JP6311422B2 - Manufacturing method of fiber reinforced material - Google Patents

Description

  The present invention relates to a method for producing a fiber reinforced material.

  Japanese Patent Application Laid-Open No. 2004-228561 discloses a technique of using a fiber reinforced plastic capable of reducing weight and ensuring rigidity in an automobile bonnet.

JP 2006-306363 A

  By the way, when manufacturing such a fiber reinforced plastic plate material, the resin is poured into a mold in which the reinforced fiber is set. Depending on the shape of the plate material, the reinforcing fiber may be the end of the molding space of the mold. In some cases, it is difficult to arrange the part (corresponding to the end of the plate). In such a case, a part such as an edge of the plate material is excessive in resin and insufficient in reinforcing fibers, causing a decrease in strength.

  Therefore, an object of the present invention is to increase the strength of the fiber reinforced material.

The present invention includes a first step of releasing the holding state by the yarn in at least a part of the reinforcing fiber body, a second step of applying an adhesive to a part of the reinforcing fiber body released from the holding state by the yarn, After setting the reinforcing fiber body to which the adhesive was applied in the second step in the mold, the resin was injected into the mold from a part different from the part where the holding state of the reinforcing fiber body by the yarn was released, and this injection was performed. And a third step of moving a reinforcing fiber in a part different from the part of the reinforcing fiber body toward a part of the reinforcing fiber body by the flow of the resin.

According to the present invention, the flow of the resin injected into the mold, the reinforcing fibers of different sites and part of the reinforcing fiber member is moved toward the portion of the reinforcing fiber body releasing the holding state by the thread . Thereby, it can suppress that some parts, such as an edge part of a board | plate material, become short of a reinforced fiber, and can raise the intensity | strength of a fiber reinforced material.

FIG. 1 is a plan view of a back door of an automobile as a fiber reinforced material according to an embodiment of the present invention as viewed from the inside of the vehicle body. FIG. 2 is a cross-sectional view taken along the line AA of FIG. FIG. 3A is a cross-sectional view of the reinforcing fiber body showing the first embodiment of the present invention, and FIG. 3B is a diagram illustrating the removal of the stitch yarn located at the end of the reinforcing fiber body of FIG. FIG. 3 (c) is an operation explanatory diagram showing the operation of applying an adhesive to the end of the reinforcing fiber body in the portion where the stitch yarn is removed in FIG. 3 (b). 4 (a) is a cross-sectional view showing a state in which the reinforcing fiber body of FIG. 3 (c) is set in a mold, and FIG. 4 (b) shows an operation of filling a resin in the mold of FIG. 4 (a). It is an operation explanatory view. FIG. 5 is an operation explanatory view corresponding to FIG. 3B, showing the second embodiment of the present invention. FIG. 6 is an operation explanatory diagram corresponding to FIG. 3B, showing a third embodiment of the present invention. FIG. 7 (a) shows a fourth embodiment of the present invention, and is an operation explanatory view corresponding to FIG. 4 (a). FIG. 7 (b) shows a fourth embodiment of the present invention, FIG. It is an operation explanatory view corresponding to (b). FIG. 8 is a cross-sectional view of the case where the stitch yarn is arranged on both upper and lower sides of the reinforcing fiber to hold the reinforcing fiber.

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

  A fiber reinforced plastic as a fiber reinforced material according to an embodiment of the present invention is used in a back door 1 of an automobile as shown in FIG. The back door 1 has a structure in which an inner member 3 positioned on the inner side of the vehicle body (front side in FIG. 1) and an outer member 5 positioned on the outer side of the vehicle body (back side of the paper in FIG. 1) overlap each other in the closed state. It has become. An opening 7 for forming a window is provided on the upper portion of the back door 1 in FIG.

  As shown in FIG. 2 which is an AA cross-sectional view of FIG. 1, a terminal portion 5 a that protrudes toward the inner side of the vehicle body is provided on the outer peripheral edge of the outer member 5. The terminal portion 5 a is bent at an angle of approximately 90 degrees with respect to the main body portion 5 b of the outer member 5 so as to cover the side surface of the end portion of the inner member 3. By providing such a terminal portion 5a, the appearance of the back door 1 when viewed from the outside of the vehicle body is improved and the appearance quality is enhanced.

  Each of the inner member 3 and the outer member 5 is a plate material made of fiber reinforced plastic, and the contact surfaces thereof are bonded and fixed with an adhesive. The terminal portion 5a also plays a role of suppressing leakage of the adhesive from the end portion.

