JP7395219B1 - Fiber-reinforced resin hollow or composite molded body - Google Patents
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Abstract
【課題】内部に中空部又は内部部材を有しながらもプレス成形の際層がずれず、精度の高い成形品が得られる繊維強化樹脂中空又は複合成形体。【解決手段】第一プリプレグ、膨張性中空小球体又は内部部材、第二プリプレグを積層し、第一プリプレグと第二プリプレグを糸で縫合し、加熱プレスをすることにより、内部に中空部又は内部部材を有しながらずれの無い繊維強化樹脂中空又は複合成形体。【選択図】図１An object of the present invention is to provide a fiber-reinforced resin hollow or composite molded product that has a hollow portion or internal member inside, but does not cause layers to shift during press molding, and allows a highly accurate molded product to be obtained. [Solution] A first prepreg, an expandable hollow small sphere or an internal member, and a second prepreg are laminated, the first prepreg and the second prepreg are sewn together with a thread, and heat pressed to form a hollow part or an internal member. A fiber-reinforced resin hollow or composite molded body that has components but does not shift. [Selection diagram] Figure 1
Description
本発明は、繊維強化樹脂複合体を構成部材として含む繊維強化樹脂中空又は複合成形体に関する。 The present invention relates to a fiber-reinforced resin hollow or composite molded body containing a fiber-reinforced resin composite as a constituent member.
繊維強化樹脂複合体は、軽量で高強度な材料として、近年注目されている。繊維強化樹脂複合体を用いた成形体は、プレス成形する場合には繊維強化樹脂のプリプレグと異素材の部材とを積層させた積層体をプレス成形することにより製造することができる。
積層体は、プリプレグ同士、またはプリプレグとプリプレグに積層させた異素材の部材とがプレス時にずれてしまうため、接着シート又は接着剤を用いて接着させることが従来から行われている。
Fiber-reinforced resin composites have attracted attention in recent years as lightweight and high-strength materials. In the case of press molding, a molded body using a fiber-reinforced resin composite can be manufactured by press-molding a laminate in which a fiber-reinforced resin prepreg and a member made of a different material are laminated.
Conventionally, the laminate is bonded using an adhesive sheet or an adhesive because the prepregs or the prepregs and the members made of different materials stacked on the prepregs may shift during pressing.
繊維強化樹脂複合体としては、例えば特許文献１のように、金属部材と、強化繊維材料とマトリックス樹脂とを複合させたＦＲＰ層とを、フェノキシ樹脂の固化物、またはフェノキシ樹脂を含む接着樹脂組成物の硬化物である接着層で接着したものが挙げられる（特許文献１）。
また、例えば特許文献２には、金属とプリプレグの間に、複数の貫通孔を有する金属から構成される接着強化層を配置することにより、製造コストを抑えつつ、接着力の高い、加熱プレス成形できる金属－プリプレグ複合体が記載されている（特許文献２）。
これらの従来技術は、層同士の接着のため樹脂や接着シートから成る接着層を設けているが、接着樹脂や接着シート、接着剤では接合能力が十分ではなく、プレス時にプリプレグ同士がずれてしまう場合がある。特に、プリプレグ層間に異部材を含む場合はそのずれが顕著になるという問題があった。
As a fiber-reinforced resin composite, for example, as in Patent Document 1, a metal member and an FRP layer that is a composite of a reinforcing fiber material and a matrix resin are combined with a solidified phenoxy resin or an adhesive resin composition containing a phenoxy resin. Examples include those adhered with an adhesive layer that is a cured product (Patent Document 1).
In addition, for example, Patent Document 2 discloses that by arranging an adhesion reinforcing layer made of metal having a plurality of through holes between the metal and the prepreg, hot press molding with high adhesive strength can be achieved while suppressing manufacturing costs. A metal-prepreg composite that can be produced is described (Patent Document 2).
These conventional technologies provide an adhesive layer made of resin or adhesive sheet to bond the layers together, but the adhesive resin, adhesive sheet, or adhesive does not have sufficient bonding ability, and the prepregs may shift when pressed. There are cases. In particular, when different members are included between the prepreg layers, there is a problem in that the deviation becomes noticeable.
