圧を行うことで、繊維強化樹脂成形品を得た。得られた成形品は強度、外観に優れており、また、成形時の安定性にも優れていた。   Thereafter, as shown in FIG. 8, the tension of the tension applying mechanism 42 is removed and the clamp 41 is removed, and then the female mold 10 is raised, and the prepreg 30 is removed from the male mold 20 as shown in FIG. did. The removed prepreg 30 was shaped into a preform having a desired shape without wrinkles. The preform was placed in a lower mold for compression molding that was heated to a predetermined temperature, sandwiched between upper molds, and heated and pressurized to obtain a fiber reinforced resin molded product. The obtained molded product was excellent in strength and appearance, and was also excellent in stability during molding.
(実施例2)
炭素繊維織物にエポキシ樹脂組成物を加熱含浸したクロスプリプレグシートを用いたこと以外は、実施例1と同様の方法でプリフォームを製作した。得られたプリフォームはシワなく所望の形状へ賦形されていた。
また、このプリフォームを実施例1と同様の方法で圧縮成形したところ、得られた成形品は強度、外観に優れており、また、成形時の安定性にも優れていた。
(Example 2)
A preform was produced in the same manner as in Example 1 except that a cloth prepreg sheet obtained by impregnating a carbon fiber fabric with an epoxy resin composition by heating was used. The obtained preform was shaped into a desired shape without wrinkles.
Further, when this preform was compression-molded by the same method as in Example 1, the obtained molded product was excellent in strength and appearance, and was also excellent in stability during molding.
(比較例1)
張力付与手段40を使用しないこと以外は、実施例1と同様の方法でプリフォームを製造した。得られたプリフォームにはシワが多発している状態であった。
また、このプリフォームを実施例1と同様の方法で圧縮成形したところ、得られた成形品は強度、外観が優れず、また、成形時の安定性にも欠けるものであった。
(Comparative Example 1)
A preform was produced in the same manner as in Example 1 except that the tension applying means 40 was not used. The resulting preform was wrinkled frequently.
Further, when this preform was compression-molded by the same method as in Example 1, the resulting molded product was not excellent in strength and appearance, and lacked stability during molding.
(比較例2)
図3に示すように、張力付与機構42にて垂直方向より上方向に張力を付与させた以外は、実施例1と同様の方法でプリフォームを製造した。
その結果、雄雌型でプレスする際、型の移動を妨げる方向に荷重が加わり、所望の形状にプリプレグを賦形させることができなかった。このプリフォームを実施例1と同様の方法で圧縮成形したところ、得られた成形品は強度、外観が優れず、また、成形時の安定性にも欠けるものであった。
(Comparative Example 2)
As shown in FIG. 3, a preform was manufactured in the same manner as in Example 1 except that tension was applied upward from the vertical direction by the tension applying mechanism 42.
As a result, when pressing with a male and female mold, a load was applied in a direction that hindered movement of the mold, and the prepreg could not be shaped into a desired shape. When this preform was compression molded in the same manner as in Example 1, the resulting molded product was not excellent in strength and appearance, and lacked stability during molding.
(比較例3)
図4に示すように、張力付与機構42にて垂直方向より下方向に張力を付与させた以外は、実施例1と同様の方法でプリフォームを製造した。
その結果、雄雌型でプレスする前に、プリプレグと型が接触してしまい、その状態のまま雄雌型でプレスしたため、プリフォームの形状が大きく乱れてしまった。このプリフォームを実施例1と同様の方法で圧縮成形したところ、得られた成形品は強度、外観が優れず、また、成形時の安定性にも欠けるものであった。
(Comparative Example 3)
As shown in FIG. 4, a preform was manufactured in the same manner as in Example 1 except that tension was applied downward from the vertical direction by the tension applying mechanism 42.
As a result, the prepreg and the mold contacted each other before pressing with the male and female dies, and the pressing was performed with the male and female dies in that state, so that the shape of the preform was greatly disturbed. When this preform was compression molded in the same manner as in Example 1, the resulting molded product was not excellent in strength and appearance, and lacked stability during molding.
(比較例4)
図5に示すように、位置可動機構43を使用しないこと以外は、実施例1と同様の方法でプリフォームを製造した。得られたプリフォームにシワは回避されていたが、プリプレグが拘束されてしまい、所望の形状に賦形することができなかった。
このプリフォームを実施例1と同様の方法で圧縮成形したところ、得られた成形品は強度、外観が優れず、また、成形時の安定性にも欠けるものであった。
(Comparative Example 4)
As shown in FIG. 5, a preform was manufactured in the same manner as in Example 1 except that the position movable mechanism 43 was not used. Although wrinkles were avoided in the obtained preform, the prepreg was restrained and could not be shaped into a desired shape.
When this preform was compression molded in the same manner as in Example 1, the resulting molded product was not excellent in strength and appearance, and lacked stability during molding.
10 雌型
20 雄型
30 プリプレグ
40 張力付与手段
41 クランプ
42 張力付与機構
43 位置可動機構
50 加熱機
DESCRIPTION OF SYMBOLS 10 Female type 20 Male type 30 Pre-preg 40 Tension applying means 41 Clamp 42 Tension applying mechanism 43 Position movable mechanism 50 Heating machine

Claims (2)

  1. 立体形状を有する繊維強化樹脂成形品を得るべく、強化繊維とマトリックス樹脂を含むシート状のプリプレグを雄雌型でプレスすることで、プリフォームとするプリフォームの製造方法であって、
    前記シート状のプリプレグを雄雌型のプレスする際に、シート状のプリプレグの中心部から外縁部に向かって、雄雌型でプレスする方向に対して垂直な方向に張力を加えながらシート状のプリプレグを雄雌型でプレスすることで賦形するプリフォームの製造方法。
    In order to obtain a fiber-reinforced resin molded article having a three-dimensional shape, a sheet-like prepreg containing reinforcing fibers and a matrix resin is pressed with a male-female mold to produce a preform,
    When the male and female prepregs are pressed on the sheet-like prepreg, the sheet-like prepreg is pressed while applying tension in the direction perpendicular to the male and female dies to be pressed from the center to the outer edge. A method for producing a preform, which is formed by pressing a prepreg with a male-female mold.
  2. 前記雄雌型によるプレスが完了するまでの間、中心部から外縁部に向かって同じ方向に張力を加える請求項1に記載のプリフォームの製造方法。   The method for manufacturing a preform according to claim 1, wherein tension is applied in the same direction from the center to the outer edge until the male and female dies are pressed.
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