  Next, 1st Embodiment of the manufacturing method of the outer member 5 provided with the terminal part 5a is demonstrated among the inner member 3 and the outer member 5 which were mentioned above. However, in the manufacturing method of the outer member 5 shown in FIG. 3 and subsequent figures, not the entire outer member 5 shown in FIG. 1 but a part of the members including the peripheral terminal portion 5a will be described.

  Fig.3 (a) is sectional drawing of the reinforced fiber body 11 provided with the reinforced fiber 9 which consists of carbon fibers, for example. The reinforcing fiber 9 is formed by superimposing a plurality of longitudinal fibers 9a extending in a direction orthogonal to the paper surface in FIG. 3A and a plurality of transverse fibers 9b extending in the left-right direction in FIG. The longitudinal fibers 9a and the transverse fibers 9b are held by knitting with stitch yarns 13 as yarns to form reinforcing fiber bodies 11. In addition, although the reinforced fiber body 11 of Fig.3 (a) has piled up the vertical fiber 9a and the horizontal fiber 9b one layer at a time, you may pile up two or more layers.

  The stitch yarn 13 is pulled by using the robot 15 or the like as shown in FIG. 3B to the peripheral edge of the portion corresponding to the terminal portion 5a of the reinforcing fiber body 11 of FIG. Remove and fray. That is, as a first step, by pulling the stitch yarn 13, the holding state of at least a part of the reinforcing fiber body 11 by the stitch yarn 13 is released, and the frayed portion 11 a is formed.

  Next, as a second step, an adhesive 19 is applied around the reinforcing fibers 9 of the frayed portion 11a using another robot 17 as shown in FIG. 3C, and the reinforcing fibers 9 of the frayed portion 11a are applied. By solidifying, the reinforcing fibers 9 are prevented from being scattered. Thereby, the deterioration of the handleability of the subsequent reinforcement fiber body 11 is suppressed.

  FIG. 4A shows a state in which the reinforcing fiber body 11 in a state where the periphery of the reinforcing fiber 9 of the frayed portion 11a is hardened with the adhesive 19 in FIG. The mold 21 includes a lower mold 23 and an upper mold 25, and a cavity 27 serving as a molding space is formed therebetween.

  The cavity 27 includes a flat cavity main body 27 a between a concave portion 23 a provided in the lower mold 23 and a convex portion 25 a provided in the upper mold 25. Further, the cavity 27 includes a cavity end portion 27b that is continuous with the cavity main body 27a and serves as a bending molding space located at the right end portion in FIG. The cavity end portion 27b is bent upward at a substantially right angle with respect to the flat plate-shaped cavity main body 27a by forming the curved concave portion 25b in the upper die 25. It is assumed that the cavity end portion 27b extends in a direction perpendicular to the paper surface in FIG.

  As shown in FIG. 4A, the reinforcing fiber body 11 is disposed so as to fill almost the entire region of the recess 23a of the lower mold 23, that is, almost the entire region in the cavity body 27a. At this time, the frayed portion 11a of the reinforcing fiber body 11 is at a position corresponding to the cavity end portion 27b.

  In this state, as a third step, as shown in FIG. 4 (b), the molten resin 29 is injected from the resin injection port 23b provided in the lower mold 23 in another part opposite to the cavity end 27b. For example, it inject | pours into the cavity main body 27a of the cavity 27 with the resin pressure of 3-20 Mpa. The resin 29 injected into the cavity main body 27 a moves so as to spread over the entire area of the reinforcing fiber body 11 so as to be impregnated between the reinforcing fibers 9 of the reinforcing fiber body 11.

When the moving resin 29 reaches the frayed portion 11a, the reinforcing fiber 9 in a state in which the holding by the stitch yarn 13 is released while the adhesive 19 is melted is directed upward as indicated by an arrow B. And moved toward the bent cavity end 27b. That is, due to the flow of the resin 29 injected into the mold 21, the reinforcing fiber 9 in a portion different from the frayed portion 11 a that is a part of the reinforcing fiber body 11 is transferred to the frayed portion 11 a released from the holding state by the stitch yarn 13. Move towards.

  As a result, the reinforcing fiber 9 is filled in the cavity end portion 27b that is bent upward with respect to the cavity body 27a as well as the cavity body 27a. As a result, it is possible to prevent a part of the end of the plate member such as the terminal portion 5a of the outer member 5 shown in FIG. 2 from being insufficient in reinforcing fibers, and to increase the strength of the fiber reinforced material.

