JP6125706B1 - FRP molded composite and method for producing the same - Google Patents

Abstract

An object of the present invention is to provide a molded body having a desired thickness, a high degree of freedom in molding, and excellent surface aesthetics, even though it is an FRP molded body. SOLUTION: An FRP molded composite A including a core material B including a polystyrene foam 3 and a cured epoxy resin 4 and a fiber reinforced resin (FRP) 5 covering the periphery of the core material is provided. [Selection] Figure 1

Description

  The present invention relates to an FRP molded composite and a method for producing the same.

  FRP (Fiber Reinforced Plastics) is lightweight and has high strength and is used in various applications. Regarding FRP, for example, in Patent Document 1, as an FRP molding method capable of performing high-precision FRP molding, a mold is sealed using a sealing putty containing gluten, and the inside is sucked to inject a resin. Technology is disclosed.

Japanese Patent No. 5972499

  In FRP molding, it is not easy to produce a product having a thickness of 5 mm or more due to repeated coating operations, heat generation, and the like. On the other hand, if the thickness is increased, the weight increases, so that the degree of freedom of molding is limited and handling becomes difficult.

  The present invention has been made in view of such circumstances, and provides a molded body having a desired thickness, a high degree of freedom in molding, and excellent surface aesthetics, even though it is an FRP molded body. Objective.

  As a result of intensive studies in order to solve the above-mentioned problems, the present inventor has come up with the idea of using a core material including a polystyrene foam and a cured epoxy resin, and has completed the present invention. That is, the present invention is as follows.

The FRP molded composite according to the present invention is an FRP molded composite including a core material including a mixture of polystyrene foam and a cured epoxy resin, and a fiber reinforced resin covering the periphery of the core material.
1-5 mm may be sufficient as the average particle diameter of the said polystyrene foam.
The FRP molded composite may include a plurality of the core materials, and the core materials may be collectively covered.
In the FRP molded composite, a plurality of the core materials may be arranged substantially in parallel.
The core material may include a concave flow groove on the surface.
The fiber reinforced resin may contain polyester.
The fiber reinforced resin may contain an epoxy resin.

  Moreover, the manufacturing method of the FRP shaping | molding composite_body | complex which concerns on this invention is a process which obtains a core material by mixing and hardening a polystyrene foam and an epoxy resin, and coat | covers the circumference | surroundings of a core material with a FRP precursor, and makes it harden | cure. By this, it is the manufacturing method of a FRP shaping | molding composite_body | complex including the process of obtaining a FRP shaping | molding composite_body | complex.

  ADVANTAGE OF THE INVENTION According to this invention, although it is a FRP molded object, there exists a desired thickness, the freedom degree of shaping | molding is high, and the molded object excellent in the beauty of the surface can be obtained.

It is a schematic perspective view of the FRP molding composite concerning this embodiment. It is a schematic perspective view of the primary molding in the FRP molding composite concerning this embodiment. It is an expanded sectional view of a primary fabrication object. It is a simplified sectional view of one mode using a split mold in a manufacturing method of an FRP fabrication complex concerning this embodiment.

  Hereinafter, modes for carrying out the present invention (hereinafter simply referred to as “the present embodiment”) will be described in detail with reference to the drawings as necessary. The following embodiments are examples for explaining the present invention, and are not intended to limit the present invention to the following contents. And this invention can be deform | transformed suitably and implemented within the range of the summary. In the drawings, positional relationships such as up, down, left and right are based on the positional relationships shown in the drawings unless otherwise specified. Further, the dimensional ratios in the drawings are not limited to the illustrated ratios. Further, in this specification, the term with “abbreviation” indicates the meaning of the term excluding the “abbreviation” within the technical common sense of those skilled in the art. Shall also be included.

(FRP molded composite)
FIG. 1 is a schematic perspective view of the FRP molded composite according to the present embodiment. The FRP molding composite A according to the present embodiment includes an FRP molding including a core material B including a polystyrene foam 3 and a cured epoxy resin 4, and a fiber reinforced resin (FRP) 5 covering the periphery of the core material B. It is a complex. The FRP molded composite A is obtained by using a core material B including a polystyrene foam 3 and a cured epoxy resin 4 as a primary molded body, and coating this with FRP.

  The thickness of the FRP molded composite A can be 15 mm or more. In normal FRP molding, it is difficult to produce a product of 5 mm or more due to the influence of heat generation or the like. However, according to this embodiment, by adjusting the number of combinations of core materials B, etc. You can get a body.

