JP6675231B2 - Preform for fiber reinforced plastic and method for producing the same - Google Patents
Preform for fiber reinforced plastic and method for producing the same Download PDFInfo
- Publication number
- JP6675231B2 JP6675231B2 JP2016042568A JP2016042568A JP6675231B2 JP 6675231 B2 JP6675231 B2 JP 6675231B2 JP 2016042568 A JP2016042568 A JP 2016042568A JP 2016042568 A JP2016042568 A JP 2016042568A JP 6675231 B2 JP6675231 B2 JP 6675231B2
- Authority
- JP
- Japan
- Prior art keywords
- fiber
- reinforced plastic
- yarn
- auxiliary
- preform
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
- 229920002430 Fibre-reinforced plastic Polymers 0.000 title claims description 221
- 239000011151 fibre-reinforced plastic Substances 0.000 title claims description 221
- 238000004519 manufacturing process Methods 0.000 title claims description 17
- 239000000835 fiber Substances 0.000 claims description 133
- 239000012783 reinforcing fiber Substances 0.000 claims description 114
- 239000000758 substrate Substances 0.000 claims description 108
- 239000000463 material Substances 0.000 claims description 69
- 239000004840 adhesive resin Substances 0.000 claims description 31
- 229920006223 adhesive resin Polymers 0.000 claims description 31
- 238000000465 moulding Methods 0.000 claims description 26
- 238000010438 heat treatment Methods 0.000 claims description 10
- 230000037303 wrinkles Effects 0.000 description 15
- 229920000049 Carbon (fiber) Polymers 0.000 description 11
- 239000004917 carbon fiber Substances 0.000 description 11
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 11
- 230000000052 comparative effect Effects 0.000 description 8
- 229920003023 plastic Polymers 0.000 description 7
- 239000004033 plastic Substances 0.000 description 7
- 239000003365 glass fiber Substances 0.000 description 6
- 229920005989 resin Polymers 0.000 description 6
- 239000011347 resin Substances 0.000 description 6
- 239000003822 epoxy resin Substances 0.000 description 5
- 239000012784 inorganic fiber Substances 0.000 description 5
- 229920000647 polyepoxide Polymers 0.000 description 5
- -1 polyethylene Polymers 0.000 description 5
- 238000003475 lamination Methods 0.000 description 4
- 229920001778 nylon Polymers 0.000 description 4
- 229920000139 polyethylene terephthalate Polymers 0.000 description 4
- 239000005020 polyethylene terephthalate Substances 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 3
- 230000001070 adhesive effect Effects 0.000 description 3
- 229920000728 polyester Polymers 0.000 description 3
- 229920006231 aramid fiber Polymers 0.000 description 2
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 229920002577 polybenzoxazole Polymers 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 229920005992 thermoplastic resin Polymers 0.000 description 2
- 229920001187 thermosetting polymer Polymers 0.000 description 2
- 238000007666 vacuum forming Methods 0.000 description 2
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 244000025254 Cannabis sativa Species 0.000 description 1
- 235000012766 Cannabis sativa ssp. sativa var. sativa Nutrition 0.000 description 1
- 235000012765 Cannabis sativa ssp. sativa var. spontanea Nutrition 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004962 Polyamide-imide Substances 0.000 description 1
- 239000004695 Polyether sulfone Substances 0.000 description 1
- 239000004697 Polyetherimide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 239000004372 Polyvinyl alcohol Substances 0.000 description 1
- 229920000297 Rayon Polymers 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 235000009120 camo Nutrition 0.000 description 1
- 235000005607 chanvre indien Nutrition 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 239000011487 hemp Substances 0.000 description 1
- 238000005304 joining Methods 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 230000008018 melting Effects 0.000 description 1
- 125000000951 phenoxy group Chemical group [H]C1=C([H])C([H])=C(O*)C([H])=C1[H] 0.000 description 1
- 229920003192 poly(bis maleimide) Polymers 0.000 description 1
- 229920002492 poly(sulfone) Polymers 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920002312 polyamide-imide Polymers 0.000 description 1
- 229920001230 polyarylate Polymers 0.000 description 1
- 229920006393 polyether sulfone Polymers 0.000 description 1
- 229920001601 polyetherimide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 229920001955 polyphenylene ether Polymers 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920002451 polyvinyl alcohol Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 230000001629 suppression Effects 0.000 description 1
- 229920002994 synthetic fiber Polymers 0.000 description 1
- 239000012209 synthetic fiber Substances 0.000 description 1
- 229920006305 unsaturated polyester Polymers 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
Landscapes
- Processing And Handling Of Plastics And Other Materials For Molding In General (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Nonwoven Fabrics (AREA)
- Reinforced Plastic Materials (AREA)
- Laminated Bodies (AREA)
Description
本発明は、立体形状を有し、皺の発生が抑制された繊維強化プラスチック用プリフォーム及びその製造方法に関する。 The present invention relates to a preform for a fiber-reinforced plastic having a three-dimensional shape and suppressing generation of wrinkles, and a method for producing the same.
プラスチックに強化繊維を混入した繊維強化プラスチック（ＦＲＰとも称される。）は、軽量で高強度であることから、スポーツ用品及び車両などの一般産業用として利用されている。また、コンクリートの補強にも繊維が用いられている。 BACKGROUND ART Fiber reinforced plastics (FRPs) in which reinforced fibers are mixed with plastics have been used for general industries such as sports goods and vehicles because of their light weight and high strength. Fibers are also used to reinforce concrete.
プラスチックやコンクリートの補強に用いられる強化繊維は、多軸ステッチ基材の形態で用いられることがある。例えば、特許文献１〜３には、強化繊維基材として、強化繊維束を平行にシート状に配列した層を２層以上積層し、それらの層をステッチ糸等により一体化した多軸ステッチ基材が提案されている。 Reinforcing fibers used to reinforce plastics and concrete are sometimes used in the form of multiaxial stitched substrates. For example, Patent Documents 1 to 3 disclose, as a reinforcing fiber base, a multiaxial stitch base in which two or more layers in which reinforcing fiber bundles are arranged in a sheet shape in parallel are laminated, and the layers are integrated with stitch yarn or the like. Materials have been proposed.
しかしながら、強化繊維基材として多軸ステッチ基材を用いた場合、強化繊維束を平行にシート状に配列した層を２層以上積層し、それらの層をステッチ糸等により一体化しているため、曲面を有する立体形状にプレス成形する場合、賦形性が悪く、皺が発生するという問題があった。 However, when a multiaxial stitch base material is used as a reinforcing fiber base material, two or more layers in which reinforcing fiber bundles are arranged in a sheet shape in parallel are laminated, and those layers are integrated with stitch yarn or the like. When press-molding into a three-dimensional shape having a curved surface, there is a problem that the shapeability is poor and wrinkles are generated.
本発明は、前記従来の問題を解決するため、立体形状を有し、皺の発生が抑制された繊維強化プラスチック用プリフォーム及びその製造方法を提供する。 The present invention provides a preform for a fiber-reinforced plastic having a three-dimensional shape, in which wrinkles are suppressed, and a method for manufacturing the same, in order to solve the conventional problems.
本発明は、繊維強化プラスチック用基材を２層以上含み、立体形状を有する繊維強化プラスチック用プリフォームであり、前記繊維強化プラスチック用基材は、複数本の強化繊維糸が一方向に引き揃えられた強化繊維シートをステッチ糸で一体化したものであり、前記２層以上の繊維強化プラスチック用基材は、接着性樹脂で接合されており、隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向は異なり、かつ隣接する繊維強化プラスチック用基材の端部はずれていることを特徴とする繊維強化プラスチック用プリフォームに関する。 The present invention is a preform for a fiber reinforced plastic having two or more layers of a substrate for a fiber reinforced plastic and having a three-dimensional shape, wherein the substrate for a fiber reinforced plastic has a plurality of reinforcing fiber yarns aligned in one direction. The reinforcing fiber sheet is integrated with a stitch yarn, and the two or more layers of the fiber reinforced plastic substrate are bonded with an adhesive resin, and the reinforcing fiber yarn in the adjacent fiber reinforced plastic substrate is formed. The present invention relates to a preform for fiber reinforced plastic, wherein the alignment directions of the base materials are different from each other, and the ends of adjacent base materials for fiber reinforced plastic are shifted.
本発明は、また、繊維強化プラスチック用基材を２層以上含み、立体形状を有する繊維強化プラスチック用プリフォームの製造方法であって、前記繊維強化プラスチック用基材は、複数本の強化繊維糸が一方向に引き揃えられた強化繊維シートをステッチ糸で一体化したものであり、繊維強化プラスチック用基材を２層以上積層した繊維強化プラスチック用多層基材において、少なくとも１層の繊維強化樹脂プラスチック用基材のいずれかの面に接着性樹脂を配置し、該繊維強化プラスチック用多層基材を所定の温度で加熱して接着性樹脂を溶解させた後、プレス成形により前記繊維強化プラスチック用多層基材を接着性樹脂で接合させるとともに立体形状に賦形し、立体形状を有する繊維強化プラスチック用プリフォームを得る工程を含み、前記前記繊維強化プラスチック用多層基材において、隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向が異なっており、前記プレス成形の際に、積層される各々の繊維強化プラスチック用基材が変形しながら層間で滑ることを特徴とする繊維強化プラスチック用プリフォームの製造方法に関する。 The present invention is also a method for producing a preform for a fiber-reinforced plastic having two or more layers of a substrate for a fiber-reinforced plastic and having a three-dimensional shape, wherein the substrate for a fiber-reinforced plastic comprises a plurality of reinforcing fiber yarns. Is a unidirectionally reinforced fiber sheet integrated with stitch yarns, and in a fiber reinforced plastic multilayer substrate in which two or more fiber reinforced plastic substrates are laminated, at least one layer of fiber reinforced resin An adhesive resin is disposed on any surface of the plastic base material, and the fiber reinforced plastic multilayer base material is heated at a predetermined temperature to dissolve the adhesive resin, and then the fiber reinforced plastic is formed by press molding. Includes the step of bonding the multilayer base material with an adhesive resin and shaping it into a three-dimensional shape to obtain a preform for a fiber-reinforced plastic having a three-dimensional shape. In the multilayer substrate for fiber-reinforced plastics, the direction in which the reinforcing fiber yarns are aligned in the adjacent substrate for fiber-reinforced plastics is different, and at the time of the press molding, each substrate for fiber-reinforced plastics laminated The present invention relates to a method for producing a preform for fiber-reinforced plastic, characterized in that the preform for fiber reinforced plastics slides between layers while deforming.