  Moreover, in this embodiment, it is good to cancel | release the holding state by the stitch thread | yarn 13 extended in the direction which cross | intersects the flow direction of the resin 29 inject | poured into the type | mold 21 among the stitch thread | yarns 13 holding the reinforcing fiber 9. . Here, the stitch yarn 13 extending in a direction intersecting the flow direction of the resin 29 is the stitch yarn 13 extending in a direction orthogonal to the paper surface in FIG. By removing the stitch yarn 13, the flow of the resin 29 becomes smoother, and the reinforcing fiber 9 can be easily moved toward the cavity end portion 27b.

  In this embodiment, the reinforcing fiber body 11 is released from the holding state by the stitch yarn 13 by the reinforcing fiber 9 being knitted with the stitch yarn 13 and the stitch yarn 13 being frayed frayed. In this way, by fraying the stitch yarn 13, the reinforcing fiber 9 is also frayed, and the frayed reinforcing fiber 9 can be easily moved by the flow of the resin 29.

  In the present embodiment, the mold 21 in which the reinforcing fiber body 11 is set includes a cavity end portion 27 b as a bending molding space that is bent with respect to the flow direction of the resin 29. In this case, the resin 29 flowing through the cavity main body 27a flows into the cavity end portion 27b that is bent with respect to the cavity main body 27a, so that the reinforcing fibers 9 at the frayed portion move to the cavity end portion 27b. Thereby, it can shape | mold in the state which filled the reinforcement fiber 9 in the terminal part 5a shape | molded by the cavity edge part 27b, and can raise the intensity | strength of the terminal part 5a.

  Furthermore, in the present embodiment, the cavity end portion 27 b as the bending molding space is provided at the end portion in the flow direction of the resin 29. In this case, in the terminal portion 5a formed on the outer peripheral edge of the outer member 5 of the back door 1 as shown in FIG. 1, the strength can be increased by suppressing the shortage of reinforcing fibers.

  FIG. 5 shows a second embodiment of the present invention. In the second embodiment, instead of the operation of pulling the stitch yarn 13 by the robot 15 in FIG. 3B of the first embodiment, the stitch yarn 13 is burned out by the flame 34 of the burner 33 held by the robot 31. Do work. As a result, the stitch yarn 13 is removed from the peripheral edge portion of the reinforcing fiber body 11 corresponding to the terminal portion 5a, and the reinforcing fibers 9 in the vicinity thereof are frayed. That is, by burning out the stitch yarn 13, the state held by the stitch yarn 13 knitting in at least a part of the reinforcing fiber body 11 is released, and the frayed portion 11a is formed.

  Thereafter, similar to FIG. 3C in the first embodiment, the reinforcing fiber 9 is applied to the periphery of the reinforcing fiber 9 of the frayed portion 11a, and the reinforcing fiber 9 of the frayed portion 11a is hardened, whereby the reinforcing fiber 9 is Suppress the release. Further, the resin 29 is poured into the cavity 27 of the mold 21 as shown in FIG. 4B after being set in the mold 21 as shown in FIG. The end portion 27b is also filled with the reinforcing fiber 9 in the same manner as the cavity body 27a. As a result, it is possible to prevent a part of the end of the plate member such as the terminal portion 5a of the outer member 5 shown in FIG.

  In the second embodiment, the holding state by the stitch yarn 13 is released by burning out the stitch yarn 13 in at least a part of the reinforcing fiber body 11. For this reason, the stitch yarn 13 can be more reliably removed by burning, and the reinforcing fibers 9 are more surely frayed. The frayed reinforcing fibers 9 can be easily moved by the flow of the resin 29. it can.

  FIG. 6 shows a third embodiment of the present invention. In the third embodiment, instead of the operation of pulling the stitch yarn 13 by the robot 15 in FIG. 3B of the first embodiment, the operation of cutting the stitch yarn 13 by the scissors 37 held by the robot 35 is performed. . As a result, the stitch yarn 13 is removed from the peripheral edge portion of the reinforcing fiber body 11 corresponding to the terminal portion 5a, and the reinforcing fibers 9 in the vicinity thereof are frayed. That is, by cutting the stitch yarn 13, the state held by the stitch yarn 13 knitting in at least a part of the reinforcing fiber body 11 is released, and the frayed portion 11a is formed.

  Thereafter, similar to FIG. 3C in the first embodiment, the reinforcing fiber 9 is applied to the periphery of the reinforcing fiber 9 of the frayed portion 11a, and the reinforcing fiber 9 of the frayed portion 11a is hardened, whereby the reinforcing fiber 9 is Suppress the release. Further, the resin 29 is poured into the cavity 27 of the mold 21 as shown in FIG. 4B after being set in the mold 21 as shown in FIG. The end portion 27b is also filled with the reinforcing fiber 9 in the same manner as the cavity body 27a. As a result, it is possible to prevent a part of the end of the plate member such as the terminal portion 5a of the outer member 5 shown in FIG. 2 from being insufficient in reinforcing fibers, and to increase the strength of the fiber reinforced material.

