JPH01237130A - Continuous, length light-weight fiber reinforced composite resin pultrusion product and its manufacture - Google Patents

Abstract

PURPOSE:To manufacture fiber reinforced composite resin pultrusion product of not only superior tensile strength and compression strength in the axial direction but also compression strength in the square direction to the bending strength and axial direction by providing a long and narrow shaped light-weight honeycomb structure and a fiber reinforced resin layer formed by encircling the whole or part of the outer periphery. CONSTITUTION:A continuous, light-weight fiber reinforced composite resin pultrusion product 1 consists of a long and narrow, continous, light-weight reinforcing material having an oblong section, that is, a honeycomb structure 2, a fiber reinforced resin layer 4 formed by encircling the whole of outer periphery of the honeycomb structure. The honeycomb structure 2 is constituted of light metal such as aluminum and duralumin, or paper or a light material of plastic or the like such as Aramid resin or the like. The reinforcing fibers of the fiber reinforced resin layer 4 are carbon fibers, glass fibers or Aramid fibers, and the matrix resin applied to fibers is thermosetting resin such as epoxy, unsaturated polyester, vinyl ester or the like, and thermoplastic resin such as nylon 6, nylon 66, polycarbonate, polyacetal, polyphenylene sulfide, polypropylene or the like is used.

Description

DETAILED DESCRIPTION OF THE INVENTION (1) The present invention relates to a long and lightweight fiber-reinforced composite resin pultrusion molded product in which a fiber-reinforced resin layer is formed on the surface of an elongated honeycomb structure, and a method for manufacturing the same.

The elongated lightweight fiber-reinforced composite resin pultruded product according to the present invention is embodied as an elongated shape with a rectangular cross-section, and can sufficiently withstand not only axial tensile force and compressive force but also bending force. For example, it can be used as frames and mechanical parts in the fields of aviation, space, automobiles, ships, and railways, as frame structural materials such as columns in the civil engineering and architectural fields, and as lightweight structural materials in various other fields. can.

'Nobibe-hashi' Traditionally, long and lightweight structural materials have been required in the various fields mentioned above, and fiber-reinforced composite materials using carbon fibers, glass fibers, etc. as reinforcing fibers have been proposed as such structural materials. ing. In order to further reduce weight, the composite material is molded into a hollow pipe shape.
In order to further reduce weight, the wall thickness of hollow pipes tends to be thinner, but as the wall thickness becomes thinner, the bending strength and compressive strength in the direction perpendicular to the axial direction (buckling resistance) decrease. There was a limit to how thin the wall could be. In particular, in pultrusion molding, problems such as damage to the molded product inside the mold and at the take-off portion occurred, making molding difficult.

The present inventors have developed an axial structure by forming a thin fiber-reinforced resin layer on the outer surface of an elongated lightweight reinforcing material consisting of an elongated honeycomb structure made of paper, plastic, or lightweight metal material. It is possible to realize a long and lightweight fiber-reinforced composite resin molded product that has excellent not only directional tensile strength and compressive strength but also bending strength and compressive strength (buckling resistance) in a direction perpendicular to the axial direction. It has been found that a molded article can be manufactured very suitably by a conventional pultrusion method.

In addition, such a long honeycomb structure can function as a mandrel when manufacturing a molded product by a pultrusion method,
Therefore, it has been found that there is an advantage that there is no need to specially prepare a mandrel, and that the molded product can be manufactured extremely efficiently and quickly without damage.

The present invention has been made based on this new knowledge.

The object of the present invention is to provide a lightweight material that can be used in various fields, with excellent not only axial tensile strength and compressive strength, but also bending strength and compressive strength (buckling resistance) in a direction perpendicular to the axial direction. An object of the present invention is to provide a long, lightweight fiber-reinforced composite resin pultrusion molded product having a rectangular cross section that can be used as a structural material, and a method for manufacturing the same.

Another object of the present invention is to produce a long and lightweight fiber-reinforced composite resin pultruded product using a pultrusion method very efficiently without requiring a special mandrel and without damaging the molded product, and a method for producing the same. It is to provide.