前記繊維強化プラスチック用基材は、前記強化繊維シートの一方の表面に前記強化繊維糸の引き揃え方向と交差する方向に所定の間隔で配置されている複数本の補助繊維糸を含み、前記強化繊維シート及び前記補助繊維糸がステッチ糸で一体化されていることが好ましい。前記補助繊維糸の長さが、該補助繊維糸の長さ方向の両端点を結んだ直線の長さより長いことが好ましい。隣接する補助繊維糸の間隔が５ｍｍ〜５５ｍｍであることが好ましい。 The fiber-reinforced plastic base material includes a plurality of auxiliary fiber yarns arranged on one surface of the reinforcing fiber sheet at predetermined intervals in a direction intersecting a direction in which the reinforcing fiber yarns are aligned. It is preferable that the fiber sheet and the auxiliary fiber yarn are integrated by a stitch yarn. It is preferable that the length of the auxiliary fiber yarn is longer than the length of a straight line connecting both end points in the length direction of the auxiliary fiber yarn. It is preferable that the interval between adjacent auxiliary fiber yarns is 5 mm to 55 mm.
また、前記加熱は、温度１００〜１８０℃で、２０〜１２０秒間行うことが好ましい。 The heating is preferably performed at a temperature of 100 to 180 ° C. for 20 to 120 seconds.
本発明によると、立体形状を有し、皺の発生が抑制された繊維強化プラスチック用プリフォーム及びその製造方法を提供することができる。 ADVANTAGE OF THE INVENTION According to this invention, the preform for fiber reinforced plastic which has a three-dimensional shape and generation | occurrence | production of wrinkles is suppressed, and its manufacturing method can be provided.
本発明の発明者らは、繊維強化プラスチック用基材を２層以上含み、立体形状を有する繊維強化プラスチック用プリフォームにおける皺の発生を抑制することについて鋭意検討した。その結果、繊維強化プラスチック用基材を２層以上含み、立体形状を有する繊維強化プラスチック用プリフォームにおいて、複数本の強化繊維糸が一方向に引き揃えられた強化繊維シートをステッチ糸で一体化した繊維強化プラスチック用基材を用い、２層以上の繊維強化プラスチック用基材を接着性樹脂で接合するとともに、隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向を異なるようにし、かつ隣接する繊維強化プラスチック用基材の端部をずらすことにより、皺の発生を抑制することを見出し、本発明に至った。 Means for Solving the Problems The inventors of the present invention have conducted intensive studies on suppressing the occurrence of wrinkles in a preform for a fiber-reinforced plastic having two or more layers of a substrate for a fiber-reinforced plastic and having a three-dimensional shape. As a result, in a fiber reinforced plastic preform having two or more layers of a fiber reinforced plastic base material and a three-dimensional shape, a reinforcing fiber sheet in which a plurality of reinforcing fiber yarns are aligned in one direction is integrated with stitch yarns. Using the fiber reinforced plastic substrate, the two or more layers of the fiber reinforced plastic substrate are bonded with an adhesive resin, and the alignment directions of the reinforcing fiber yarns in the adjacent fiber reinforced plastic substrates are made different, In addition, the present inventors have found that the generation of wrinkles is suppressed by shifting the end of the adjacent substrate for fiber-reinforced plastic, and have reached the present invention.
本発明の維強化プラスチック用プリフォームの製造方法によると、隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向が異なるように繊維強化プラスチック用基材を２層以上積層した繊維強化プラスチック用多層基材において、少なくとも１層の繊維強化樹脂プラスチック用基材のいずれかの面に接着性樹脂を配置し、該繊維強化プラスチック用多層基材を立体形状を有する金型上に配置し、所定の温度で加熱して接着性樹脂を溶解させた後、プレス成形により前記繊維強化プラスチック用多層基材を接着性樹脂で接合させるとともに立体形状に賦形する際、積層される各々の繊維強化プラスチック用基材が変形しながら層間で滑ることで、各繊維強化プラスチック用基材の立体形状への成形追随性が高まり、皺の発生が抑制される。 According to the method for producing a preform for fiber-reinforced plastic of the present invention, a fiber-reinforced plastic in which two or more layers of fiber-reinforced plastic substrates are laminated so that the alignment directions of reinforcing fiber yarns in adjacent fiber-reinforced plastic substrates are different. In the multilayer base material, an adhesive resin is disposed on any surface of at least one layer of the fiber-reinforced plastic substrate, and the fiber-reinforced plastic multilayer substrate is disposed on a mold having a three-dimensional shape, After heating at a predetermined temperature to dissolve the adhesive resin, the fiber-reinforced plastic multilayer base material is joined by the adhesive resin by press molding and formed into a three-dimensional shape. As the plastic substrate deforms and slides between layers, the ability of each fiber-reinforced plastic substrate to conform to the three-dimensional shape increases, and wrinkles occur. It is suppressed.
前記繊維強化プラスチック用基材は、複数本の強化繊維糸が一方向に引き揃えられた強化繊維シートがステッチ糸で縫い合わせられて一体化されてものを用いる。すなわち、強化繊維シートとステッチ糸は連結されている。繊維強化プラスチック用基材を２層以上含む繊維強化プラスチック用多層基材を立体形状に賦形する際の目開きを抑制する観点から、前記繊維強化プラスチック用基材は、強化繊維シートの一方の表面に強化繊維糸の引き揃え方向と交差する方向に所定の間隔で配置されている複数本の補助繊維糸を含み、強化繊維シート及び補助繊維糸はステッチ糸で一体化（連結）されていることが好ましい。 As the base material for a fiber-reinforced plastic, a reinforcing fiber sheet in which a plurality of reinforcing fiber yarns are aligned in one direction is stitched with a stitch yarn and integrated. That is, the reinforcing fiber sheet and the stitch yarn are connected. From the viewpoint of suppressing apertures when shaping the multilayer substrate for fiber-reinforced plastic including two or more layers of the substrate for fiber-reinforced plastic into a three-dimensional shape, the substrate for fiber-reinforced plastic is one of the reinforcing fiber sheets. Including a plurality of auxiliary fiber yarns arranged on the surface at predetermined intervals in a direction intersecting with the alignment direction of the reinforcing fiber yarns, the reinforcing fiber sheet and the auxiliary fiber yarns are integrated (connected) with stitch yarns. Is preferred.
立体形状への成形追随性及び目開きの抑制の観点から、前記繊維強化プラスチック用基材において、前記補助繊維糸の長さが、該補助繊維糸の長さ方向の両端点を結んだ直線の長さより長い。すなわち、前記補助繊維糸は、前記強化繊維シートの一方の表面に直線状に配置されているのではなく、蛇行するように配置されている。これにより、前記繊維強化プラスチック用基材を２層以上積層して立体形状にプレス成形した場合でも、皺の発生が抑制される。前記繊維強化プラスチック用基材において、補助繊維糸の長さが補助繊維糸の長さ方向の両端点を結んだ直線の長さの１０１〜１５０％の範囲であることが好ましく、１０５〜１２０％の範囲であることがより好ましい。前記補助繊維糸の長さが上記の範囲であると、前記繊維強化プラスチック用基材を２層以上積層して立体形状にプレス成形する場合に、金型の形状に追従する賦形性が良好になり皺の発生が抑制されるとともに、目開きが生じることも効果的に防止することができる。本発明において、補助繊維糸の長さは、補助繊維糸を弛まない程度に直線状に引っ張ったときに常温下で測定するものである。 From the viewpoint of molding followability to a three-dimensional shape and suppression of apertures, in the fiber-reinforced plastic substrate, the length of the auxiliary fiber yarn is a straight line connecting both end points in the length direction of the auxiliary fiber yarn. Longer than the length. That is, the auxiliary fiber yarns are not linearly arranged on one surface of the reinforcing fiber sheet, but are arranged in a meandering manner. Accordingly, even when two or more layers of the fiber-reinforced plastic substrate are laminated and press-formed into a three-dimensional shape, wrinkling is suppressed. In the base material for a fiber-reinforced plastic, the length of the auxiliary fiber yarn is preferably in the range of 101 to 150% of the length of a straight line connecting both end points in the length direction of the auxiliary fiber yarn, and is preferably 105 to 120%. More preferably, it is within the range. When the length of the auxiliary fiber yarn is within the above range, when two or more layers of the fiber-reinforced plastic base material are laminated and press-formed into a three-dimensional shape, the shape-forming property that follows the shape of a mold is good. And the occurrence of wrinkles can be suppressed, and the occurrence of openings can also be effectively prevented. In the present invention, the length of the auxiliary fiber yarn is measured at room temperature when the auxiliary fiber yarn is pulled straight so as not to loosen.
前記強化繊維糸は、特に限定されず、無機系繊維糸であってもよく、有機系繊維糸であってもよい。 The reinforcing fiber yarn is not particularly limited, and may be an inorganic fiber yarn or an organic fiber yarn.
無機系繊維糸としては、例えば、炭素繊維糸、ガラス繊維糸、ボロン繊維糸、鋼繊維糸等が挙げられる。無機系繊維糸は、モノフィラメント糸であってもよく、マルチフィラメント糸であってもよいが、繊維強化プラスチック用基材が変形しやすい観点から、マルチフィラメント糸であることが好ましい。無機系繊維糸の太さは用途及び求められる強度により適宜設定すればよく、特に限定されない。例えば、炭素繊維糸の場合であれば、２００〜４０００ｔｅｘの範囲がよく、８００〜４０００ｔｅｘの範囲がより好ましい。 Examples of the inorganic fiber yarn include a carbon fiber yarn, a glass fiber yarn, a boron fiber yarn, and a steel fiber yarn. The inorganic fiber yarn may be a monofilament yarn or a multifilament yarn, but is preferably a multifilament yarn from the viewpoint that the substrate for fiber reinforced plastic is easily deformed. The thickness of the inorganic fiber yarn may be appropriately set depending on the application and the required strength, and is not particularly limited. For example, in the case of a carbon fiber yarn, the range of 200 to 4000 tex is good, and the range of 800 to 4000 tex is more preferable.