  In the third embodiment, the holding state by the stitch yarn 13 is released by cutting the stitch yarn 13 in at least a part of the reinforcing fiber body 11. Thus, by cutting the stitch yarn 13, the reinforcing fibers 9 are also frayed, and the frayed reinforcing fibers 9 can be easily moved by the flow of the resin 29.

  In the third embodiment as well, in the same manner as in the first embodiment, among the stitch yarns 13 holding the reinforcing fibers 9, at least in the direction intersecting the flow direction of the resin 29 injected into the mold 21. It is preferable to release the holding state by cutting the extending stitch yarn 13. Thereby, the flow of the resin 29 becomes smoother, and the reinforcing fiber 9 can be easily moved toward the cavity end portion 27b.

  As a fourth embodiment of the present invention, instead of cutting the stitch yarn 13 with the scissors 37 in FIG. 6 of the third embodiment, the reinforcing fibers 9 are cut with the scissors 37. Thereby, the reinforcing fiber 9 at the peripheral edge portion of the portion corresponding to the end portion 5a of the reinforcing fiber body 11 is frayed. That is, by cutting the reinforcing fiber 9, the holding state of the at least part of the reinforcing fiber body 11 by weaving the stitch yarn 13 is released, and the frayed portion 11 a is formed.

  Thereafter, similar to FIG. 3C in the first embodiment, the reinforcing fiber 9 is applied to the periphery of the reinforcing fiber 9 of the frayed portion 11a, and the reinforcing fiber 9 of the frayed portion 11a is hardened, whereby the reinforcing fiber 9 is Suppress the release. Further, the resin 29 is poured into the cavity 27 of the mold 21 as shown in FIG. 4B after being set in the mold 21 as shown in FIG. The end portion 27b is also filled with the reinforcing fiber 9 in the same manner as the cavity body 27a. As a result, it is possible to prevent a part of the end of the plate member such as the terminal portion 5a of the outer member 5 shown in FIG. 2 from being insufficient in reinforcing fibers, and to increase the strength of the fiber reinforced material.

  In the fourth embodiment, the holding state by the stitch yarn 13 is released by cutting the reinforcing fiber 9 in at least a part of the reinforcing fiber body 11. By cutting the reinforcing fibers 9 in this manner, the reinforcing fibers 9 are more reliably frayed, and the frayed reinforcing fibers 9 can be easily moved by the flow of the resin 29.

  FIG. 7 shows a fifth embodiment of the present invention. In the fifth embodiment, in the reinforcing fiber body 11 </ b> A corresponding to the reinforcing fiber body 11 in FIG. 3A, the stitch thread 13 is a stitch thread 13 </ b> A that is melted by the heat of the resin 29. Examples of the meltable stitch yarn 13A include polyethylene, polypropylene, and EVA (ethylene-vinyl acetate copolymer resin) that melt at around 100 ° C.

  The reinforcing fiber body 11A using the stitch yarn 13A is set on the mold 21 as shown in FIG. 7A, as in FIG. 4A. In this state, as the first step, as in FIG. 4B, the resin 29 is injected into the cavity main body 27a of the cavity 27 as shown in FIG. The resin 29 injected into the cavity main body 27a moves so as to spread across the entire reinforcing fiber body 11A so as to be impregnated between the reinforcing fibers 9 of the reinforcing fiber body 11A.

  At this time, in this embodiment, the stitch yarn 13A is melted by the heat of the resin 29 (130 ° C. to 150 ° C.). That is, as a second step, the stitch yarn 13A is melted by the resin 29 that has flowed into the mold 21 to release the holding state of the stitch yarn 13A. When the stitch yarn 13A is melted, the reinforcing fibers 9 are frayed, and the frayed reinforcing fibers 9 are moved toward the cavity end portion 27b by the flow of the resin 29. That is, as the third step, the reinforcing fiber 9 that has been loosened by melting the stitch yarn 13A is moved toward a part of the reinforcing fiber body 11A.

  Therefore, also in the fifth embodiment, the reinforcing fiber 9 is filled in the cavity end portion 27b as well as the cavity body 27a. As a result, it is possible to prevent a part of the end of the plate member such as the terminal portion 5a of the outer member 5 shown in FIG. 2 from being insufficient in reinforcing fibers, and to increase the strength of the fiber reinforced material.