Therefore, the above-mentioned objectives are achieved by the long lightweight fiber-reinforced composite resin pultrusion molded product and the manufacturing method thereof according to the present invention. In summary, the present invention is characterized by comprising an elongated lightweight honeycomb structure and a fiber-reinforced resin layer formed by entirely or partially surrounding the outer periphery of the lightweight honeycomb structure. Long lightweight ta! 11 reinforced composite resin pultrusion molded product. An adhesive layer can also be interposed between the honeycomb structure and the U&fiber reinforced resin layer. The honeycomb structure is made of paper, plastic such as aramid, or lightweight metal material, and the reinforcing fibers of the fiber-reinforced resin layer are carbon m1m1, glass fiber, or aramid fiber, and the matrix resin impregnated into the a fibers is epoxy. , thermosetting resins such as unsaturated polyester and vinyl ester, and thermoplastic resins such as nylon 6, nylon 66, polycarbonate, polyacetal, polyphenylene sulfide, and polypropylene.

Such a long lightweight fiber-reinforced composite resin pultruded product is produced by (a) preparing an elongated honeycomb structure; (b) adhering all or part of the outer periphery of the honeycomb structure, if necessary; a step of forming a layer; (c) a step of arranging a resin-impregnated resin layer on the honeycomb structure to form a fiber-reinforced resin layer having a predetermined thickness; then (d) a step of forming the fiber-reinforced resin layer. Suitably manufactured by a method for manufacturing a long lightweight Fam-reinforced composite resin pultrusion molded product, which is characterized by the step of drawing a lightweight reinforcing material into a mold, shaping it into a predetermined size and shape, and solidifying it. .

Strut j Next, the elongated lightweight fiber-reinforced composite resin pultrusion molded product according to the present invention will be described in more detail.

FIG. 1 shows an example of an elongated lightweight fiber-reinforced composite resin pultrusion molded product having a rectangular cross section according to the present invention. The composite resin pultrusion molded product 1 consists of an elongated lightweight reinforcing material with a rectangular cross section, that is, a honeycomb structure 2, and a fiber reinforced resin layer formed by surrounding the entire outer periphery of the honeycomb structure. It consists of 4. The honeycomb structure 2 is a commercially available ALL/8-5052-. made of aluminum, for example.
002 (trade name: manufactured by Showa Aircraft Industry Co., Ltd.) etc. can be suitably used. The cam structure can be made of light metals other than aluminum, such as duralumin, paper,
It is also possible to construct it from a light material such as plastic such as aramid resin or the like.

According to the present invention, the fiber-reinforced resin layer 4 does not need to be formed around the entire outer periphery of the honeycomb structure 2, but may be formed by partially surrounding the honeycomb structure 2, as shown in FIG. It can also be formed. In the embodiment of FIG. 2, the 1ata reinforcing resin layer 4 is formed on two opposite sides of the honeycomb structure 2 where the hole openings are located to increase the compressive strength.

Also, according to the present invention, as will be explained later, the uncured, flowable liquid matrix resin from the fiber-reinforced resin layer that is fitted around the honeycomb structure during pultrusion forms the honeycomb structure. During manufacturing, the hole opening is
It is preferable to arrange them so that they are located on both sides as shown in FIG.

Furthermore, as shown in FIG. 3, prior to forming the fiber-reinforced resin layer 4, a tape-like adhesive 6 is pasted onto the hole openings of the honeycomb structure, so that the matrix resin is bonded to the holes of the honeycomb structure during manufacturing. It is preferable to prevent the adhesive from entering the interior through the opening. In this case, a thermosetting adhesive tape or a tape coated with thermosetting adhesive on both sides is used as the tape adhesive 6. The bonding strength between the honeycomb structure 2 and the fiber-reinforced resin layer 4 can be increased, and as a result, the bending and compressive strengths of the fiber-reinforced composite resin pultruded product 1 can be improved. As such tape-like adhesive 6, for example, FM 123-5 Adhesive Film (trade name, manufactured by American Cyanamid Company) can be suitably used.

Additionally, another embodiment of the invention is illustrated in FIG. 4A. In other words, in the long and lightweight m-fiber-reinforced composite resin pultruded product 1 according to the present invention, the fiber-reinforced resin layer 4 is formed by surrounding the entire outer periphery of the lightweight reinforcing material 2, and the reinforcing fibers are oriented in the axial direction. The axial fiber layer 4a formed in alignment and the l! ! It can also be configured to include a spiral fiber layer 4b. Further, a plurality of axial fiber layers 4a and spiral m* layers 4b can be formed alternately. The innermost layer of the molded article can be an axial fiber layer 4a, as shown, but it can also be a helical fiber layer 4b.