有機系繊維糸としては、特に限定されないが、例えば、高強度ポリエチレン繊維糸、アラミド繊維糸、ポリビニルアルコール繊維糸、ナイロン繊維糸、ポリエステル繊維糸、ポリアリレート繊維糸、ＰＢＯ（ポリフェニレンベンゾビスオキサゾール）繊維糸等の合成繊維糸や、麻等の天然繊維糸等が使用可能である。有機系繊維糸は、モノフィラメント糸であってもよく、マルチフィラメント糸であってもよいが、繊維強化プラスチック用基材が変形しやすい観点から、マルチフィラメント糸であることが好ましい。有機系繊維糸の太さも、多層繊維基材の用途及び求められる強度により適宜設定されるものである。 Examples of the organic fiber yarn include, but are not particularly limited to, high-strength polyethylene fiber yarn, aramid fiber yarn, polyvinyl alcohol fiber yarn, nylon fiber yarn, polyester fiber yarn, polyarylate fiber yarn, and PBO (polyphenylene benzobisoxazole) fiber. Synthetic fiber yarns such as yarns and natural fiber yarns such as hemp can be used. The organic fiber yarn may be a monofilament yarn or a multifilament yarn, but is preferably a multifilament yarn from the viewpoint that the substrate for fiber reinforced plastic is easily deformed. The thickness of the organic fiber yarn is also appropriately set depending on the use of the multilayer fiber base material and the required strength.
上述した無機系繊維糸及び有機系繊維糸は、一種で用いても良く、二種以上を組合わせて用いても良い。強化繊維糸は、機械的な物性に優れる観点から、炭素繊維糸やガラス繊維糸であることが好ましく、炭素繊維糸であることがより好ましい。炭素繊維糸としてマルチフィラメント糸を用いる場合、フィラメントの数は特に限定されないが、例えば、１〜６０Ｋであることが好ましく、より好ましくは１２〜６０Ｋである。１Ｋは、１０００本を意味する。また、炭素繊維糸としては、市販のトウの状態の炭素繊維糸をそのまま用いても良く、市販のトウの状態の炭素繊維糸を薄く広げて扁平にした開繊糸を用いても良い。 The above-mentioned inorganic fiber yarn and organic fiber yarn may be used alone or in combination of two or more. The reinforcing fiber yarn is preferably a carbon fiber yarn or a glass fiber yarn, and more preferably a carbon fiber yarn, from the viewpoint of excellent mechanical properties. When a multifilament yarn is used as the carbon fiber yarn, the number of filaments is not particularly limited, but is preferably, for example, 1 to 60K, and more preferably 12 to 60K. 1K means 1000 lines. Further, as the carbon fiber yarn, a commercially available tow carbon fiber yarn may be used as it is, or a commercially available tow carbon fiber yarn may be thinly spread and flattened.
前記強化繊維糸は一方向に引き揃えられて強化繊維シートを形成する。強化繊維糸の本数及び引き揃え方は、用途及び求められる強度により適宜設定すればよく、特に限定されない。一定の間隔を開けて引き揃えてもよく、密に引き揃えてもよい。強度を高める観点から、密に引き揃えることが好ましい。 The reinforcing fiber yarns are aligned in one direction to form a reinforcing fiber sheet. The number and arrangement of the reinforcing fiber yarns may be appropriately set depending on the application and the required strength, and are not particularly limited. They may be aligned at regular intervals or may be aligned closely. From the viewpoint of increasing the strength, it is preferable to closely align them.
前記強化繊維シートの単位面積あたりの重量は、特に限定されない。例えば、前記強化繊維シートが炭素繊維糸で構成されている場合、強化繊維シートの単位面積あたりの重量は２０〜５００ｇ／ｍ2であることが好ましく、５０〜４００ｇ／ｍ2であることがより好ましい。 The weight per unit area of the reinforcing fiber sheet is not particularly limited. For example, when the reinforcing fiber sheet is composed of carbon fiber yarn, more that the weight per unit area of the reinforcing fiber sheet is preferably from 20 to 500 g / m 2, is 50 to 400 g / m 2 preferable.
多目的用途のために前記強化繊維シートの厚みを薄くする場合、炭素繊維フィラメント群の厚みは０．０３〜０．２２ｍｍであること好ましい。 When the thickness of the reinforcing fiber sheet is reduced for multipurpose use, the thickness of the carbon fiber filament group is preferably 0.03 to 0.22 mm.
前記補助繊維糸は、主に繊維強化プラスチック用基材の保形性に寄与するものであり、強化繊維糸より繊度が小さいものが用いられる。前記補助繊維糸は、マルチフィラメント糸であってもよく、モノフィラメント糸であってもよいが、使いやすさのため、マルチフィラメント糸であることが好ましい。前記補助繊維糸としては、後述する繊維強化プラスチック用多層基材の繊維強化プラスチック基材の間に配置されている接着樹脂を加熱して融解させる温度よりも高い融点を有する糸であることが望ましいことから、ガラス繊維糸、ナイロン繊維糸、ポリエチレンテレフタレート（ＰＥＴ）繊維糸を用いることが好ましく、ガラス繊維糸であることがより好ましい。保形性能及び立体成形時の賦形性に優れる観点から、前記補助繊維糸は、繊度が５〜７０ｔｅｘであることが好ましく、より好ましくは１５〜４０ｔｅｘである。 The auxiliary fiber yarn mainly contributes to the shape-retaining property of the base material for fiber-reinforced plastics, and has a smaller fineness than the reinforcing fiber yarn. The auxiliary fiber yarn may be a multifilament yarn or a monofilament yarn, but is preferably a multifilament yarn for ease of use. The auxiliary fiber yarn is preferably a yarn having a melting point higher than the temperature at which the adhesive resin disposed between the fiber reinforced plastic substrates of the multilayer substrate for fiber reinforced plastic described below is heated and melted. For this reason, it is preferable to use glass fiber yarn, nylon fiber yarn, or polyethylene terephthalate (PET) fiber yarn, and it is more preferable to use glass fiber yarn. From the viewpoint of excellent shape retention performance and shapeability during three-dimensional molding, the fineness of the auxiliary fiber yarn is preferably from 5 to 70 tex, more preferably from 15 to 40 tex.
前記補助繊維糸は、前記強化繊維シートの一方の表面に前記強化繊維糸の引き揃え方向と交差する方向に所定の間隔で配置されている。本発明において、補助繊維糸の配置方向とは、強化繊維シート上に配置されている補助繊維糸において、長さ方向の両端点を結んだ直線の配置方向をいう。強化繊維糸と補助繊維糸間の狭角が、０度より大きく、９０度以下になるように積層する。強化繊維シート上に補助繊維糸を配置しやすく、繊維強化プラスチック用基材の保形性を高める観点から、強化繊維糸と補助繊維糸間の狭角は１５〜８５度であることが好ましく、より好ましくは２０〜６０度である。 The auxiliary fiber yarns are arranged on one surface of the reinforcing fiber sheet at predetermined intervals in a direction intersecting the direction in which the reinforcing fiber yarns are aligned. In the present invention, the arrangement direction of the auxiliary fiber yarn refers to a direction in which the auxiliary fiber yarn arranged on the reinforcing fiber sheet is a straight line connecting both end points in the length direction. Lamination is performed so that the narrow angle between the reinforcing fiber yarn and the auxiliary fiber yarn is larger than 0 degree and 90 degrees or less. It is preferable that the narrow angle between the reinforcing fiber yarn and the auxiliary fiber yarn is 15 to 85 degrees from the viewpoint of easily arranging the auxiliary fiber yarn on the reinforcing fiber sheet and enhancing the shape retention of the substrate for fiber reinforced plastic, More preferably, it is 20 to 60 degrees.
前記繊維強化プラスチック用基材において、隣接する補助繊維糸の間隔が５ｍｍ〜５５ｍｍであることが好ましく、１０〜３５ｍｍであることがより好ましい。隣接する補助繊維糸の間隔は、図１に示されているように、強化繊維シート上に配置されている第１の補助繊維糸の長さ方向の端点を結んだ直線と、強化繊維シート上に第１の補助繊維糸と隣接するように配置されている第２の補助繊維糸の長さ方向の端点を結んだ直線間の距離をいう。隣接する補助繊維糸の間隔が上述した範囲内であると、前記繊維強化プラスチック用基材を２層以上積層して立体形状にプレス成形する場合に、金型の形状に追随する賦形性が良好になり皺の発生が抑制されるとともに、目開きが生じることも効果的に防止することができる。 In the fiber-reinforced plastic substrate, the distance between adjacent auxiliary fiber yarns is preferably 5 mm to 55 mm, more preferably 10 mm to 35 mm. As shown in FIG. 1, the distance between the adjacent auxiliary fiber yarns is a straight line connecting the longitudinal end points of the first auxiliary fiber yarns arranged on the reinforcing fiber sheet, and the distance on the reinforcing fiber sheet. Means the distance between straight lines connecting end points in the length direction of the second auxiliary fiber yarn arranged adjacent to the first auxiliary fiber yarn. When the distance between adjacent auxiliary fiber yarns is within the above-described range, when two or more layers of the fiber-reinforced plastic base material are laminated and press-formed into a three-dimensional shape, the shapeability that follows the shape of the mold is reduced. As a result, the occurrence of wrinkles can be suppressed, and the occurrence of openings can be effectively prevented.
前記強化繊維シート、或いは、前記強化繊維シートと前記補助繊維糸はステッチ糸で縫い合わされて一体化されている。前記ステッチ糸としては、特に限定されないが、例えば、ポリエステル繊維糸、ナイロン繊維糸、ガラス繊維糸、アラミド繊維糸、ポリプロピレン繊維糸、ポリフェニレンスルフィド繊維糸等を用いることができる。生産性、コスト等の観点から、ポリエステル繊維糸及び／又はナイロン繊維糸が好ましい。ステッチ糸の太さは、１０〜１５０ｄｔｅｘ程度が好ましく、作業性の観点から、２０〜１００ｄｔｅｘであることがより好ましい。縫い合わせ方は、公知の種々の方法を用いればよく、特に限定されない。ステッチ糸にて強化繊維シートと補助繊維糸を一体化することで、前記繊維強化プラスチック用基材が、持ち運び、運搬等により大きく型くずれ、変形、破壊されない。 The reinforcing fiber sheet, or the reinforcing fiber sheet and the auxiliary fiber yarn are stitched together with a stitch thread to be integrated. The stitch yarn is not particularly limited. For example, polyester fiber yarn, nylon fiber yarn, glass fiber yarn, aramid fiber yarn, polypropylene fiber yarn, polyphenylene sulfide fiber yarn, and the like can be used. From the viewpoints of productivity, cost, and the like, polyester fiber yarns and / or nylon fiber yarns are preferred. The thickness of the stitch yarn is preferably about 10 to 150 dtex, and more preferably 20 to 100 dtex from the viewpoint of workability. Various known methods may be used for stitching, and there is no particular limitation. By integrating the reinforcing fiber sheet and the auxiliary fiber yarn with the stitch yarn, the fiber reinforced plastic substrate is not largely deformed, deformed, or broken by carrying or transporting.