従来の技術によってプリプレグを積層させプレス成形する場合は、接着シート又は接着剤を使って接着した上で、プレス成形を行っていた。しかし、接着シート又は接着剤を用いても、プレス時にずれてしまい、精度の高い成形品を得ることが難しい場合もあった。
本発明では、積層したプリプレグを縫合することにより、精度の高い成形品を得ることを目的とする。特に、プリプレグの積層間に熱膨張性中空小球体又は内部部材を配置してから縫合し成形することにより、内部に中空部又は内部部材を有しながらも、プリプレグにずれのない成形体を提供することを目的とする。
When prepregs are laminated and press-molded using conventional techniques, they are bonded using an adhesive sheet or an adhesive, and then press-molded. However, even if an adhesive sheet or adhesive is used, it may shift during pressing, making it difficult to obtain a molded product with high precision.
The present invention aims to obtain a molded product with high precision by sewing laminated prepregs together. In particular, by placing heat-expandable hollow small spheres or internal members between the laminated layers of prepreg and then sewing and molding, a molded article that does not shift in the prepreg even though it has a hollow part or internal member inside can be provided. The purpose is to
本発明者らは鋭意研究を重ねた結果、第一プリプレグと第二プリプレグとを、その積層間に熱膨張性中空小球体又は内部部材を挿入し、その縁を糸によって縫合することで、プレス成形時に熱膨張性中空小球体または内部部材等を挟んだ第一プリプレグと第二プリプレグとがずれずにプレス出来ることを発見した。
すなわち、本発明は、以下を包含する。
［１］ １層又は複数層の第一繊維強化樹脂と、
１層又は複数層の第二繊維強化樹脂と、
前記第一繊維強化樹脂と、前記第二繊維強化樹脂との間に位置する中空部又は内部部材とを含み、
前記第一繊維強化樹脂と、前記第二繊維強化樹脂とは、縫合されている、繊維強化樹脂中空又は複合成形体。
［２］ 前記中空部又は内部部材を囲うように縫合されている、［１］に記載の繊維強化樹脂中空又は複合成形体。
［３］ 縫合糸は、ナイロン製の糸である、［１］に記載の繊維強化樹脂中空又は複合成形体。
［４］ 第一及び第二繊維強化樹脂は、いずれも、繊維織物を含む、［１］に記載の繊維強化樹脂中空又は複合成形体。
［５］ ［１］乃至［４］のいずれか一項に記載の繊維強化樹脂中空又は複合成形体の製造方法であって、
１層又は複数層の繊維強化樹脂プリプレグである第一プリプレグを準備する工程と、
１層又は複数層の繊維強化樹脂プリプレグである第二プリプレグを準備する工程と、
前記第一プリプレグと、熱膨張性中空小球体又は内部部材と、前記第二プリプレグとをこの順に積層させることにより成形前積層体を得る工程と、
前記成形前積層体において、前記第一プリプレグ及び前記第二プリプレグを縫合する工程と、
前記成形前積層体を上金型と下金型とで加熱プレスする工程とを含む、繊維強化樹脂中空又は複合成形体の製造方法。
As a result of extensive research, the present inventors have found that the first prepreg and the second prepreg can be pressed by inserting a thermally expandable hollow small sphere or an internal member between the laminated layers and sewing the edges with a thread. It has been discovered that the first and second prepregs sandwiching the thermally expandable hollow small spheres or internal members can be pressed without shifting during molding.
That is, the present invention includes the following.
[1] One layer or multiple layers of first fiber reinforced resin,
one or more layers of second fiber-reinforced resin;
a hollow part or an internal member located between the first fiber-reinforced resin and the second fiber-reinforced resin,
The first fiber-reinforced resin and the second fiber-reinforced resin are a fiber-reinforced resin hollow or composite molded body, in which the first fiber-reinforced resin and the second fiber-reinforced resin are sewn together.
[2] The fiber-reinforced resin hollow or composite molded article according to [1], which is sutured to surround the hollow portion or internal member.
[3] The fiber-reinforced resin hollow or composite molded article according to [1], wherein the suture thread is a nylon thread.
[4] The fiber-reinforced resin hollow or composite molded article according to [1], wherein both the first and second fiber-reinforced resins include a fiber fabric.
[5] A method for producing a fiber-reinforced resin hollow or composite molded article according to any one of [1] to [4], comprising:
a step of preparing a first prepreg that is one or more layers of fiber-reinforced resin prepreg;
preparing a second prepreg that is one or more layers of fiber-reinforced resin prepreg;
Obtaining a pre-molding laminate by laminating the first prepreg, the thermally expandable hollow small sphere or internal member, and the second prepreg in this order;
In the pre-molding laminate, suturing the first prepreg and the second prepreg;
A method for producing a fiber-reinforced resin hollow or composite molded body, comprising the step of hot pressing the pre-molding laminate using an upper mold and a lower mold.