  FIG. 2 is a schematic perspective view of a primary molded body in the FRP molded composite according to the present embodiment, and FIG. 3 is an enlarged cross-sectional view of the primary molded body. In the core material B, the surfaces of the plurality of foamed polystyrenes 3 are bonded via the epoxy cured product 4. In the present embodiment, it is sufficient that at least a part of the surface of the core material B is covered with the FRP 5, and the entire surface of the core material B may not be covered with the FRP 5. Design can be selected.

  The core material B is provided with a plurality of concave flow grooves 45 on the surface thereof. For example, a plurality of flow grooves 45 are provided so as to make a round in the vertical direction or the horizontal direction at intervals. As will be described later, the flow groove 45 is provided in order to facilitate the penetration of the FRP resin at the time of manufacture.

  The raw material of the expanded polystyrene 3 is not particularly limited, and known materials can be used. Specific examples of the expanded polystyrene 3 include, for example, bead method expanded polystyrene (EPS), expanded polystyrene sheet (PSP), extruded expanded polystyrene (XPS), and the like. Furthermore, you may contain well-known additives, such as a foaming agent.

  The shape of the expanded polystyrene 3 is not particularly limited, and is preferably granular (sometimes referred to as pellets or beads) (see FIGS. 2 and 3). When the expanded polystyrene 3 is granular, the particle diameter is preferably 1 to 15 mm, more preferably 1 to 10 mm, from the viewpoint of the appearance and beauty of the molded composite and ease of handling. The average particle diameter is preferably 1 to 5 mm, more preferably 1 to 3 mm, and still more preferably 1 to 2 mm.

The average particle diameter here is a value represented by D _50. Specifically, using a low-tap type sieve shaker, sieve openings 4.00 mm, 3.35 mm, 2.80 mm, 2.36 mm, 2.00 mm, 1.70 mm, 1.40 mm, 1.18 mm, JIS standard sieves (JIS Z8801) of 1.00mm, 0.85mm, 0.71mm, 0.60mm, 0.50mm, 0.425mm, 0.355mm, 0.300mm, 0.250mm, 0.212mm and 0.180mm −1: 2006), a cumulative weight distribution curve is created from the results, and the particle diameter (median diameter) at which the cumulative weight is 50% is defined as the average particle diameter.

  The cured epoxy resin 4 may be any material that can adhere the polystyrene foam 3. The cured epoxy resin 4 is obtained by curing an epoxy resin as a main agent with a curing agent or the like.

  The epoxy resin is not particularly limited, and is a bisphenol A type epoxy resin, a glycidyl ester type epoxy resin, a glycidyl amine type epoxy resin, a novolak type epoxy resin (cresol novolak type, phenol novolak type, etc.), a cyclic aliphatic type epoxy resin, Examples include flame retardant epoxy resins and isocyanurate type epoxy resins.

  The curing agent is not particularly limited, and amine-based curing agents (aliphatic polyamines such as diethylenetriamine and triacetylenetetramine), acid anhydride-based curing agents (tetrahydrophthalic anhydride, hexahydrophthalic anhydride, methyl nadic anhydride, Pyromellitic anhydride, etc.), imidazole curing agents, polyamide curing agents and the like. Among these, from the viewpoint of improving the physical properties of the FRP molded composite A, an amine curing agent is preferable.

  The FRP molding composite A according to the present embodiment may include a plurality of core materials B, and the core materials B may be collectively covered with FRP 5 (see FIG. 1). Thereby, the freedom degree of the shape selection of a molded object can be raised.

  The number of the core materials B can be freely selected in consideration of the shape, strength balance, and the like desired for the FRP molded composite A. For example, the FRP molded composite A shown in FIG. 1 is obtained by coating five core materials B with FRP5. A plurality of core materials B may be collectively covered or may be covered as a whole while covering each of them.

  In the case where the plurality of core materials B are covered with the FRP 5, the plurality of core materials B may be arranged substantially in parallel. By arranging such a plurality of core materials B, a large molded body (molded body such as a plate or a column) can be obtained while maintaining high strength.

  The FRP 5 may be a composite material in which fibers are mixed and impregnated with a resin (fiber reinforced resin), and the type thereof is not particularly limited. The kind of fiber is not particularly limited, and glass fiber, carbon fiber, organic fiber (aramid fiber, polyethylene fiber, zylon fiber, boron fiber, etc.) can be used. The shape of the fiber is not particularly limited, and the cut fiber may be uniformly mixed / impregnated into the fiber reinforced resin, or may be mixed / impregnated into the fiber reinforced resin with the fiber having directionality. It may be made.