前記繊維強化プラスチック用プリフォームにおいて、異なる繊維強化プラスチック用基材の補助繊維糸が配置された面と補助繊維糸が配置されていない面が近接するように、２層以上の繊維強化プラスチック用基材を重ねて配置することが好ましい。また、繊維強化プラスチック用プリフォームの長手方向の角度を０度としたとき、繊維強化プラスチック用基材における強化繊維糸の引き揃え方向の角度が０度、２０〜９０度、−２０〜−９０度の範囲になるように２層以上の繊維強化プラスチック用基材を重ねて配置することが好ましい。繊維強化プラスチック用プリフォームにおいて、強化繊維糸が多方向に配置されていることにより、プラスチックやコンクリートを多方向に補強することができる。隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向は、互いに異なければよく、特に限定されない。例えば、５層の繊維強化プラスチック用基材を含む繊維強化プラスチック用プリフォームの場合は、繊維強化プラスチック用プリフォームの角度を０度としたとき、繊維強化プラスチック用基材における強化繊維糸の引き揃え方向の角度は、表面から裏面にかけて、＋４５度／−４５度／０度／−４５度／−４５度であってもよい。 In the fiber reinforced plastic preform, two or more layers of the fiber reinforced plastic base material are arranged so that the surface of the different fiber reinforced plastic base material on which the auxiliary fiber yarn is arranged and the surface on which the auxiliary fiber yarn is not arranged are close to each other. It is preferable to arrange the materials in an overlapping manner. When the angle in the longitudinal direction of the preform for fiber reinforced plastic is set to 0 degree, the angle in the direction in which the reinforcing fiber yarns are aligned in the base material for fiber reinforced plastic is 0 degree, 20 to 90 degrees, and -20 to -90. It is preferable to arrange two or more layers of the base material for fiber reinforced plastic so as to be in the range of degrees. In the preform for fiber reinforced plastic, the reinforcing fiber yarns are arranged in multiple directions, so that plastic or concrete can be reinforced in multiple directions. The directions in which the reinforcing fiber yarns are aligned in adjacent fiber-reinforced plastic substrates may be different from each other and are not particularly limited. For example, in the case of a preform for a fiber reinforced plastic including five layers of a base material for a fiber reinforced plastic, when the angle of the preform for a fiber reinforced plastic is set to 0 °, the drawing of the reinforced fiber yarn in the base material for the fiber reinforced plastic is performed. The angle of the alignment direction may be +45 degrees / −45 degrees / 0 degrees / −45 degrees / −45 degrees from the front surface to the back surface.
前記繊維強化プラスチック用プリフォームにおいて、２層以上の繊維強化プラスチック用基材は接着性樹脂で接合されている。少なくとも１層の繊維強化プラスチック用基材のいずれかの面に接着性樹脂が配置されていることが好ましい。接着性樹脂の量は、繊維強化プラスチック用基材の表面積に対して５〜６０ｇ／ｍ2であることが好ましく、１０〜５０ｇ／ｍ2であることがより好ましい。接着性樹脂は、プリフォームやＦＲＰに成形時の加熱により溶解し、その後硬化することで２層以上の繊維強化プラスチック用基材を少なくとも部分的に接着させることで、成形後の取扱い時に生じやすい繊維強化プラスチック用基材間の大きなズレを抑制することができる。繊維強化プラスチック用基材は、全面的に接着していてもよく、部分的に接着していてもよい。 In the preform for fiber-reinforced plastic, two or more layers of the base material for fiber-reinforced plastic are bonded with an adhesive resin. It is preferable that the adhesive resin is disposed on any surface of at least one layer of the base material for fiber reinforced plastic. The amount of the adhesive resin is preferably 5 to 60 g / m 2 , more preferably 10 to 50 g / m 2 , based on the surface area of the substrate for fiber reinforced plastic. The adhesive resin dissolves in the preform or FRP by heating at the time of molding, and then cures, thereby at least partially bonding the base material for two or more layers of the fiber-reinforced plastic, so that it is likely to occur during handling after molding. A large deviation between base materials for fiber reinforced plastic can be suppressed. The substrate for fiber reinforced plastics may be adhered entirely or partially.
前記接着性樹脂としては、熱硬化性樹脂及び／又は熱可塑性樹脂を適宜選択して用いることができる。熱硬化性樹脂としては、特に限定されないが、例えば、エポキシ系樹脂、不飽和ポリエステル、ビニルエステル、フェノール、ビスマレイミド等が挙げられる。熱可塑性樹脂としては、ポリアミド、ポリスルフォン、ポリエーテルスルフォン、ポリエーテルイミド、ポリフェニレンエーテル、ポリイミド、ポリアミドイミド、フェノキシなどが挙げられる。中でも、成形で使用するマトリックス樹脂としてエポキシ樹脂が多く使用されることから、親和性の観点よりエポキシ樹脂が好ましく、さらに使いやすさの観点から、常温では固体で、加熱により溶解する粉体及びフィルム状の接着剤が好ましい。 As the adhesive resin, a thermosetting resin and / or a thermoplastic resin can be appropriately selected and used. Although it does not specifically limit as a thermosetting resin, For example, an epoxy resin, unsaturated polyester, vinyl ester, phenol, bismaleimide, etc. are mentioned. Examples of the thermoplastic resin include polyamide, polysulfone, polyethersulfone, polyetherimide, polyphenylene ether, polyimide, polyamideimide, and phenoxy. Among them, since epoxy resins are often used as a matrix resin used in molding, epoxy resins are preferred from the viewpoint of affinity, and from the viewpoint of ease of use, powders and films that are solid at room temperature and are dissolved by heating Adhesives are preferred.
本発明の繊維強化プラスチック用プリフォームは、下記のように製造することができる。まず、隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向が異なるように繊維強化プラスチック用基材を２層以上積層した繊維強化プラスチック用多層基材において、少なくとも１層の繊維強化樹脂プラスチック用基材のいずれかの面に接着性樹脂を配置する。その後、該繊維強化プラスチック用多層基材を立体形状を有する金型上に配置し、所定の温度で加熱して接着性樹脂を溶解させる。次に、プレス成形工程において、２層以上の繊維強化プラスチック用基材を接着性樹脂で接合させるとともに立体形状に賦形する。加熱工程にて溶解した接着性樹脂が、プレス成形の際に硬化することで、繊維強化プラスチック用基材が少なくとも部分的に接合される。プレス成形の際に、強化繊維糸の引き揃え方向が異なる繊維強化プラスチック用基材がそれぞれ異なる方向に伸びることで、金型の立体形状へ追随しやすく、皺の発生が抑制される。具体的には、接着性樹脂による接合が完了する前に各々の繊維強化プラスチック用基材が各々の繊維強化プラスチック用基材における強化繊維糸の引き揃え方向とは異なる方向に伸びることで、金型の立体形状へ追随しやすく、皺の発生が抑制される。すなわち、積層される各々の繊維強化プラスチック用基材がプレス成形の前に互いにステッチ糸等で一体化されていないため、プレス成形の際にそれぞれの繊維強化プラスチック用基材が変形し、層間で滑りながら伸びるため皺の発生が抑制される。 The preform for fiber-reinforced plastic of the present invention can be manufactured as follows. First, in a multilayer substrate for fiber reinforced plastic in which two or more layers of fiber reinforced plastic substrates are laminated so that the alignment directions of reinforcing fiber yarns in adjacent fiber reinforced plastic substrates are different, at least one layer of fiber reinforced resin An adhesive resin is disposed on any surface of the plastic substrate. Thereafter, the multilayer substrate for fiber-reinforced plastic is placed on a mold having a three-dimensional shape, and heated at a predetermined temperature to dissolve the adhesive resin. Next, in a press molding step, two or more layers of the fiber reinforced plastic substrate are joined with an adhesive resin and shaped into a three-dimensional shape. The adhesive resin melted in the heating step is cured during press molding, so that the fiber-reinforced plastic substrate is at least partially joined. At the time of press molding, the fiber-reinforced plastic base materials having different alignment directions of the reinforcing fiber yarns extend in different directions, respectively, so that the base material can easily follow the three-dimensional shape of the mold and the generation of wrinkles is suppressed. Specifically, before the joining with the adhesive resin is completed, each fiber-reinforced plastic base material extends in a direction different from the direction in which the reinforcing fiber yarns are aligned in each fiber-reinforced plastic base material. It is easy to follow the three-dimensional shape of the mold, and generation of wrinkles is suppressed. That is, since the respective fiber reinforced plastic substrates to be laminated are not integrated with each other with stitch yarns or the like before the press molding, the respective fiber reinforced plastic substrates are deformed at the time of the press molding, and between the layers. Since it stretches while sliding, generation of wrinkles is suppressed.
加熱の条件は、接着性樹脂を溶解させることができればよく、特に限定されない。例えば、温度１００〜１８０℃、時間２０〜１２０秒間行うことができる。加熱装置としては、繊維基材を加熱することができるものであればよく、特に限定されない。例えば、ヒーターなどを用いることができる。 The heating condition is not particularly limited as long as the adhesive resin can be dissolved. For example, it can be performed at a temperature of 100 to 180 ° C. for a time of 20 to 120 seconds. The heating device is not particularly limited as long as it can heat the fiber base material. For example, a heater or the like can be used.
プレス成形の条件として、例えば、温度５〜４０℃、圧力０．１〜１０ＭＰａ、時間５〜６０秒とすることができる。プレス成形装置は、特に限定されず、繊維基材をプレス成形することができる装置を適宜に用いることができる。所定の立体形状を有する金型を用いることで、目的の立体形状を有する繊維強化プラスチック用プリフォームを得ることができる。プレス成形は、真空成形又は減圧成形と組み合わせることもできる。 The conditions for press molding include, for example, a temperature of 5 to 40 ° C., a pressure of 0.1 to 10 MPa, and a time of 5 to 60 seconds. The press forming apparatus is not particularly limited, and an apparatus capable of press forming the fiber base material can be appropriately used. By using a mold having a predetermined three-dimensional shape, a preform for a fiber-reinforced plastic having a desired three-dimensional shape can be obtained. Press forming can also be combined with vacuum forming or vacuum forming.