繊維強化樹脂中空又は複合成形体は、積層したプリプレグが縫合されていることにより、内部に中空部又は内部部材を有しながらも、成形時にプリプレグ同士がずれることがなく、高い精度を有するものである。 Fiber-reinforced resin hollow or composite molded products are made of laminated prepregs that are sewn together, so even though they have hollow parts or internal members inside, the prepregs do not shift from each other during molding and have high precision. be.
［繊維強化樹脂中空又は複合成形体］
以下、本発明を詳細に説明するが、本発明の趣旨を逸脱しない範囲において、本発明は下記された内容のみならず、当業者に容易な修正や置換できる範囲まで及ぶものとする。
本明細書では、繊維強化樹脂中空成形体と、繊維強化樹脂複合成形体とを総称して、繊維強化樹脂中空又は複合成形体とする。
[Fiber-reinforced resin hollow or composite molded body]
Hereinafter, the present invention will be described in detail, but within the scope of the invention, the present invention extends not only to the contents described below but also to the scope that can be easily modified or replaced by those skilled in the art.
In this specification, fiber-reinforced resin hollow molded bodies and fiber-reinforced resin composite molded bodies are collectively referred to as fiber-reinforced resin hollow or composite molded bodies.
図１（ａ）は、繊維強化樹脂中空成形体１Ａの斜視図であり、図１（ｂ）は、繊維強化樹脂中空成形体１Ａの平面図である。繊維強化樹脂中空成形体１Ａは、第一繊維強化樹脂４、中空小球体６と、第二繊維強化樹脂５が積層されている状態であり、フランジ部３をナイロン糸１１によって縫合してあるもので、成形体本体２中に中空小球体６を含む中空部を有している。 FIG. 1(a) is a perspective view of the fiber-reinforced resin hollow molded body 1A, and FIG. 1(b) is a plan view of the fiber-reinforced resin hollow molded body 1A. The fiber-reinforced resin hollow molded body 1A is a state in which a first fiber-reinforced resin 4, a hollow small sphere 6, and a second fiber-reinforced resin 5 are laminated, and the flange portion 3 is sewn with a nylon thread 11. The molded body 2 has a hollow portion containing the hollow small spheres 6.
図２は、繊維強化樹脂中空成形体１Ａの長手方向の断面図である。第一繊維強化樹脂４と第二繊維強化樹脂５とはフランジ部３で縫合されており、中空小球体６が内部に配置されている。 FIG. 2 is a longitudinal sectional view of the fiber-reinforced resin hollow molded body 1A. The first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 are sewn together at the flange portion 3, and a small hollow sphere 6 is arranged inside.
図３は、繊維強化樹脂複合成形体１Ｂの長手方向の断面図である。繊維強化樹脂複合成形体１Ｂについては第一繊維強化樹脂４と第二繊維強化樹脂５とはフランジ部３で縫合されており、内部に内部部材７が配置されている。 FIG. 3 is a longitudinal cross-sectional view of the fiber-reinforced resin composite molded body 1B. In the fiber-reinforced resin composite molded body 1B, the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 are sewn together at the flange portion 3, and an internal member 7 is disposed inside.
繊維強化樹脂とは繊維と樹脂の複合材料を意味する。
第一繊維強化樹脂４、第二繊維強化樹脂５を構成する繊維としては、高強度でありシート状である必要があるため、繊維織物であることが好ましいが、プレス成形出来る材料であれば特に限定されるものではなく、ガラス繊維、炭素繊維、金属繊維、アラミド繊維（化学繊維および天然繊維）、ポリビニルアルコール系繊維、ポリエステル系繊維、ポリアミド系繊維、ポリエチレン系繊維、ポリパラフェニレンベンゾビスオキサゾール繊維などが挙げられる。ガラス繊維としては、Ｅガラス、Ｓガラス、Ｄガラス、Ｑガラス等を用いたガラス繊維が挙げられる。また、ポリアクリルニトリルを原料とするＰＡＮ系炭素繊維とピッチを原料とするピッチ系炭素繊維等を用いることが出来る。
第一繊維強化樹脂４、第二繊維強化樹脂５中の炭素繊維としては、ＰＡＮ系炭素繊維が好ましいが、それに限定されるものではない。また、第一繊維強化樹脂４、第二繊維強化樹脂５を構成する繊維強化樹脂には、ＳＭＣ（Ｓｈｅｅｔ Ｍｏｌｄｉｎｇ Ｃｏｍｐｏｕｎｄ）、ＦＲＰ（Ｆｉｒｂｅｒ Ｒｅｉｎｆｏｒｃｅｄ Ｐｌａｓｔｉｃｓ）、ＧＭＴ（Ｇｌａｓｓ Ｒｅｉｎｆｏｒｃｅｄ Ｔｈｅｒｍｏｐｌａｓｔｉｃｓ）、Ｎｏｎ－ｃｒｉｍｐｆｉｂｅｒを含む樹脂などの複合体も包含されるものとする。これらは１種類の繊維あるいは複数種類の繊維の組み合わせを用いてもよい。
Fiber-reinforced resin means a composite material of fibers and resin.