  The kind of fiber reinforced resin contained in FRP5 is not particularly limited, and polyester, vinyl ester, phenol resin, epoxy resin, thermoplastic resin (propylene, polycarbonate, etc.) and the like can be used. Among these, unsaturated polyester and epoxy resin are preferable. If it is an epoxy resin, it will have higher strength.

  Polyester has high solubility resistance to the epoxy resin contained in the cured epoxy resin 4. Therefore, the FRP containing polyester can be effectively prevented from being eroded by the polystyrene foam, and the degree of freedom in designing the molded body, the beauty of the surface, the dimensional accuracy, and the like are further improved. The kind of polyester is not specifically limited, A well-known thing can be used.

  The FRP 5 may contain various curing agents, curing accelerators, pigments, fillers and the like as necessary.

  Specific examples of FRP5 include GFRP, CFRP, AFRP, DFRP, BFRP, and the like. Among these, GFRP and CFRP are preferable.

  According to the present embodiment, it is possible to suppress the foamed polystyrene from being attacked by the components contained in the FRP while being an FRP molded composite using the foamed polystyrene as the core material. Therefore, a lightweight and large core material such as expanded polystyrene can be used, and a thick molded body can be obtained. As a preferred embodiment, the thickness of the FRP molded composite A can be 15 mm or more. The thickness here refers to the thickness of the FRP molded composite A in the thickness direction.

(Production method)
A suitable manufacturing method of the FRP molded composite according to the present embodiment includes a first step of obtaining a core material by mixing and curing foamed polystyrene pellets and an epoxy resin, and covering the periphery of the core material with an FRP precursor. And a second step of obtaining an FRP molded composite by curing, and a method for producing an FRP molded composite.

  First, the core material B is obtained by mixing and curing a polystyrene foam pellet and an epoxy resin (first step). The core material B can be obtained by curing and adhering an expanded polystyrene (for example, a granular expanded polystyrene such as pellets and beads) using an epoxy resin as an epoxy adhesive. As the epoxy-based adhesive, those known as the above-mentioned epoxy cured product can be used. For example, a two-component adhesive in which a liquid epoxy resin (main agent) is cured by a chemical reaction (crosslinking) with a polyamine curing agent. Agents and the like.

  At this time, a mold in which convex ribs are formed at positions corresponding to the flow grooves 45 so that the flow grooves 45 are formed can be used. In that mold, a mixture of polystyrene foam pellets and epoxy resin is placed and cured.

  Next, the FRP molded composite A is obtained by coating the periphery of the core material B with an FRP precursor and curing it (second step). The FRP precursor here refers to a fiber (glass fiber, carbon fiber or the like) constituting FRP impregnated with a resin (polyester or the like), and examples thereof include a prepreg. When the FRP precursor is cured, it becomes FRP5, and adheres to and coats the outer periphery of the core material B.

  In the second step, for example, it can be performed using a split mold. FIG. 4 is a simplified cross-sectional view of one mode when a split mold is used in the method for manufacturing an FRP molded composite according to the present embodiment. The split mold C includes an upper mold 1 and a main body mold 2. The upper mold 1 includes a strong vacuum suction port 7 and a weak vacuum suction port 8 for decompressing the inside of the split mold in which the core material (primary molded body) B and the FRP precursor are set.

  The main body mold 2 includes a resin injection port 10 and a resin discharge port 9. An FRP precursor that also serves as a strength-enhancing fiber is disposed inside the mold of the main body mold 2, and then the core material B is disposed. As the FRP precursor, for example, fiber reinforced resin (polyester or the like) and glass fiber sheet (glass mat, roving cloth, glass cloth or the like) can be used. Then, a putty 6 is applied as a sealing allowance where the upper mold 1 and the main body mold 2 are in contact with each other. By applying the putty 6, a gap can be secured even when the core material B is stacked inside the mold. This gap serves as a passage through which resin (not shown) into which the gap has been injected passes, making it easy to spread the resin throughout without stopping.

  After covering the main body mold 2 thus prepared with the upper mold 1, first, strong vacuum suction is started from the strong vacuum suction port 7. The strong vacuum suction is performed until the injection of the resin from the resin injection port 10 is completed. Thereby, sealing of the space inside a formwork can be ensured.