以下、図面に基づいて説明する。図１は、本発明の一実施形態の繊維強化プラスチック用基材の模式的平面図である。該実施形態の繊維強化プラスチック用基材１は、複数本の強化繊維糸２ａが一方向に引き揃えられた強化繊維シート２と、強化繊維シート２の一方の表面に強化繊維糸の引き揃え方向と交差する方向に所定の間隔で配置されている複数本の補助繊維糸３を含み、強化繊維シート２及び補助繊維糸３がステッチ糸４で一体化されている。補助繊維糸３は、強化繊維シート２の一方の表面に蛇行するように配置されており、補助繊維糸３の長さＬｆが、補助繊維糸３の長さ方向の両端点を結んだ直線Ｓの長さＬｓより長い。補助繊維糸３の長さＬｆが補助繊維糸３の長さ方向の両端点を結んだ直線Ｓの長さＬｓの１０１〜１５０％の範囲であることが好ましく、１０５〜１２０％の範囲であることがより好ましい。隣接する補助繊維糸３の間隔αは、５ｍｍ〜５５ｍｍであることが好ましく、１０〜３５ｍｍであることがより好ましい。該実施形態の繊維強化プラスチック用基材１において、複数本の強化繊維糸２ａは密に引き揃えられているが、図１において、説明の便宜上、太い線で各強化繊維糸２ａを区分けしている。以下の図面においても、説明の便宜上、各強化繊維糸を太い線で区分けしているが、複数本の強化繊維糸は密に引き揃えられている。図１において、矢印ａは繊維強化プラスチック用基材の長手方向を意味し、矢印ｂは繊維強化プラスチック用基材の幅方向を意味する。 Hereinafter, description will be given based on the drawings. FIG. 1 is a schematic plan view of a fiber-reinforced plastic substrate according to one embodiment of the present invention. The fiber-reinforced plastic substrate 1 of this embodiment includes a reinforcing fiber sheet 2 in which a plurality of reinforcing fiber yarns 2a are aligned in one direction, and a reinforcing fiber yarn alignment direction on one surface of the reinforcing fiber sheet 2. The reinforcing fiber sheet 2 and the auxiliary fiber yarn 3 are integrated by a stitch yarn 4 including a plurality of auxiliary fiber yarns 3 arranged at predetermined intervals in a direction intersecting with the reinforcing fiber sheet 3. The auxiliary fiber yarn 3 is arranged so as to meander on one surface of the reinforcing fiber sheet 2, and the length Lf of the auxiliary fiber yarn 3 is a straight line S connecting both end points in the length direction of the auxiliary fiber yarn 3. Is longer than the length Ls. The length Lf of the auxiliary fiber yarn 3 is preferably in the range of 101 to 150% of the length Ls of the straight line S connecting the both end points in the length direction of the auxiliary fiber yarn 3, and is preferably in the range of 105 to 120%. Is more preferable. The distance α between the adjacent auxiliary fiber yarns 3 is preferably 5 mm to 55 mm, and more preferably 10 mm to 35 mm. In the fiber-reinforced plastic substrate 1 of the embodiment, the plurality of reinforcing fiber yarns 2a are densely aligned, but in FIG. 1, for convenience of explanation, each reinforcing fiber yarn 2a is divided by a thick line. I have. Also in the following drawings, for the sake of convenience of description, each reinforcing fiber yarn is divided by a thick line, but a plurality of reinforcing fiber yarns are densely aligned. In FIG. 1, an arrow a indicates a longitudinal direction of the substrate for a fiber-reinforced plastic, and an arrow b indicates a width direction of the substrate for a fiber-reinforced plastic.
図３は、４層の繊維強化プラスチック用基材からなる繊維強化プラスチック用多層基材における各繊維強化プラスチック用基材の積層順番及び構成を説明する模式的説明図である。該繊維強化プラスチック用多層基材１０は、繊維強化プラスチック用基材１１、繊維強化プラスチック用基材２１、繊維強化プラスチック用基材３１、及び繊維強化プラスチック用基材４１の４層の繊維強化プラスチック用基材を重ねて配置した積層体である。 FIG. 3 is a schematic explanatory view illustrating the lamination order and configuration of each fiber-reinforced plastic substrate in a fiber-reinforced plastic multilayer substrate composed of four layers of fiber-reinforced plastic substrates. The multilayer substrate 10 for fiber-reinforced plastics has four layers of a fiber-reinforced plastic substrate 11, a fiber-reinforced plastic substrate 21, a fiber-reinforced plastic substrate 31, and a fiber-reinforced plastic substrate 41. It is a laminated body in which base materials for use are stacked.
繊維強化プラスチック用基材１１は、複数本の強化繊維糸１２ａが一方向に引き揃えられた強化繊維シート１２と、強化繊維シート１２の一方の表面に強化繊維糸１２ａの引き揃え方向とほぼ直交方向に所定の間隔で配置されている複数本の補助繊維糸１３を含み、強化繊維シート１２及び補助繊維糸１３がステッチ糸１４で一体化されている。 The base material 11 for a fiber-reinforced plastic includes a reinforcing fiber sheet 12 in which a plurality of reinforcing fiber yarns 12a are aligned in one direction, and a direction in which the reinforcing fiber yarns 12a are aligned on one surface of the reinforcing fiber sheet 12 substantially orthogonally. The reinforcing fiber sheet 12 and the auxiliary fiber yarns 13 are integrated by a stitch yarn 14 including a plurality of auxiliary fiber yarns 13 arranged at predetermined intervals in the direction.
繊維強化プラスチック用基材２１は、複数本の強化繊維糸２２ａが一方向に引き揃えられた強化繊維シート２２と、強化繊維シート２２の一方の表面に強化繊維糸２２ａの引き揃え方向とほぼ直交する方向に所定の間隔で配置されている複数本の補助繊維糸２３を含み、強化繊維シート２２及び補助繊維糸２３がステッチ糸２４で一体化されている。 The fiber-reinforced plastic base material 21 includes a reinforcing fiber sheet 22 in which a plurality of reinforcing fiber yarns 22a are aligned in one direction, and a direction in which one surface of the reinforcing fiber sheet 22 is aligned with the reinforcing fiber yarns 22a. The reinforcing fiber sheet 22 and the auxiliary fiber yarn 23 are integrated by a stitch yarn 24 including a plurality of auxiliary fiber yarns 23 arranged at predetermined intervals in the direction in which the auxiliary fiber yarns 23 are formed.
繊維強化プラスチック用基材３１は、複数本の強化繊維糸３２ａが一方向に引き揃えられた強化繊維シート３２と、強化繊維シート３２の一方の表面に強化繊維糸３２ａの引き揃え方向とほぼ直交する方向に所定の間隔で配置されている複数本の補助繊維糸３３を含み、強化繊維シート３２及び補助繊維糸３３がステッチ糸３４で一体化されている。 The base material 31 for fiber-reinforced plastic includes a reinforcing fiber sheet 32 in which a plurality of reinforcing fiber yarns 32a are aligned in one direction, and a direction in which the reinforcing fiber yarns 32a are aligned on one surface of the reinforcing fiber sheet 32 substantially orthogonally. The reinforcing fiber sheet 32 and the auxiliary fiber yarns 33 are integrated by a stitch yarn 34 including a plurality of auxiliary fiber yarns 33 arranged at predetermined intervals in a direction in which the auxiliary fiber yarns 33 are formed.
繊維強化プラスチック用基材４１は、複数本の強化繊維糸４２ａが一方向に引き揃えられた強化繊維シート４２と、強化繊維シート４２の一方の表面に強化繊維糸４２ａの引き揃え方向とほぼ直交する方向に所定の間隔で配置されている複数本の補助繊維糸４３を含み、強化繊維シート４２及び補助繊維糸４３がステッチ糸４４で一体化されている。 The fiber-reinforced plastic base material 41 includes a reinforcing fiber sheet 42 in which a plurality of reinforcing fiber yarns 42a are aligned in one direction, and a direction in which the reinforcing fiber yarns 42a are aligned on one surface of the reinforcing fiber sheet 42. The reinforcing fiber sheet 42 and the auxiliary fiber yarn 43 are integrated by a stitch yarn 44 including a plurality of auxiliary fiber yarns 43 arranged at predetermined intervals in the direction in which the auxiliary fiber yarns 43 are formed.
繊維強化プラスチック用多層基材１０の長手方向（矢印Ｉで示されている）の角度を０度としたとき、繊維強化プラスチック用基材１１の強化繊維糸１２ａの引き揃え方向の角度は９０度であり、繊維強化プラスチック用基材２１の強化繊維糸２２ａの引き揃え方向の角度は０度であり、繊維強化プラスチック用基材３１の強化繊維糸３２ａの引き揃え方向の角度は９０度であり、繊維強化プラスチック用多層基材１０の長手方向と繊維強化プラスチック用基材４１の強化繊維糸４２ａの引き揃え方向の角度は０度である。図示は無いが、繊維強化プラスチック用基材４１、繊維強化プラスチック用基材３１、及び繊維強化プラスチック用基材２１の補助繊維糸が配置されている表面に接着性樹脂が配置されている。 When the angle in the longitudinal direction (indicated by the arrow I) of the multilayer substrate 10 for fiber reinforced plastic is 0 degree, the angle in the direction in which the reinforcing fiber yarns 12a of the substrate 11 for fiber reinforced plastic are aligned is 90 degrees. The angle of the alignment direction of the reinforcing fiber yarns 22a of the substrate 21 for fiber reinforced plastic is 0 degree, and the angle of the alignment direction of the reinforcing fiber yarns 32a of the substrate 31 for fiber reinforced plastic is 90 degrees. The angle between the longitudinal direction of the multilayer substrate for fiber reinforced plastic 10 and the alignment direction of the reinforcing fiber yarns 42a of the substrate 41 for fiber reinforced plastic is 0 degree. Although not shown, the adhesive resin is disposed on the surface of the substrate 41 for fiber reinforced plastic, the substrate 31 for fiber reinforced plastic, and the surface of the substrate 21 for fiber reinforced plastic on which the auxiliary fiber yarns are disposed.