The fibers constituting the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 need to be high-strength and sheet-like, so they are preferably woven fibers, but especially if they are made of materials that can be press-formed. Examples include, but are not limited to, glass fibers, carbon fibers, metal fibers, aramid fibers (chemical fibers and natural fibers), polyvinyl alcohol fibers, polyester fibers, polyamide fibers, polyethylene fibers, polyparaphenylene benzobisoxazole fibers. Examples include. Examples of the glass fiber include glass fibers using E glass, S glass, D glass, Q glass, and the like. Further, PAN-based carbon fibers made from polyacrylonitrile as a raw material, pitch-based carbon fibers made from pitch, etc. can be used.
The carbon fibers in the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 are preferably PAN-based carbon fibers, but are not limited thereto. Further, the fiber reinforced resins constituting the first fiber reinforced resin 4 and the second fiber reinforced resin 5 include SMC (Sheet Molding Compound), FRP (Fiber Reinforced Plastics), GMT (Glass Reinforced Thermoplastics), -Includes crimp fiber Composites such as resins are also included. For these, one type of fiber or a combination of multiple types of fibers may be used.
第一繊維強化樹脂４、第二繊維強化樹脂５中の繊維織物等の繊維基材としては、０．０３ｍｍ～０．５ｍｍの厚さのガラス繊維織物、炭素繊維織物等のガラス繊維材又は炭素繊維材が好ましいが、それに限定されるものではない。 The fiber base materials such as fiber fabrics in the first fiber reinforced resin 4 and the second fiber reinforced resin 5 are glass fiber materials such as glass fiber fabrics and carbon fiber fabrics having a thickness of 0.03 mm to 0.5 mm, or carbon fibers. Fibrous materials are preferred, but not limited thereto.
第一繊維強化樹脂４、第二繊維強化樹脂５を構成する樹脂は熱硬化性樹脂、熱可塑性樹脂のいずれも用いてよい。具体的には、熱硬化性樹脂としては、エポキシ樹脂、ビニルエステル樹脂、不飽和ポリエステル樹脂、ポリウレタン樹脂、フェノール樹脂等が挙げられ、これらは組み合わせて使用することができる。熱可塑性樹脂としては、アクリル樹脂、ポリエステル樹脂、ポリカーボネート樹脂、ポリプロピレン樹脂、ポリエチレン樹脂、ポリスチレン樹脂、塩化ビニール樹脂、ポリアミド樹脂等が挙げられる。これらは、単独で用いてもよいし、複数混合して用いてもよい。 The resin constituting the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 may be either a thermosetting resin or a thermoplastic resin. Specifically, examples of thermosetting resins include epoxy resins, vinyl ester resins, unsaturated polyester resins, polyurethane resins, and phenol resins, and these can be used in combination. Examples of the thermoplastic resin include acrylic resin, polyester resin, polycarbonate resin, polypropylene resin, polyethylene resin, polystyrene resin, vinyl chloride resin, and polyamide resin. These may be used alone or in combination.
第一繊維強化樹脂４、第二繊維強化樹脂５の厚さは、好ましくは、０．２～８ｍｍ、特に０．５～５ｍｍである。第一繊維強化樹脂４、第二繊維強化樹脂５の厚さが過度に小さいと材料の剛性や強度が低く、破損や切断などを生じやすく実用性に劣る。第一繊維強化樹脂４、第二繊維強化樹脂５の厚さが過度に大きいと、繊維強化樹脂中空又は複合成形体の重量が大きくなる。 The thickness of the first fiber reinforced resin 4 and the second fiber reinforced resin 5 is preferably 0.2 to 8 mm, particularly 0.5 to 5 mm. If the thickness of the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 is too small, the rigidity and strength of the materials will be low, and they will be easily damaged or cut, resulting in poor practicality. If the thicknesses of the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 are excessively large, the weight of the fiber-reinforced resin hollow or composite molded body becomes large.
