JPH04286633A - Fiber reinforced plastic roll and manufacture thereof - Google Patents

Abstract

PURPOSE:To manufacture a machine screw of superior strength and the like and carry out integrally metal plating in the state of incorporating the machine screw into a roll by means of conductivity of the machine screw by using CFRP reinforced with a fiber-like material as a constituting material of the machine screw. CONSTITUTION:(1) An FRP roll 7 of light-weight and of superior resistance to wear and resistance to scratching is composed of an FRP roll 2 and a CFRP machine screw 1 fitted in the inner end of the roll, and a metal plated layer 6 is formed on the whole of the roll and the machine screw. (2) The manufacturing method consists of the first process for manufacturing the FRP machine screw 1, the second process for fitting and bonding the machine screw 1 on both ends of the FRP machine screw 1 through a conductive bonding agent 3 and integrating them, the third process for boring a bearing hols 4 and the like in the state of being integrated with the roll 2 and finishing into the roll shape, and the fourth process for electrical plating a roll 5 with the machine screw 1 and forming metal plated layers 6 on the roll 2 and the machine screw 1.

Description

[Detailed description of the invention]

0001

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced plastic roll having a metal plating layer, in which the bearing boss is also made of fiber-reinforced plastic, and a method for manufacturing the same. More specifically, the present invention has high strength and high rigidity,
To provide an inexpensive lightweight roll made of fiber-reinforced plastic that has excellent wear resistance and scratch resistance.

0002

2. Description of the Related Art In rotating rolls, the moment of inertia during rotation becomes smaller due to the reduction in weight. For this reason, fiber-reinforced plastic rolls or tubular products developed with the aim of reducing weight include those in which fiber-reinforced plastic is formed on the surface layer of a metal cylindrical body, or fiber-reinforced plastic layers are laminated and formed on a mandrel. Rolls made of fiber-reinforced plastic are also known, and rolls with a metal layer provided on the surface of the rolls have surface characteristics comparable to those of metals.

0003

[Problems to be Solved by the Invention] By using fiber-reinforced plastic for rotating rolls, considerable weight reduction has been achieved and at the same time the roll properties have been improved, but it has not yet become widely used. That is, there are still problems such as insufficient weight reduction, which requires labor to replace the rolls, etc., and the roll manufacturing process being complicated, which increases costs and makes the rolls too expensive.

0004

[Means for Solving the Problems] As a result of various studies on the above-mentioned problems, the present inventors have found that by using carbon fiber reinforced plastic reinforced with reinforcing fibers mainly composed of carbon fibers as the constituent material of the boss portion, It was discovered that the boss part is lightweight and has excellent strength, and its conductivity makes it possible to metal plate the boss part when it is incorporated into the roll part, leading to the completion of the present invention. Ta.

That is, the present invention provides: (1) A fiber-reinforced plastic roll portion and a carbon fiber-reinforced plastic reinforced with reinforcing fibers mainly composed of carbon fibers, which are fitted into the inner end portions of the rolls at both ends thereof. (2) the fiber-reinforced plastic boss part is made of carbon fibers; long fiber strands and/or their aggregate layer (a), fibrous material layer (b) or their (a) layer mainly consisting of (
b) It is also characterized in that it is reinforced by a combination of layers, and (3) the fibrous material layer (b) constituting the carbon fiber reinforced plastic boss portion is mainly made of short fibrous carbon fibers. (4) The carbon fiber reinforced plastic boss has at least 50
It is also characterized by having a bending elastic modulus of kg/mm2. Also,

(5) In manufacturing a roll made of fiber reinforced plastic, (a) long fiber strands mainly composed of carbon fibers and/or an aggregate layer thereof (a), a fibrous material layer (b) or a layer thereof (a); ) layer and (b) layer, formed into a predetermined shape and then impregnated with resin and cured, or impregnated with resin and molded into a predetermined shape and then cured,
Alternatively, a first step of forming a resin-impregnated fiber aggregate into a predetermined shape and curing it to form a fiber-reinforced plastic boss part; (c) a third step of applying desired processing such as grinding to the integrated fiber-reinforced plastic roll with the boss portion fitted and bonded; ) A fourth step of electroplating the fiber-reinforced plastic roll to provide a metal layer on the roll portion and the boss portion, provides a method for manufacturing a fiber-reinforced plastic roll. Furthermore, (6) After laminating prepregs, which are resin-impregnated fibrous sheet materials mainly composed of carbon fibers, in the mold,
Another feature is that the carbon fiber-reinforced plastic boss is formed by heating and pressurizing, and (7) the fiber-reinforced plastic boss is made of filaments using long fiber strands mainly composed of carbon fibers.・It is also characterized by being made using the winding method, and

(8) In a fiber-reinforced plastic roll that is made up of a fiber-reinforced plastic roll portion and boss portions at both ends, the volume resistivity between the boss portions at both ends is at least 0.1 Ωcm or less before a metal plating layer is applied. It is also characterized by (9) that the fiber-reinforced plastic boss part is fitted and bonded inside both ends of the fiber-reinforced plastic roll part via a conductive adhesive to integrate it. It has the characteristics and also (
10) After applying desired processing such as grinding to the fiber-reinforced plastic roll with the fiber-reinforced plastic boss attached to the final shape, electroplating is performed.
Another feature is that the metal layer is provided even on the roll part and the boss part. (11) Furthermore, by fitting the boss part 1 to the inner end of the roll part 2 and integrating it, there is no seam on the surface of the roll part 2, so there are no voids or uneven thickness in the metal plating layer on the roll surface. It is also characterized by no defects.