Furthermore, the outermost layer can be a helical fiber layer 4b, but as illustrated in FIG. 4A, the helical mis layer 4b
It is preferable to form the axial fiber layer 4a on top of the molded product, because by forming the axial fiber layer 4a as the outermost layer of the molded product, smooth operation becomes possible during continuous production of the molded product. be.

The winding angle with respect to the axial direction in the helical direction fiber layer 4b, the density of the fibers in each fiber R4a, 4b, layer thickness, etc. can be arbitrarily selected, but to give an example, the winding angle is 45. 80 degrees, and the fiber content in the fiber layers 4a and 4b is preferably 50 to 60% by volume.

Furthermore, any reinforcing fibers and matrix resin can be used for the v11 fiber-reinforced resin layer 4, but carbon fibers, glass fibers, or aramid fibers are usually suitable as the reinforcing fibers, and the matrix resin impregnated with the am The resins include thermosetting resins such as epoxy, unsaturated polyester, and vinyl ester, and thermoplastic resins such as nylon 6, nylon 66, polycarbonate, polyacetal, polyphenylene sulfide, and polypropylene. For matrix resin,
If desired, fillers such as CaCO3, mica, Amon (OH)3, and talc, as well as additives and colorants for improving heat resistance and weather resistance, are added. As mentioned above, the fiber content in the fiber reinforced resin layer 4 is 50% by volume.
It is suitable that it is made into 60%.

Furthermore, in this embodiment as well, as shown in FIG. 4B, the honeycomb structure is It is preferable to apply a tape-shaped adhesive 6 to the hole openings of the honeycomb structure to prevent the matrix resin from entering the honeycomb structure through the hole openings during manufacturing. 6, an M-curing adhesive tape or a tape coated with a thermosetting adhesive on both sides is used to increase the bonding strength between the honeycomb structure 2 and the axial fiber layer 4a, and as a result, Reinforced composite resin pultrusion molded product
It is possible to stably improve the bending and compressive strength of. As such tape-shaped adhesive 6, - as mentioned above,
For example, FM 123-5 Adhesive Film (
(Product name: American Cyanamid Company)
You can use it suitably yourself.

For the purpose of increasing the bending and compressive strength of the fiber-reinforced composite resin pultrusion molded product 1, the adhesive layer consisting of the tape-like adhesive IjI'1116 is used between the pores of the honeycomb structure. It may be provided on the periphery, or even over the entire outer periphery of the honeycomb structure.

Next, a method for producing a long lightweight m-fiber reinforced composite resin-drawn U-molded product according to the present invention will be described.

Referring to FIG. 5, a finely shaped honeycomb structure 2 is continuously supplied to a mold (die) 8. As shown in FIG. If necessary, a tape-like adhesive 6 is adhered to the entire or partial outer periphery of the honeycomb structure 2. On the other hand, the reinforced FiAmf impregnated with matrix resin is supplied around the honeycomb structure 2 and drawn into the mold 8 together with the honeycomb structure 2, and in the mold the fiber reinforced resin layer 4 is formed into a predetermined size and shape. It is shaped and solidified.

The U & male reinforcing resin layer 4 is a plurality of layers, that is, the axial fiber layer 4
a and a spiral fiber layer 4b, the resin-impregnated fibers are arranged on the honeycomb structure 2 in the axial direction δ or wound in the helical direction via the adhesive layer 6 as necessary. to form a first fiber layer having a predetermined thickness, and before solidifying the first fiber layer, resin-impregnated m-fibers are applied on the fiber layer. A second fiber layer A is formed by arranging fibers in different directions, and if necessary, the above step is repeated nine times to form an uncured fiber layer laminate consisting of an axial fiber layer and a helical fiber layer. A fiber-reinforced resin layer 4 is formed. The honeycomb structure 2 on which the fiber-reinforced resin layer 4 is formed is, as shown in 5'A,
The fiber-reinforced resin layer 4 is drawn into a mold 8, shaped into a predetermined size and shape in the mold, and solidified.

The above-mentioned pultrusion molding is suitably carried out in a normal overwinter.

Next, the case where the carbon fiber reinforced composite resin pultrusion molded product according to the present invention shown in FIG. 4 is manufactured using the *-/<-ry inder will be described with reference to FIG. 6.