ナイロン糸１１は、第一繊維強化樹脂４と第二繊維強化樹脂５とをしっかりと縫合出来るものであれば特に限定されるものではないが、強度の観点から樹脂繊維からなる糸が好ましく、ポリプロピレン、ポリエステル等を用いることが出来るが、特にナイロンを好適に用いることが出来る。ナイロン糸１１は、中空部や内部部材７を囲うように縫合している。繊維強化樹脂中空成形体１Ａ及び繊維強化樹脂複合成形体１Ｂにおいては、フランジ部３において縫合されている状態となることが好ましい。 The nylon thread 11 is not particularly limited as long as it can securely suture the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5, but from the viewpoint of strength, a thread made of resin fiber is preferable, and polypropylene is preferable. , polyester, etc. can be used, and nylon can be particularly preferably used. The nylon thread 11 is sutured so as to surround the hollow part and the internal member 7. In the fiber-reinforced resin hollow molded body 1A and the fiber-reinforced resin composite molded body 1B, it is preferable that the flange portion 3 be sewn together.
中空小球体６とは、膨張性中空小球体６Ａを加熱することにより膨張したものであり、空気や各種ガスを内包した外殻を形成したものであれば、特に制限されるものではなく、第一繊維強化樹脂４、第二繊維強化樹脂５の間に中空部を設けることが出来る材料であれば特に限定されない。中空小球体６の粒径は適宜設定されるものであるが、例えば３０μｍ以上２５０μｍ以下とすることができる。
また、粒径については、ランダム選択された複数個（例えば、１０個）の膨張性中空小球体６Ａまたは中空小球体６の粒径の平均値を用いることができる。
なお、繊維強化樹脂に挟まれたコア材としての中空小球体６は、金属等のコア材に比べて、切削コストがかからず、さらには、軽量にすることができます。
The hollow small spheres 6 are expanded by heating the expandable hollow small spheres 6A, and are not particularly limited as long as they form an outer shell containing air or various gases. The material is not particularly limited as long as it is possible to provide a hollow portion between the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5. Although the particle size of the hollow small spheres 6 is set appropriately, it can be, for example, 30 μm or more and 250 μm or less.
As for the particle size, the average value of the particle sizes of a plurality of (for example, 10) randomly selected expandable hollow small spheres 6A or hollow small spheres 6 can be used.
In addition, the hollow small sphere 6 as a core material sandwiched between fiber-reinforced resins requires less cutting cost and can be made lighter than core materials such as metal.
内部部材７とは、金属やその他異なる素材の部材を用いることができ、棒（バー）のように内部に中空部がなく塊状のもの、パイプのように内部に中空部があるものいずれでもよい。内部部材７の素材には、例えばアルミニウム、アルミニウム合金、マグネシウム合金、チタン、チタン合金、鋼、銅、銅合金、エポキシ樹脂、ビニルエステル樹脂、不飽和ポリエステル樹脂、ポリウレタン樹脂、フェノール樹脂などが挙げられるが、これらに限定されない。 The internal member 7 can be made of metal or other different materials, and can be either a block without a hollow part like a bar, or a piece with a hollow part like a pipe. . Examples of the material for the internal member 7 include aluminum, aluminum alloy, magnesium alloy, titanium, titanium alloy, steel, copper, copper alloy, epoxy resin, vinyl ester resin, unsaturated polyester resin, polyurethane resin, and phenol resin. However, it is not limited to these.
繊維強化樹脂中空成形体は、第一繊維強化樹脂４、第二繊維強化樹脂５の間に中空部が設けられているため、軽い材料として用いることができる。また、中空部は空隙のため、断熱効果も有する。また、中空小球体６ではなく内部部材７を第一繊維強化樹脂４、第二繊維強化樹脂５の間に設けた繊維強化樹脂複合成形体の場合は、パイプ形状の内部部材７であれば、内部の空洞によって断熱効果が高く軽く、しかも剛性の高い材料として用いることができる。内部部材７が空洞の無い金属棒や金属片、樹脂棒などであった場合は、第一繊維強化樹脂４、第二繊維強化樹脂５の材料に、低価格でさらに高い強度を実現できる。 The fiber-reinforced resin hollow molded body can be used as a light material because a hollow portion is provided between the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5. Furthermore, since the hollow portion is a void, it also has a heat insulating effect. In addition, in the case of a fiber-reinforced resin composite molded body in which the internal member 7 is provided between the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 instead of the hollow small sphere 6, if the internal member 7 is pipe-shaped, The internal cavity allows it to be used as a material that is highly insulating, lightweight, and highly rigid. If the internal member 7 is a metal rod, metal piece, resin rod, etc. without a cavity, the materials of the first fiber-reinforced resin 4 and the second fiber-reinforced resin 5 can have even higher strength at a lower cost.