  In the fifth embodiment, the stitch yarn 13A is melted by the resin 29 flowing into the mold 21 from the resin injection port 23b opposite to the cavity end portion 27b, and the holding state by the stitch yarn 13A is released. At that time, since the entire stitch yarn 13A is melted, the entire reinforcing fiber body 11A is frayed, and a large amount of frayed reinforcing fibers 9 can be moved to the cavity end portion 27b. It is effective for improving the strength.

  Examples of the reinforcing fiber 9 include, in addition to carbon fibers, inorganic fibers such as glass fibers, and organic fibers such as Kepler fibers, polyethylene fibers, and polyamide fibers. Of these, carbon fiber is preferred when used for a vehicle body member. Moreover, as resin 29 used as matrix resin, thermosetting resins, such as an epoxy resin, unsaturated polyester resin, vinyl ester resin, a phenol resin, are mentioned, for example. Furthermore, thermoplastic resins such as polyamide resin, polyolefin resin, dicyclopentadiene resin, and polyurethane resin can also be used.

  As mentioned above, although embodiment of this invention was described, these embodiment is only the illustration described in order to make an understanding of this invention easy, and this invention is not limited to the said embodiment. The technical scope of the present invention is not limited to the specific technical matters disclosed in the above embodiment, but includes various modifications, changes, alternative techniques, and the like that can be easily derived therefrom. For example, in the above-described embodiment, the back door 1 of the automobile has been described. However, the present invention is not limited to the back door 1 and may be another body member, or may be applied to a plate-like member different from the body member. be able to.

  Further, in each of the above-described embodiments, the cavity end portion 27b positioned at the end portion of the plate-like member has been described as an example of the bending molding space that is bent with respect to the flow direction of the resin 29 in the mold 21. However, the present invention can also be applied to molding a rib formed at the center portion or the like in addition to the end portion of the plate-like member such as the terminal portion 5a. Furthermore, the stitch yarns 13 and 13A may be held by being bonded to the upper and lower surfaces with an adhesive or the like as shown in FIG.

9 Reinforcing fiber 11, 11A Reinforcing fiber body 13, 13A Stitch yarn (yarn)
19 Adhesive 21 Type 27b Cavity edge (bending molding space)
29 resin

Claims (9)

A first step of releasing the holding state by the yarn in at least a part of the reinforcing fiber body configured by holding the reinforcing fiber with the yarn;
A second step of applying an adhesive to a part of the reinforcing fiber body released from the holding state by the yarn in the first step;
After the reinforcing fiber body to which the adhesive has been applied in the second step is set in a mold, a resin is injected into the mold from a part other than the part of the reinforcing fiber body that has been released from the holding state by the thread. and, by the flow of the injected resin, the reinforcing fibers of different sites and a portion of the reinforcing fiber material, and a third step of moving toward a portion of the reinforcing fiber material,
The manufacturing method of the fiber reinforced material characterized by including.   The first step is to release a holding state by a thread extending in a direction intersecting at least a flow direction of the resin injected into the mold among the threads holding the reinforcing fiber. The manufacturing method of the fiber reinforced material as described in 1 .. In the reinforcing fiber body, the reinforcing fiber is knitted with a thread,
3. The method for producing a fiber reinforced material according to claim 1, wherein in the first step, the held state by the yarn is released by fraying the knitted yarn.   2. The method for producing a fiber-reinforced material according to claim 1, wherein the first step releases the holding state by the yarn by burning out the yarn in at least a part of the reinforcing fiber body.   3. The method for producing a fiber reinforced material according to claim 1, wherein the first step releases the holding state by the yarn by cutting the yarn in at least a part of the reinforcing fiber body.   2. The method for producing a fiber-reinforced material according to claim 1, wherein the first step releases the holding state by the yarn by cutting the reinforcing fiber in at least a part of the reinforcing fiber body. A first step of flowing a resin into the mold in a state where a reinforcing fiber body constituted by holding the reinforcing fibers with a thread is set in a molding space in the mold ;
The molding space in the mold in a state where the reinforcing fiber body is set is formed with a portion where the reinforcing fiber body is not set in a portion different from a resin injection port into which resin is poured,
A second step of releasing the holding state by the yarn by melting the yarn with the resin flowed into the mold in the first step;
A third step of moving the reinforcing fiber released from the holding state by the yarn by melting the yarn in the second step toward a portion of the molding space where the reinforcing fiber body is not set ;
The manufacturing method of the fiber reinforced material characterized by including.   The fiber reinforced material manufacturing method according to any one of claims 1 to 7, wherein the mold in which the reinforcing fiber body is set includes a bent molding space that is bent with respect to a resin flow direction. Method.   The method for producing a fiber reinforced material according to claim 8, wherein the bending molding space is provided at an end portion in a resin flow direction.

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