FIG. 6 shows an embodiment of the pultrusion molding machine 10 for manufacturing the carbon fiber reinforced composite resin pultrusion molded product 1 having the rectangular cross-sectional shape. As shown in FIG.
a, a five-layer carbon fiber reinforced composite resin drawing consisting of a spiral carbon fiber reinforced resin layer 4b, an axial carbon fiber reinforced resin layer 4a, a spiral carbon H & fiber reinforced resin layer b, and an axial carbon fiber reinforced resin layer 4a Assume that a molded product l is manufactured.

According to the present pultrusion molding machine 10, a large number of creels 14 around which carbon m male 12 are wound are mounted on a creel stand 16 (16a).
, 16b). In this embodiment, three creel stands 16 are provided, and the first creel stand 16
The XmMl 12a from a to l is introduced into the resin impregnation tank 20 by the guide plate 18, and is impregnated with matrix resin. 4!4 impregnated jewel fiber 12a with excess resin squeezed out
is supplied to the overwine goo 24 by the guide plate 22, and is vertically aligned in the axial direction with respect to the mandrel attached to the overwine goo 24, that is, the elongated honeycomb structure 2 in the present invention (innermost layer (Formation of axial carbon fiber reinforced resin layer 4a) At the same time, the overwinder 24 has carbon fibers 24b unwound from a plurality of creels 24a mounted on the overwinder 24, and the carbon fibers 24b are attached vertically to the shaft. The spiral carbon fiber reinforced resin layer 4b is wound on the carbon fiber reinforced resin layer 4a at a predetermined angle, for example, 70 degrees. The carbon fibers from the creel 24a are not impregnated with matrix resin, but when wound around the honeycomb structure 2, the carbon fibers are impregnated with the lower axial carbon fiber-reinforced resin layer and the axial carbon fibers that are attached longitudinally in the next step. Excess matrix resin from the fiber reinforced resin layer is impregnated.

The second and third creel stands 16b are arranged symmetrically with the creel stand 16a in between, and in order to operate in the same manner, in FIG.
6b will be illustrated and explained in detail, and the explanation of the other creel stand 16b will be omitted. Creel stand 16b
A part of the m-fibers 12c among the carbon fibers 112b are introduced into the resin impregnation tank 30 by the guide plate 28 and impregnated with matrix resin. The resin-impregnated carbon fiber 12c from which excess resin has been squeezed is supplied to the overwinder 36 by guide plates 32, 34. The resin-impregnated carbon fiber 12c is
It is fed in the axial direction to the honeycomb structure 2 in which two reinforced carbon fiber reinforced resin layers, one in the axial direction and the other in the helical direction, are formed, passing through the center of the overwinders 24 and 36. Vertically attached on the carbon fiber 24b (
(formation of the second axial carbon fiber reinforced resin layer 4a), at the same time, the overwinder 36 allows the carbon fibers 36b unwound from the plurality of creels 36a mounted on the overwinder 36 to The spiral carbon fiber reinforced resin fi is wound on the carbon fiber reinforced resin layer 4a at a predetermined angle, for example, 70 degrees.
4b is formed. The overwinder 36 is rotated in the opposite direction to the overwinder 24, so that the winding direction of the spiral carbon fiber reinforced resin layer 4b formed by the overwinder 36 and the spiral shape formed by the overwinder 24 are different. The winding direction is opposite to the winding direction of the carbon fiber reinforced resin layer 4b.

The carbon am from the creel 36a is not impregnated with matrix resin, but when wound around the mandrel, the lower axial carbon fiber-reinforced resin layer and the axial carbon fiber-reinforced resin that will be longitudinally applied in the next step Excess matrix resin from the layer is impregnated.

On the spirally wound carbon fiber 36b, the remaining fibers M112d of the carbon fiber 12b from the second creel stand 16b are introduced into the resin impregnation tank 44 by the guide plate 40.42. The carbon fibers 12d impregnated with a matrix resin are then squeezed out, and the carbon fibers 12d impregnated with one finger are guided and supplied by guide plates 46 and 48 and arranged in alignment in the axial direction, and the axial carbon fibers of the outermost layer are A reinforced resin layer 4a is formed.

In this way, a carbon fiber reinforced resin layer laminate 50 is formed on the mandrel 26, in which a predetermined number of the axial white charcoal J fiber reinforced resin layer 4a and the spiral carbon fiber reinforced resin layer 4b are laminated.