［繊維強化樹脂中空又は複合成形体の製造方法］
本発明において、繊維強化樹脂中空又は複合成形体の製造は、まず図４（ａ）に図示するように、繊維織物に樹脂を含浸させた半硬化状態のプリプレグを１層又は複数層積層させた第一プリプレグ８、第二プリプレグ９を準備する。半硬化状態の繊維強化樹脂とは、繊維強化樹脂の製造において、樹脂中の硬化剤が働く温度未満で、繊維と樹脂を一体化させた状態を指す。第一プリプレグ８と第二プリプレグ９を構成する半硬化状態の繊維強化樹脂は、全て同じ半硬化状態の繊維強化樹脂を用いてもよいし異なっていてもよい。これらのプリプレグは、上記の繊維強化樹脂の完全硬化前の材料である。
[Method for manufacturing fiber-reinforced resin hollow or composite molded bodies]
In the present invention, the fiber-reinforced resin hollow or composite molded body is manufactured by first laminating one or more layers of semi-cured prepreg in which a fiber fabric is impregnated with resin, as shown in FIG. 4(a). A first prepreg 8 and a second prepreg 9 are prepared. A semi-cured fiber-reinforced resin refers to a state in which fibers and resin are integrated at a temperature below the temperature at which the curing agent in the resin works in the production of fiber-reinforced resin. The semi-cured fiber-reinforced resins forming the first prepreg 8 and the second prepreg 9 may be the same semi-cured fiber-reinforced resin or may be different. These prepregs are materials of the above-mentioned fiber-reinforced resin that have not yet been completely cured.
図４（ｂ）に図示するように、第一プリプレグ８、膨張性中空小球体６Ａ又は内部部材７、第二プリプレグ９をこの順番で積層することにより、図４（ｃ）に図示するように成形前積層体１０Ａを得る。
その後、図４（ｄ）に図示するように、第一プリプレグ８及び第二プリプレグ９をナイロン糸１１によって縫合する。なお、本明細書において、成形前積層体１０Ａとは、第一プリプレグ８、第二プリプレグ９との間に、膨張性中空小球体６Ａ又は、内部部材７が配置されている積層体のことを意味する。
As illustrated in FIG. 4(b), by laminating the first prepreg 8, expandable hollow small spheres 6A or internal member 7, and second prepreg 9 in this order, as illustrated in FIG. 4(c), A pre-molding laminate 10A is obtained.
Thereafter, as shown in FIG. 4(d), the first prepreg 8 and the second prepreg 9 are sewn together using a nylon thread 11. In addition, in this specification, the pre-molding laminate 10A refers to a laminate in which the expandable hollow small spheres 6A or the internal member 7 are arranged between the first prepreg 8 and the second prepreg 9. means.
第一プリプレグ８、第二プリプレグ９はそれぞれ１層だけでもよいし、複数層積層されてよく、加熱プレス後の第一繊維強化樹脂４、第二繊維強化樹脂５もそれぞれ１層又は複数層積層されてよい。
第一プリプレグ８と第二プリプレグ９との縫合方法は、第一プリプレグ８及び第二プリプレグ９とをしっかりと縫合出来るものであれば特に限定されるものではないが、ランニングステッチ、アウトラインステッチ、バックステッチ、サテンステッチ、クロスステッチ、チェーンステッチ、ブランケットステッチなどが挙げられ、その他にも、チェーン編み、或いはトリコット編み、かがり縫い、まつり縫いが適している。縫合の位置は、中空部又は内部部材７が設けられれば特に限定されないが、下金型１２と上金型１３の凹部分を囲うように縫合することが好ましい。
加熱プレスにより第一プリプレグ８は硬化し第一繊維強化樹脂４になり、第二プリプレグ９は硬化し第二繊維強化樹脂５となる。
The first prepreg 8 and the second prepreg 9 may each have only one layer or may be laminated in multiple layers, and the first fiber reinforced resin 4 and the second fiber reinforced resin 5 after hot pressing may also be laminated in one layer or multiple layers, respectively. It's okay to be.