図４は、立体形状の繊維強化プラスチック用プリフォームを製造する製造工程を示す模式的説明図である。図示はないが、繊維強化プラスチック用基材４１、繊維強化プラスチック用基材３１、及び繊維強化プラスチック用基材２１の補助繊維糸が配置されている表面に接着性樹脂が配置した後、図４Ａに示しているように、繊維強化プラスチック用基材４１、繊維強化プラスチック用基材３１、繊維強化プラスチック用基材２１及び繊維強化プラスチック用基材１１をこの順番に積層し、図４Ｂに示しているように繊維強化プラスチック用多層基材１０を得る。各繊維強化プラスチック用基材は、補助繊維糸が配置された面と補助繊維糸が配置されていない面が近接するように、積層されている。次に、図４Ｃに示しているように、繊維強化プラスチック用多層基材１０をプレス成形装置５０に供給され、プレス成形装置５０の下金型５１上に配置する。図７は本発明で用いる一例の下金型５１の模式的斜視図であり、図８は対応する上金型５２の模式的平面図である。次に、図４Ｄに示しているように、ヒーター６０をプレス成形装置５０の中に配置し、ヒーター６０にて繊維強化プラスチック用多層基材１０を、例えば、温度１００〜１８０℃下で、２０〜１２０秒間加熱した後、ヒーター６０を引き抜く。次いで、図４Ｅに示されているように、下金型５１と上金型５２にて挟んで、温度５〜４０℃、圧力０．１〜１０ＭＰａの条件下、５〜６０秒間プレス成形することで、所定の立体形状に賦形成形され、立体形状の繊維強化プラスチック用プリフォーム１００が得られる。 FIG. 4 is a schematic explanatory view showing a manufacturing process for manufacturing a preform for a three-dimensional fiber-reinforced plastic. Although not shown, after the adhesive resin is disposed on the surface of the base material 41 for fiber-reinforced plastic, the base material 31 for fiber-reinforced plastic, and the auxiliary fiber yarn of the base material 21 for fiber-reinforced plastic, FIG. As shown in FIG. 4, the base material 41 for fiber reinforced plastic, the base material 31 for fiber reinforced plastic, the base material 21 for fiber reinforced plastic, and the base material 11 for fiber reinforced plastic are laminated in this order, and as shown in FIG. As a result, a multilayer substrate 10 for fiber reinforced plastic is obtained. Each fiber-reinforced plastic substrate is laminated such that the surface on which the auxiliary fiber yarns are arranged and the surface on which the auxiliary fiber yarns are not arranged are close to each other. Next, as shown in FIG. 4C, the multilayer substrate 10 for fiber reinforced plastic is supplied to the press molding device 50 and placed on the lower die 51 of the press molding device 50. FIG. 7 is a schematic perspective view of an example of a lower mold 51 used in the present invention, and FIG. 8 is a schematic plan view of a corresponding upper mold 52. Next, as shown in FIG. 4D, the heater 60 is disposed in the press molding apparatus 50, and the multilayer substrate 10 for fiber-reinforced plastic is heated by the heater 60 at a temperature of, for example, 100 to 180 ° C. for 20 minutes. After heating for ~ 120 seconds, the heater 60 is pulled out. Next, as shown in FIG. 4E, sandwiching the lower mold 51 and the upper mold 52 and press-molding for 5 to 60 seconds under the conditions of a temperature of 5 to 40 ° C. and a pressure of 0.1 to 10 MPa. Thus, a preform 100 for a fiber-reinforced plastic formed into a predetermined three-dimensional shape is obtained.
図５Ａは立体形状を有する繊維強化プラスチック用プリフォーム１００の模式的平面図であり、図５Ｂは同ａ−ａ方向の模式的断面図である。図５Ａ及び図５Ｂに示されているように、強化繊維糸の引き揃え方向が異なる繊維強化プラスチック用基材１１と繊維強化プラスチック用基材２１は、端部が互いにずれている。強化繊維糸の引き揃え方向が異なる繊維強化プラスチック用基材３１と繊維強化プラスチック用基材４１も、端部が互いにずれている。 FIG. 5A is a schematic plan view of a preform 100 for a fiber-reinforced plastic having a three-dimensional shape, and FIG. 5B is a schematic cross-sectional view in the aa direction. As shown in FIGS. 5A and 5B, the ends of the fiber-reinforced plastic substrate 11 and the fiber-reinforced plastic substrate 21 in which the alignment directions of the reinforcing fiber yarns are different from each other are shifted from each other. The ends of the base material 31 for fiber-reinforced plastic and the base material 41 for fiber-reinforced plastic in which the alignment directions of the reinforcing fiber yarns are different from each other are shifted from each other.
前記プレス成形工程において、繊維強化プラスチック用基材１１は、該繊維強化プラスチック用基材を構成する強化繊維糸の引き揃え方向とは異なる方向に伸びており、隣接する層である繊維強化プラスチック用基材２１とはステッチ糸等で一体化していないため、それぞれの繊維強化プラスチック用基材１１及び繊維強化プラスチック用基材１２は層間で滑りながら互いに異なる方向に伸びる。繊維強化プラスチック用基材３１及び繊維強化プラスチック用基材４１も同様に、それぞれの層間はステッチ糸で一体化されていないため、それぞれが別個に変形し、層間で滑りながら互いに異なる方向に伸びている。したがって、皺の発生は抑制される。 In the press molding step, the fiber-reinforced plastic substrate 11 extends in a direction different from the direction in which the reinforcing fiber yarns constituting the fiber-reinforced plastic substrate are aligned, and is an adjacent layer for the fiber-reinforced plastic. Since the base material 21 and the base material for fiber-reinforced plastic 11 and 12 are not integrated with each other with a stitch thread or the like, they extend in different directions while sliding between layers. Similarly, the base material 31 for the fiber reinforced plastic and the base material 41 for the fiber reinforced plastic are not integrated with the stitch yarn between the respective layers, so that they are separately deformed, and extend in different directions while sliding between the layers. I have. Therefore, generation of wrinkles is suppressed.
以下実施例を用いて本発明を具体的に説明する。なお、本発明は下記の実施例に限定されるものではない。 Hereinafter, the present invention will be described specifically with reference to Examples. In addition, this invention is not limited to a following example.
（実施例１）
＜繊維強化プラスチック用基材の作製＞
強化繊維糸として、炭素繊維糸（三菱レイヨン社製、マルチフィラメント、１２Ｋ）を用いた。補助繊維糸として、ガラス繊維糸（日東紡社製、マルチフィラメント、フィラメント本数２００本、繊度３３．７ｔｅｘ）を用いた。図２に示されているように、まず、強化繊維糸１２ａを一方向に密に引き揃えて強化繊維シート１２（目付４４４ｇ／ｍ2）を得た。次に、補助繊維糸１３を強化繊維シート１２の一方の表面に強化繊維糸１２ａの引き揃え方向とほぼ直交するように配置した。補助繊維糸１３の長さＬｆは、補助繊維糸１３の長さ方向の端点を結んだ直線Ｓの長さＬｓの１１０％であった。隣接する補助繊維糸１３の間隔αは、２．５ｃｍであった。次に、ステッチ糸１４（ＰＥＴ繊維糸、マルチフィラメント、８４ｄｔｅｘ）によって、強化繊維シート１２と補助繊維糸１３を縫い合わせて（トリコット縫い）一体化して繊維強化プラスチック用基材１１を得た。
(Example 1)
<Preparation of base material for fiber reinforced plastic>
Carbon fiber yarn (manufactured by Mitsubishi Rayon Co., multifilament, 12K) was used as the reinforcing fiber yarn. Glass fiber yarn (manufactured by Nitto Boseki Co., multifilament, number of filaments: 200, fineness: 33.7 tex) was used as the auxiliary fiber yarn. As shown in FIG. 2, first, the reinforcing fiber yarns 12a were densely aligned in one direction to obtain a reinforcing fiber sheet 12 (a basis weight of 444 g / m 2 ). Next, the auxiliary fiber yarns 13 were arranged on one surface of the reinforcing fiber sheet 12 so as to be substantially orthogonal to the direction in which the reinforcing fiber yarns 12a were aligned. The length Lf of the auxiliary fiber yarn 13 was 110% of the length Ls of the straight line S connecting the end points in the length direction of the auxiliary fiber yarn 13. The interval α between the adjacent auxiliary fiber yarns 13 was 2.5 cm. Next, the reinforcing fiber sheet 12 and the auxiliary fiber yarns 13 were sewn together (tricot stitching) with a stitch yarn 14 (PET fiber yarn, multifilament, 84 dtex) to obtain a fiber-reinforced plastic base material 11.