In this example, the honeycomb structure 2 is an aluminum honeycomb structure (product name: AL1/8-5052-
．． 002. (manufactured by Showa Aircraft Industry Co., Ltd.) was used. The outer shape of the honeycomb structure 2 was 18×1 Bmm.

The reinforcing fiber has a wire diameter of 7 μm and a strength of 340 kg/
Using m rn' carbon fiber, each resin impregnation tank 20.3
For 0.44, epoxy resin 10 is used as the matrix resin.
0wt% and 10wt% calcium carbonate as a filler.
The added resin liquid was collected and impregnated into the carbon layer.

4. As described above, an axial carbon male reinforced resin layer 4a made of resin-impregnated carbon fiber is placed on the honeycomb structure 2 from the inside,
Charcoal composed of five layers: spiral carbon fiber reinforced resin layer 4) 1, axial carbon fiber reinforced resin layer 4a, spiral carbon fiber reinforced resin layer 4b, and axial carbon fiber reinforced resin layer 4a. A layer stack 50 is formed.

The honeycomb structure? The carbon fiber reinforced resin layer 50 formed thereon is then drawn into a mold 52 having a rectangular cross-sectional shape.

In this way, the fiber reinforced resin layer 50, which has been extremely suitably shaped into a predetermined shape and size using the mold 52, is heated! (not shown) to form a carbon fiber-reinforced composite resin pultrusion molded product 1. A drawing machine 54 and a cutter 56 are arranged on the downstream side of the mold 52 to extract the carbon fiber reinforced composite resin pultrusion molded product l and cut the carbon fiber reinforced composite resin pultrusion molded product l into a predetermined length. do. The structure and operation of the puller 54 and cutter 56 are well known to those skilled in the art and will not be further described.

Using the manufacturing method and pultrusion molding machine configured as described above, a rectangular carbon fiber reinforced resin pultrusion molded product with an outer diameter of 23 x 23 mm, a thickness of each carbon fiber reinforced resin layer of 0.5 mm, and a wall thickness of 2.5 mm is produced. could be manufactured at a speed of 1 m7 minutes.

The pultrusion molded product 1 produced in this manner had sufficient strength for practical use.

As explained in Section 4 of ``Enuki LA'', the long lightweight fiber-reinforced composite resin pultruded product according to the present invention has higher strength against compression and bending (buckling resistance) not only in the axial direction but also in the lateral direction (buckling resistance) than conventional molding. The production method according to the present invention has the advantage that fiber-reinforced composite resin pultrusion molded products can be produced extremely easily and continuously.

[Brief explanation of the drawing]

FIG. 1 is a perspective view of a long lightweight fiber-reinforced composite resin pultrusion molded product according to the present invention. @ Figures 2, 3, 4A, and 4B are unreleased [! 1
FIG. 1 is a cross-sectional view of another example of a long light weight [[1] reinforced composite resin pultrusion molded product. FIG. 5 and FIG. 6 are schematic explanatory diagrams illustrating the steps of manufacturing a long lightweight & a-fiber reinforced composite resin pultrusion molded product according to the present invention. 1: Fiber-reinforced composite resin pultrusion molded product 2: Long, lightweight)\Nicum structure 4: Fiber-reinforced resin layer 6/tape adhesive 8.52: Mold Figure 1 Figure 2

Claims (1)

[Claims] 1) A lightweight honeycomb structure having an elongated shape and a fiber-reinforced resin layer formed by completely or partially surrounding the outer periphery of the lightweight honeycomb structure. A long lightweight fiber-reinforced composite resin pultruded product. 2) The elongated lightweight fiber-reinforced composite resin pultruded product according to claim 1, wherein the outer periphery of the honeycomb structure is wholly or partially joined to the fiber-reinforced resin layer via an adhesive layer. 3) (a) A step of preparing an elongated honeycomb structure; (b) A step of forming an adhesive layer on all or part of the outer periphery of the honeycomb structure, if necessary; (c) The honeycomb structure a step of arranging resin-impregnated fibers on the body to form a fiber-reinforced resin layer having a predetermined thickness; then (d) drawing the lightweight reinforcing material having the fiber-reinforced resin layer into a mold to obtain a predetermined size; A method for producing a long lightweight fiber-reinforced composite resin pultrusion molded product, comprising the steps of shaping into a shape and solidifying it.