The method of suturing the first prepreg 8 and the second prepreg 9 is not particularly limited as long as it can securely suture the first prepreg 8 and the second prepreg 9, but examples include running stitch, outline stitch, back stitch, etc. Examples include stitch, satin stitch, cross stitch, chain stitch, blanket stitch, etc. Chain stitch, tricot stitch, overlock stitch, and blind stitch are also suitable. The position of suturing is not particularly limited as long as the hollow part or the internal member 7 is provided, but it is preferable to suture so as to surround the concave portions of the lower mold 12 and the upper mold 13.
The first prepreg 8 is cured and becomes the first fiber-reinforced resin 4 by heating press, and the second prepreg 9 is cured and becomes the second fiber-reinforced resin 5.
膨張性中空小球体６Ａとは、中空小球体６の膨張の前のものを意味する。
膨張性中空小球体６Ａは特に限定されるものではなく、市販されている膨張性中空小球体６Ａとしては、具体的には、松本油脂製薬社製のマツモトマイクロスフィアー、クレハ社製のクレハマイクロスフィアー、日本フェライト社製のＥｘｐａｎｃｅｌマイクロスフィア、積水化学工業社製のＡＤＶＡＮＣＥＬＬ ＥＭ等を挙げることができる。
The expandable small hollow sphere 6A means the hollow small sphere 6 before expansion.
The expandable hollow small spheres 6A are not particularly limited, and examples of commercially available expandable hollow small spheres 6A include Matsumoto Microsphere manufactured by Matsumoto Yushi Pharmaceutical Co., Ltd., and Kureha Micro manufactured by Kureha Co., Ltd. Sphere, Expancel Microsphere manufactured by Nippon Ferrite Co., Ltd., ADVANCEL EM manufactured by Sekisui Chemical Co., Ltd., etc. can be mentioned.
次に、図５（ｅ）に図示するように、成形前積層体１０Ａを、下金型１２と上金型１３を備える加熱プレス機に配置し、上下より加熱プレスを行う。
図５（ｆ）に図示するように、加熱プレスにより第一プリプレグ８は硬化し第一繊維強化樹脂４に、第二プリプレグ９は硬化し第二繊維強化樹脂５となる。
膨張性中空小球体６Ａは加熱により膨脹し、中空小球体６となり、第一繊維強化樹脂４と第二繊維強化樹脂５の間が空隙状態となる。次に、図５（ｇ）に図示するように、下金型１２と上金型１３を取り外し、繊維強化樹脂中空成形体１Ａ又は、内部部材７を用いた場合は繊維強化樹脂複合成形体１Ｂ、すなわち繊維強化樹脂中空又は複合成形体を得る。
なお、図面では、下金型１２、上金型１３のいずれも凹部を有するものを例示したが、これに限定されるものではなく、例えば、下金型１２は凸部を有し、上金型１３は、凹部を有するものであってもよい。
Next, as shown in FIG. 5(e), the pre-molding laminate 10A is placed in a hot press machine equipped with a lower mold 12 and an upper mold 13, and hot pressing is performed from above and below.
As shown in FIG. 5(f), the first prepreg 8 is cured and becomes the first fiber-reinforced resin 4 by heating press, and the second prepreg 9 is cured and becomes the second fiber-reinforced resin 5.
The expandable hollow small spheres 6A expand by heating to become the hollow small spheres 6, and a gap is formed between the first fiber reinforced resin 4 and the second fiber reinforced resin 5. Next, as shown in FIG. 5(g), the lower mold 12 and the upper mold 13 are removed, and the fiber-reinforced resin hollow molded body 1A or, if the internal member 7 is used, the fiber-reinforced resin composite molded body 1B. That is, a fiber-reinforced resin hollow or composite molded body is obtained.
In addition, although the lower mold 12 and the upper mold 13 both have concave portions in the drawings, the present invention is not limited to this. For example, the lower mold 12 has a convex portion, and the upper mold 13 has a concave portion. The mold 13 may have a recess.