＜立体形状を有する繊維強化プラスチック用プリフォームの作製＞
まず、一部の繊維強化プラスチック用基材１１の補助繊維糸１３が配置されている表面に、２０ｇ／ｍ2になる量の接着性樹脂（エポキシ系樹脂、モメンティブ社製、品名「Ｅｐｉｋｏｔｅ ０５３９０」）を配置した。次に、接着性樹脂が配置されている繊維強化プラスチック用基材１１を繊維強化プラスチック用基材４１、３１、２１として用い、図４Ａ及び図４Ｂに示されているように、繊維強化プラスチック用基材４１、３１、２１及び１１をこの順番で繊維強化プラスチック用基材の間に接着性樹脂（図示無し）が配置されるように積層し、繊維強化プラスチック用多層基材１０を得た。図３に示されているように、繊維強化プラスチック用多層基材１０の長手方向（矢印ａで示されている）の角度を０度としたとき、繊維強化プラスチック用基材１１の強化繊維糸１２ａの引き揃え方向の角度は−３０度、繊維強化プラスチック用基材２１の強化繊維糸２２ａの引き揃え方向の角度は３０度、繊維強化プラスチック用基材３１の強化繊維糸３２ａの引き揃え方向の角度は−３０度、繊維強化プラスチック用基材４１の強化繊維糸４２ａの引き揃え方向の角度は３０度になるように配置した。次に、図４Ｃに示しているように、繊維強化プラスチック用多層基材１０をプレス成形装置５０に供給され、プレス成形装置５０の下金型５１上に配置した。次に、図４Ｄに示しているように、ヒーター６０をプレス成形装置５０の中に配置し、ヒーター６０にて繊維強化プラスチック用多層基材１０を１５０℃で４０秒間加熱し、接着性樹脂を溶解させた。次いで、図４Ｅに示されているように、加熱された繊維強化プラスチック多層基材１０を下金型５１と上金型５２にて挟んで、温度２５℃、圧力１ＭＰａの条件下、１０秒間プレス成形した。図７は下金型５１の模式的斜視図であり、図８は上金型５２の模式的斜視図である。プレス形成により、繊維強化プラスチック用多層基材１０における繊維強化プラスチック用基材１１、２１、３１及び４１が接合するとともに、立体形状に賦形され、立体形状の繊維強化プラスチック用プリフォーム１００が得られた。
<Preparation of preform for three-dimensional fiber reinforced plastic>
First, an adhesive resin (epoxy resin, manufactured by Momentive, product name “Epikote 05390”) in an amount of 20 g / m 2 is provided on the surface of a part of the base material 11 for fiber reinforced plastic on which the auxiliary fiber yarns 13 are arranged. ) Was placed. Next, as shown in FIGS. 4A and 4B, the fiber reinforced plastic substrate 11 on which the adhesive resin is disposed is used as the fiber reinforced plastic substrates 41, 31, and 21. The substrates 41, 31, 21 and 11 were laminated in this order such that an adhesive resin (not shown) was disposed between the substrates for fiber reinforced plastic, thereby obtaining a multilayer substrate 10 for fiber reinforced plastic. As shown in FIG. 3, when the angle in the longitudinal direction (indicated by an arrow a) of the multilayer substrate 10 for fiber-reinforced plastic is set to 0 °, the reinforcing fiber yarn of the substrate 11 for fiber-reinforced plastic is set. The angle of the alignment direction of 12a is -30 degrees, the angle of the alignment direction of the reinforcing fiber yarn 22a of the fiber-reinforced plastic substrate 21 is 30 degrees, and the alignment direction of the reinforcing fiber yarn 32a of the substrate 31 for fiber-reinforced plastic. Are arranged so that the angle in the direction in which the reinforcing fiber yarns 42a of the fiber-reinforced plastic base material 41 are aligned is 30 degrees. Next, as shown in FIG. 4C, the multilayer substrate 10 for fiber-reinforced plastic was supplied to the press molding device 50 and placed on the lower die 51 of the press molding device 50. Next, as shown in FIG. 4D, the heater 60 is disposed in the press molding apparatus 50, and the multilayer substrate 10 for fiber-reinforced plastic is heated at 150 ° C. for 40 seconds by the heater 60 to remove the adhesive resin. Dissolved. Next, as shown in FIG. 4E, the heated fiber-reinforced plastic multilayer base material 10 is sandwiched between a lower mold 51 and an upper mold 52, and pressed for 10 seconds under a temperature of 25 ° C. and a pressure of 1 MPa. Molded. FIG. 7 is a schematic perspective view of the lower mold 51, and FIG. 8 is a schematic perspective view of the upper mold 52. By press forming, the fiber-reinforced plastic base materials 11, 21, 31, and 41 in the fiber-reinforced plastic multilayer base material 10 are joined and shaped into a three-dimensional shape to obtain a three-dimensional shape fiber-reinforced plastic preform 100. Was done.
図５及び図６に、それぞれ、実施例１で得られた立体形状の繊維強化プラスチック用プリフォーム１００の模式的平面図及び斜視図を示した。また、図１１及び図１２に、それぞれ、実施例１で得られた立体形状の繊維強化プラスチック用プリフォームのデジタルカメラによる平面図及び斜視図を示した。なお、繊維強化プラスチック用基材の層間で滑りが生じることにより、得られた立体形状の繊維強化プラスチック用プリフォームの端部にはずれが生じていた。 5 and 6 are a schematic plan view and a perspective view, respectively, of the preform 100 for a three-dimensional fiber-reinforced plastic obtained in Example 1. 11 and 12 are a plan view and a perspective view, respectively, of a three-dimensional preform for fiber-reinforced plastic obtained in Example 1 by a digital camera. In addition, slippage occurred between the layers of the fiber-reinforced plastic base material, so that the end of the obtained three-dimensional fiber-reinforced plastic preform was shifted.
（比較例１）
強化繊維糸を一方向に密に引き揃えて第１の繊維シート（目付４４４ｇ／ｍ2）とし、第１の繊維シートの一方の表面に、第１の繊維シートの強化繊維糸の引き揃え方向とほぼ直交するように、強化繊維糸を一方向に密に引き揃えて配置して第２の繊維シートを構成した。第１の繊維シートと第２の繊維シートをステッチ糸４（ＰＥＴ繊維糸、マルチフィラメント糸、８４ｄｔｅｘ）にて縫い合わせて（トリコット縫い、）一体化して繊維強化プラスチック用基材を得た。一部の繊維強化プラスチック用基材の第２繊維シートの表面に、２０ｇ／ｍ2の量の接着性樹脂（エポキシ系樹脂、モメンティブ社製、品名「Ｅｐｉｋｏｔｅ ０５３９０」）を配置した。繊維強化プラスチック用多層基材として、上記で得られた接着剤を配置した繊維強化プラスチック用基材と接着剤を配置していない繊維強化プラスチック用基材を繊維強化プラスチック用基材の間に接着性樹脂が配置されるように積層した積層体を用いた以外は、実施例１と同様にして立体形状の繊維強化プラスチック用プリフォーム２００を作製した。得られた繊維強化プラスチック用プリフォームにおいて、積層順番は、表面から裏面にかけて第２の繊維シート、第１の繊維シート、第２の繊維シート、第１の繊維シートであった。
(Comparative Example 1)
The reinforcing fiber yarns are densely aligned in one direction to form a first fiber sheet (a unit weight of 444 g / m 2 ), and the reinforcing fiber yarns of the first fiber sheet are aligned on one surface of the first fiber sheet. The second fiber sheet was constituted by arranging the reinforcing fiber yarns closely and in one direction so as to be substantially orthogonal to. The first fiber sheet and the second fiber sheet were sewn (tricot stitch) together with stitch yarn 4 (PET fiber yarn, multifilament yarn, 84 dtex) to obtain a substrate for fiber reinforced plastic. Second fiber sheet surface of the portion of the fiber reinforced plastic base material, was 20 g / m 2 in an amount of adhesive resin (epoxy resin, Momentive Co., product name "Epikote 05,390") was placed. As a multilayer substrate for fiber reinforced plastic, the fiber reinforced plastic substrate with the adhesive obtained above and the fiber reinforced plastic substrate with no adhesive are bonded between the fiber reinforced plastic substrate A preform 200 for a three-dimensional fiber reinforced plastic was produced in the same manner as in Example 1 except that a laminated body laminated so that the conductive resin was disposed was used. In the obtained preform for fiber-reinforced plastic, the order of lamination was a second fiber sheet, a first fiber sheet, a second fiber sheet, and a first fiber sheet from the front surface to the back surface.
図９及び図１０に、それぞれ、比較例１で得られた立体形状の繊維強化プラスチック用プリフォーム２００の模式的平面図及び斜視図を示した。また、図１３及び図１４に、それぞれ、比較例１で得られた立体形状の繊維強化プラスチック用プリフォーム２００のデジタルカメラによる平面図及び斜視図を示した。 9 and 10 show a schematic plan view and a perspective view, respectively, of the three-dimensional fiber-reinforced plastic preform 200 obtained in Comparative Example 1. 13 and 14 show a plan view and a perspective view of a three-dimensional fiber-reinforced plastic preform 200 obtained in Comparative Example 1 by a digital camera, respectively.
図５、図６、図１１及び図１２、特に図５Ａ及び図５Ｂから分かるように、実施例１において、強化繊維糸の引き揃え方向が異なる繊維強化プラスチック用基材がそれぞれ層間で滑りながら伸びており、得られた立体形状の繊維強化プラスチック用プリフォームは、いずれの曲面においても皺が発生せず、表面が平滑であった。一方、図９、図１０、図１３及び図１４から分かるように、比較例１の立体形状の繊維強化プラスチック用プリフォームは、図面からみて一番手前の角に皺が発生しており、製品として適切ではなかった。 5, 6, 11, and 12, and particularly, FIGS. 5A and 5B, in Example 1, the fiber-reinforced plastic substrates having different alignment directions of the reinforcing fiber yarns are stretched while sliding between the layers. The resulting three-dimensional preform for fiber-reinforced plastic had no wrinkles on any of the curved surfaces and had a smooth surface. On the other hand, as can be seen from FIGS. 9, 10, 13 and 14, the three-dimensional fiber-reinforced plastic preform of Comparative Example 1 has wrinkles at the foremost corner when viewed from the drawings, Was not as appropriate.
本発明の繊維強化プラスチック用プリフォームは、プラスチックやコンクリートの補強などに好適である。 The preform for fiber-reinforced plastic of the present invention is suitable for reinforcing plastic or concrete.
１、１１、２１、３１、４１ 繊維強化プラスチック用基材
２、１２、２２、３２、４２ 強化繊維シート
２ａ、１２ａ、２２ａ、３２ａ、４２ａ 強化繊維糸
３、１３、２３、３３、４３ 補助繊維糸
４、１４、２４、３４、４４ ステッチ糸
１０ 繊維強化プラスチック用多層基材
１００、２００ 繊維強化プラスチック用プリフォーム
５０ プレス成形装置
５１ 下金型
５２ 上金型
６０ ヒーター
1, 11, 21, 31, 41 Base material for fiber-reinforced plastics 2, 12, 22, 32, 42 Reinforcement fiber sheets 2a, 12a, 22a, 32a, 42a Reinforcement fiber yarns 3, 13, 23, 33, 43 Auxiliary fibers Thread 4, 14, 24, 34, 44 Stitch thread 10 Multilayer base material for fiber reinforced plastic 100, 200 Preform for fiber reinforced plastic 50 Press molding device 51 Lower mold 52 Upper mold 60 Heater
Claims (9)
前記繊維強化プラスチック用基材は、複数本の強化繊維糸が一方向に引き揃えられた強化繊維シートと、前記強化繊維シートの一方の表面に前記強化繊維糸の引き揃え方向と交差する方向に所定の間隔で配置されている複数本の補助繊維糸を含み、前記強化繊維シート及び前記補助繊維糸は、前記補助繊維糸とは異なるステッチ糸で一体化され、
前記補助繊維糸の長さが、該補助繊維糸の長さ方向の両端点を結んだ直線の長さの１０１〜１５０％であり、
前記２層以上の繊維強化プラスチック用基材は、接着性樹脂で接合されており、
隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向は異なり、かつ隣接する繊維強化プラスチック用基材の端部はずれていることを特徴とする繊維強化プラスチック用プリフォーム。 A preform for a fiber-reinforced plastic having two or more layers of a base material for a fiber-reinforced plastic and having a three-dimensional shape,
The fiber-reinforced plastic base material includes a reinforcing fiber sheet in which a plurality of reinforcing fiber yarns are aligned in one direction, and a direction intersecting a direction in which the reinforcing fiber yarns are aligned on one surface of the reinforcing fiber sheet. Including a plurality of auxiliary fiber yarns arranged at predetermined intervals, the reinforcing fiber sheet and the auxiliary fiber yarn are integrated with a different stitch yarn from the auxiliary fiber yarn ,
The length of the auxiliary fiber yarn is 101 to 150% of the length of a straight line connecting both end points in the length direction of the auxiliary fiber yarn,
The two or more layers of the fiber-reinforced plastic substrate are joined with an adhesive resin,
A preform for a fiber-reinforced plastic, characterized in that the direction of alignment of the reinforcing fiber yarns in adjacent fiber-reinforced plastic substrates is different and ends of adjacent fiber-reinforced plastic substrates are offset.