  Next, weak vacuum suction is started from the weak vacuum suction port 8. As a result, the space inside the mold is depressurized, and the resin gradually flows into the interior from the resin inlet 10 and spreads throughout. Since the flow channel 45 is formed in the core material B, the resin is easily spread. From this point of view, it is preferable that the flow groove 45 be positioned at a position close to the resin inlet 10. Moreover, in order to accelerate | stimulate the flow of resin, it is preferable that each circulation groove | channel 45 of the adjacent core material B is adjoining. It is preferable to adjust the suction force of the weak vacuum suction according to the spread situation (filling situation) of the injected resin.

  In the manufacturing method according to this embodiment, precise molding can be performed more reliably by sucking the sealing allowance by strong vacuum suction and sucking the inside of the molding method separately by the weak suction portion.

  The manufacturing method according to the present embodiment is not limited to the above, and the use of alternatives, modified examples, and modified examples can be appropriately employed. For example, the circulation groove 45 is not an essential configuration, and its shape, number, installation position, and the like are not limited, and a suitable aspect can be selected as appropriate.

  The FRP molded composite A according to the present embodiment has a desired thickness, has a high degree of freedom in molding, and is excellent in surface beauty. Furthermore, it is excellent in durability while being inexpensive and lightweight. Therefore, the FRP molded composite A according to the present embodiment can be suitably used as a building material furniture member used for building materials such as building walls, pillars, partitions, furniture such as tables, chairs, and chiffons. .

  The present invention will be described in more detail with reference to the following examples and comparative examples, but the present invention is not limited to the following examples.

1. Production of Core Material (Primary Molded Body) An epoxy resin (trade name “AW106”: bisphenol A type epoxy resin, manufactured by Nagase Sangyo Co., Ltd.) and a curing agent (trade name “HV953U”: polyamidoamine are used for granular polystyrene foam. , Manufactured by Nagase Sangyo Co., Ltd.) and placed in a mold provided with ribs for forming flow grooves, to obtain a rectangular parallelepiped core B (see FIG. 2 and the like).

2. (Preparation of FRP molded composite (secondary molded body) First, a glass fiber sheet is arranged inside the mold of the main body mold 2 of the split mold C shown in FIG. 4, and five core materials B are arranged there. Then, a putty (gluten putty) 6 was applied to the joint portion between the upper die 1 and the main die 2.

  Next, a strong vacuum suction is performed from the strong vacuum suction port 7 and a weak vacuum suction is performed from the weak vacuum suction port 8, while a resin (trade name “Polybest for FRP”, manufactured by Sunday Paint Co., Ltd.) is obtained from the resin injection port 10. Supplied. And after hardening, the integrally molded body was taken out from the main body mold 2, and a rectangular parallelepiped FRP molded composite A having a thickness of 40 mm was obtained.

DESCRIPTION OF SYMBOLS 1 ... Upper type, 2 ... Main body type, 3 ... Styrofoam, 4 ... Epoxy resin (cured material), 5 ... FRP, 6 ... Putty, 7 ... Strong vacuum suction 8 ... weak vacuum suction port, 9 ... resin discharge port, 10 ... resin injection port, 45 ... flow channel, A ... FRP molding composite (secondary molding), B ... Core material (primary molded body), C ... Cut mold

Claims (9)

A core containing a mixture of polystyrene foam and a cured epoxy resin,
A fiber reinforced resin covering the periphery of the core material;
FRP molded composite containing   2. The FRP molded composite according to claim 1, wherein the polystyrene foam has an average particle diameter of 1 to 5 mm.   The FRP molding composite according to claim 1 or 2, wherein a plurality of the core materials are included and the core materials are collectively covered.   The FRP molding composite according to any one of claims 1 to 3, wherein the plurality of core members are arranged substantially in parallel.   The said core material is a FRP molding composite as described in any one of Claims 1-4 provided with a concave distribution groove | channel on the surface.   The FRP molded composite according to any one of claims 1 to 5, wherein the fiber reinforced resin includes polyester.   The FRP molded composite according to any one of claims 1 to 5, wherein the fiber reinforced resin includes an epoxy resin.   The FRP molded composite according to any one of claims 1 to 7, wherein the FRP molded composite has a thickness of 15 mm or more. Styrofoam and an epoxy resin are mixed and cured to obtain a core material,
Coating the periphery of the core material with an FRP precursor and curing to obtain an FRP molded composite;
The manufacturing method of the FRP shaping | molding composite_body | complex as described in any one of Claims 1-8 containing these.

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