本発明の繊維強化樹脂中空又は複合成形体の製造において、プレス加工温度は通常１００～３５０℃であるが、膨張性中空小球体６Ａを用いる場合は、少なくとも膨張性中空小球体６Ａが膨張する温度である必要がある。あくまでも例示であるが、プリプレグの樹脂が熱硬化性樹脂の場合は、１２０～１６０℃にすることができ、プリプレグの樹脂が熱可塑性樹脂の場合は、２３０～３５０℃にすることができる。 In the production of the fiber-reinforced resin hollow or composite molded article of the present invention, the pressing temperature is usually 100 to 350°C, but when using the expandable hollow small spheres 6A, at least the temperature at which the expandable hollow spheres 6A expand. It must be. Just as an example, if the prepreg resin is a thermosetting resin, the temperature can be 120 to 160°C, and if the prepreg resin is a thermoplastic resin, the temperature can be 230 to 350°C.
繊維強化樹脂中空又は複合成形体製造の際のプレス加工の圧力についても、特に限定されるものではなく、通常０．１～１５ＭＰａである。 There are no particular limitations on the press working pressure during the production of fiber-reinforced resin hollow or composite molded bodies, and it is usually 0.1 to 15 MPa.
繊維強化樹脂中空又は複合成形体は、電気自動車を含む車両等の自動車産業や、空飛ぶ車や飛行機などの航空産業、その他の産業に使用することができる。 Fiber-reinforced resin hollow or composite molded bodies can be used in the automobile industry for vehicles including electric cars, the aviation industry for flying cars and airplanes, and other industries.
１Ａ・・・ 繊維強化樹脂中空成形体
１Ｂ・・・ 繊維強化樹脂複合成形体
２・・・成形体本体
３・・・フランジ部
４・・・第一繊維強化樹脂
５・・・第二繊維強化樹脂
６・・・中空小球体
６Ａ・・・膨張性中空小球体（未膨張）
７・・・内部部材
８・・・第一プリプレグ
９・・・第二プリプレグ
１０Ａ・・・成形前積層体
１１・・・ナイロン糸（縫合部）
１２・・・下金型
１３・・・上金型
1A... Fiber-reinforced resin hollow molded body 1B... Fiber-reinforced resin composite molded body 2... Molded body body 3... Flange portion 4... First fiber-reinforced resin 5... Second fiber-reinforced resin Resin 6...Hollow small sphere 6A...Expansible hollow small sphere (unexpanded)
7... Internal member 8... First prepreg 9... Second prepreg 10A... Laminated body before molding 11... Nylon thread (sewn portion)
12...Lower mold 13...Upper mold
Claims (4)
１層又は複数層の第二繊維強化樹脂と、
前記第一繊維強化樹脂と、前記第二繊維強化樹脂との間に位置する中空部を含み、
前記第一繊維強化樹脂と、前記第二繊維強化樹脂とは、縫合されている、繊維強化樹脂中空成形体の製造方法であって、
前記１層又は複数層の第一繊維強化樹脂のプリプレグである第一プリプレグを準備する工程と、
前記１層又は複数層の第二繊維強化樹脂のプリプレグである第二プリプレグを準備する工程と、
前記第一プリプレグと、熱膨張性中空小球体と、前記第二プリプレグとをこの順に積層させることにより成形前積層体を得る工程と、
前記成形前積層体において、前記第一プリプレグ及び前記第二プリプレグを縫合する工程と、
前記成形前積層体を上金型と下金型とで加熱プレスする工程であって、前記熱膨張性中空小球体を前記加熱プレスの熱により膨張させ、中空小球体を形成し、膨張した中空小球体により構成される中空部を形成する工程と、
を含む、繊維強化樹脂中空成形体の製造方法。 one or more layers of first fiber-reinforced resin;
one or more layers of second fiber-reinforced resin;
including a hollow part located between the first fiber-reinforced resin and the second fiber-reinforced resin,
The first fiber-reinforced resin and the second fiber-reinforced resin are sewn together, a method for manufacturing a fiber-reinforced resin hollow molded body,
a step of preparing a first prepreg that is the one-layer or multiple-layer first fiber-reinforced resin prepreg;
preparing a second prepreg that is the one-layer or multiple-layer second fiber-reinforced resin prepreg;
Obtaining a pre-molding laminate by laminating the first prepreg, the thermally expandable hollow small spheres , and the second prepreg in this order;
In the pre-molding laminate, suturing the first prepreg and the second prepreg;
The step of hot pressing the pre-molding laminate with an upper mold and a lower mold, the thermally expandable hollow small spheres being expanded by the heat of the heating press to form hollow small spheres, and the expanded hollow forming a hollow portion composed of small spheres;
A method for producing a fiber-reinforced resin hollow molded body.
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