前記繊維強化プラスチック用基材は、複数本の強化繊維糸が一方向に引き揃えられた強化繊維シートと、前記強化繊維シートの一方の表面に前記強化繊維糸の引き揃え方向と交差する方向に所定の間隔で配置されている複数本の補助繊維糸を含み、前記強化繊維シート及び前記補助繊維糸は、前記補助繊維糸とは異なるステッチ糸で一体化され、
前記補助繊維糸の長さが、該補助繊維糸の長さ方向の両端点を結んだ直線の長さの１０１〜１５０％であり、
前記繊維強化プラスチック用基材を２層以上積層した繊維強化プラスチック用多層基材において、少なくとも１層の維強化樹脂プラスチック用基材のいずれかの面に接着性樹脂を配置し、該繊維強化プラスチック用多層基材を所定の温度で加熱して接着性樹脂を溶解させた後、プレス成形により前記繊維強化プラスチック用多層基材を接着性樹脂で接合させるとともに立体形状に賦形し、立体形状を有する繊維強化プラスチック用プリフォームを得る工程を含み、前記前記繊維強化プラスチック用多層基材において、隣接する繊維強化プラスチック用基材における強化繊維糸の引き揃え方向が異なっており、
前記プレス成形の際に、積層される各々の繊維強化プラスチック用基材が変形しながら層間で滑ることを特徴とする繊維強化プラスチック用プリフォームの製造方法 A method for producing a preform for a fiber-reinforced plastic having a three-dimensional shape, comprising two or more layers of a substrate for a fiber-reinforced plastic,
The fiber-reinforced plastic base material includes a reinforcing fiber sheet in which a plurality of reinforcing fiber yarns are aligned in one direction, and a direction intersecting a direction in which the reinforcing fiber yarns are aligned on one surface of the reinforcing fiber sheet. Including a plurality of auxiliary fiber yarns arranged at predetermined intervals, the reinforcing fiber sheet and the auxiliary fiber yarn are integrated with a different stitch yarn from the auxiliary fiber yarn ,
The length of the auxiliary fiber yarn is 101 to 150% of the length of a straight line connecting both end points in the length direction of the auxiliary fiber yarn,
In a multilayer substrate for fiber reinforced plastic in which two or more layers of the substrate for fiber reinforced plastic are laminated, an adhesive resin is disposed on any surface of at least one layer of the substrate for fiber reinforced plastic, After heating the multi-layer base material at a predetermined temperature to dissolve the adhesive resin, the multi-layer base material for fiber-reinforced plastic is joined by the adhesive resin by press molding and shaped into a three-dimensional shape, and the three-dimensional shape is formed. Including a step of obtaining a preform for fiber reinforced plastic having, in the multilayer substrate for fiber reinforced plastic, the alignment direction of the reinforcing fiber yarn in the adjacent fiber reinforced plastic substrate is different,
A method for producing a preform for a fiber reinforced plastic, characterized in that, during the press molding, each laminated fiber reinforced plastic substrate slides between layers while deforming.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016042568A JP6675231B2 (en) | 2016-03-04 | 2016-03-04 | Preform for fiber reinforced plastic and method for producing the same |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2016042568A JP6675231B2 (en) | 2016-03-04 | 2016-03-04 | Preform for fiber reinforced plastic and method for producing the same |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JP2017154471A JP2017154471A (en) | 2017-09-07 |
| JP6675231B2 true JP6675231B2 (en) | 2020-04-01 |
Family
ID=59809028
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP2016042568A Expired - Fee Related JP6675231B2 (en) | 2016-03-04 | 2016-03-04 | Preform for fiber reinforced plastic and method for producing the same |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP6675231B2 (en) |
Family Cites Families (9)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS543167A (en) * | 1977-06-10 | 1979-01-11 | Tsugio Kobayashi | Method of manufactureing gear using carbon fiber |
| JPH08337666A (en) * | 1995-06-13 | 1996-12-24 | Toray Ind Inc | Preform and its production |
| JP2002317371A (en) * | 2001-04-25 | 2002-10-31 | Toray Ind Inc | Stitch fabric of carbon fiber |
| JP4940644B2 (en) * | 2005-12-12 | 2012-05-30 | 東レ株式会社 | Biaxial stitch substrate and preform |
| JP4699238B2 (en) * | 2006-02-27 | 2011-06-08 | 三菱重工業株式会社 | Reinforced fiber substrate and fiber reinforced plastic |
| JP5336225B2 (en) * | 2009-02-21 | 2013-11-06 | 東邦テナックス株式会社 | Multi-axis stitch base material and preform using it |
| JP5847033B2 (en) * | 2012-07-19 | 2016-01-20 | 株式会社Shindo | Carbon fiber stitch substrate and wet prepreg using the same |
| DE102013103039A1 (en) * | 2013-03-25 | 2014-09-25 | Dieffenbacher GmbH Maschinen- und Anlagenbau | Method, apparatus and preform for the multi-stage production of a three-dimensional preform in the course of the production of fiber-reinforced molded parts |
| JP6277007B2 (en) * | 2014-02-04 | 2018-02-07 | 倉敷紡績株式会社 | Fiber multiaxial sheet and preform for manufacturing fiber reinforced plastic using the same |
-
2016
- 2016-03-04 JP JP2016042568A patent/JP6675231B2/en not_active Expired - Fee Related
Also Published As
| Publication number | Publication date |
|---|---|
| JP2017154471A (en) | 2017-09-07 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| JP6138045B2 (en) | Method for producing high-weight carbon fiber sheet for RTM method and RTM method | |
| JP2013176876A (en) | Manufacturing method of molding | |
| JP2007055162A (en) | Molded body of carbon fiber composite material | |
| JP2006501085A (en) | Manufacturing method of composite material | |
| US7930907B2 (en) | Crimp-free infusible reinforcement fabric and composite reinforced material therefrom | |
| WO2017212835A1 (en) | Reinforced base material for composite material component, composite material component, and method for manufacturing same | |
| CN106881931A (en) | Thermoplas tic resin composite and the preparation method of thermoplas tic resin composite | |
| JP7087337B2 (en) | Reinforced fiber base material, reinforcing fiber laminate and fiber reinforced resin | |
| JP2008132775A (en) | Multilayer substrate and preform | |
| JP2009161886A (en) | Reinforced fiber substrate, preform, composite material and method for producing the same | |
| JP2007126793A (en) | Cutting method and preform substrate for laminate, and preform production method using the same | |
| JP2010214704A (en) | Base material for preform using binder including superfine fiber, and method of manufacturing the same | |
| JP2007269034A (en) | Fiber-reinforced composite material | |
| JP6650296B2 (en) | Substrate for fiber reinforced plastic, multilayer substrate for fiber reinforced plastic, preform for fiber reinforced plastic, and method for producing the same | |
| JP6675231B2 (en) | Preform for fiber reinforced plastic and method for producing the same | |
| JP4759303B2 (en) | Composite material using multiaxial fabric | |
| JP5990030B2 (en) | Method for molding fiber reinforced plastic structure and method for producing reinforced fiber sheet for VaRTM | |
| JP2008307818A (en) | Multiaxial material for fiber-reinforced thermoplastic resin, and molded product | |
| JP4019822B2 (en) | Manufacturing method of fiber reinforced composite material | |
| KR20170140587A (en) | Multilayer Composite Agent Stitched With Reinforcing Fibers And The Process For Producing The Same | |
| JP2006200094A (en) | Reinforcing fiber base material, preform, composite material, and method for producing the same | |
| JP3915614B2 (en) | Fiber structure and composite material having deformed portion | |
| KR101777732B1 (en) | Long-fiber nonwoven textile preforms including Long-fiber web layer and method of manufacturing the same and composite material including Long-fiber nonwoven textile preforms and method of manufacturing the same | |
| JP4376118B2 (en) | Multi-axis fabric, preform material, and fiber reinforced plastic molding | |
| JP6771265B2 (en) | A preform, a method for producing the preform, and a fiber reinforced plastic using the above preform. |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| A621 | Written request for application examination |
Free format text: JAPANESE INTERMEDIATE CODE: A621 Effective date: 20180920 |
|
| A977 | Report on retrieval |
Free format text: JAPANESE INTERMEDIATE CODE: A971007 Effective date: 20190717 |
|
| A131 | Notification of reasons for refusal |
Free format text: JAPANESE INTERMEDIATE CODE: A131 Effective date: 20190725 |
|
| A521 | Request for written amendment filed |
Free format text: JAPANESE INTERMEDIATE CODE: A523 Effective date: 20190920 |
|
| TRDD | Decision of grant or rejection written | ||
| A01 | Written decision to grant a patent or to grant a registration (utility model) |
Free format text: JAPANESE INTERMEDIATE CODE: A01 Effective date: 20200213 |
|
| A61 | First payment of annual fees (during grant procedure) |
Free format text: JAPANESE INTERMEDIATE CODE: A61 Effective date: 20200310 |
|
| R150 | Certificate of patent or registration of utility model |
Ref document number: 6675231 Country of ref document: JP Free format text: JAPANESE INTERMEDIATE CODE: R150 |
|
| LAPS | Cancellation because of no payment of annual fees |