The present invention will be explained in detail below with reference to the drawings. FIG. 1 is a typical schematic diagram showing the process of manufacturing a lightweight fiber-reinforced plastic roll of the present invention. In FIG. 1, (a) the first step of manufacturing the fiber-reinforced plastic boss part 1 according to a laminated molding technique such as mold molding, filament winding molding, etc., and (b) conductive bonding on the surface of the boss part 1. A second coated agent 3 is applied and fitted onto both inner ends of the roll portion 2 to be integrated into a roll shape.
Step (c) In the integrated state with the roll part 2, a bearing hole 4 is bored in the boss part 1, and further processing such as grinding is performed on the roll surface to form a (lightweight) roll 5 in a desired shape.
(d) Next, the roll 5 is electroplated to form a metal plating layer 6 on the boss portion 1 and the roll portion 2, and the desired lightweight roll product 7 made of fiber reinforced plastic is obtained. Four steps are shown below, and the fiber-reinforced plastic lightweight roll product 7 is manufactured through these steps.

Further, each step will be explained. (First step; Manufacture of fiber-reinforced plastic boss 1) The manufacturing method of fiber-reinforced plastic boss 1 is not particularly limited, but filament winding molding may be used depending on the mechanical properties required for the boss. It is also effective to use That is, on a mold such as a mandrel which has been coated with a release agent in advance if necessary, an aggregate layer (a) of long fiber strands, bundles, or aligned long fiber strands as reinforcing fibers, or non-woven fabric, mat, etc. A fibrous material layer mainly composed of short fibers such as felt (b
) or a mixed layered state of (a) and (b) is molded into a tubular or cylindrical shape and removed from the mold.

[0010] When manufacturing the fiber-reinforced plastic boss by this filament winding molding method, the order of the resin impregnation, curing, and molding steps can be changed as necessary. For example, (a) after molding into a predetermined shape, (b) After being impregnated with resin and molded into a predetermined shape and then hardened; or (c) After molding a fiber aggregate impregnated with resin into a predetermined shape and then hardened. It's okay.

Alternatively, a fibrous sheet material mainly composed of carbon fibers is impregnated with resin in advance, and a plurality of semi-cured sheets are laminated in a mold, and then hardened under pressure and heat using a mold press or the like. It can also be manufactured by In this case, it may be laminated into a cylindrical shape in advance so as to fit into the roll part 2, but generally, after forming a laminated body corresponding to the boss part 1, the molded body is molded to fit into the inner diameter of the roll part 2. Then, the laminated molded body is cut.

In particular, the boss portion 1 formed by molding has the following features:
It is preferable to use the above-mentioned fibrous sheet material mainly composed of short fibers as the reinforcing fiber layer. The fiber-reinforced plastic obtained from the fibrous sheet material as described above is desirable because it has a uniform strength distribution in any direction necessary for the boss portion. As the fibrous sheet material, a fibrous sheet material or paper material such as a mat, felt, or nonwoven fabric can be preferably used.

The matrix resin is not particularly limited, but may include thermosetting resins that are generally used for manufacturing the roll portion 2 as well as thermoplastic resins. Preferably, a resin that provides properties such as high strength, high rigidity, and corrosion resistance to the boss portion 1, such as unsaturated polyester resin (isophthalic acid type, bisphenol type, etc.), vinyl ester resin (
bisphenol type, novolac type, etc.), epoxy resin (
Bisphenol type, novolac type, etc.), furan resin, phenol resin, polyimide resin, etc. can be preferably used. Further, the same or the same resin as that used in the roll portion may be used. Furthermore, conductive powder may be added to the matrix resin in order to benefit the subsequent formation of the metal plating layer 6 (of course, it may be mixed with the matrix resin constituting the roll portion 2). This is particularly effective when non-conductive fibers such as glass fibers are used together as reinforcing fibers.

The material for the reinforcing fibers is not particularly limited, but generally fibers that provide high rigidity and high strength, such as carbon fibers, glass fibers, aromatic polyamide fibers, silicon carbide fibers, boron fibers, and alumina-silica fibers, are used alone. Or they can be used in combination. Preferably, carbon fibers or glass fibers are used, but those mainly composed of carbon fibers are desirable from the viewpoint of imparting high rigidity, high strength, and conductivity, as well as for the subsequent formation of the metal plating layer 6. In this case, as the reinforcing fibers that can be mixed with carbon fibers in a small proportion, fibers that provide high strength and high rigidity similar to those used in manufacturing the roll portion, such as glass fibers, can be used. Furthermore, in order to benefit the formation of a metal plating layer in the post-processing, it is also possible to partially mix conductive fibers or metal fibers with a conductive metal layer formed on the surface as reinforcing fibers (of course, It may also be applied to the reinforcing fibers constituting the roll portion 2).

[0015] In the present invention, when carbon fibers that easily conduct electricity are mainly used as described above, when forming the metal plating layer 6 later, it is possible to perform metal plating while the roll part 2 is integrated with the metal plating layer 6. A lightweight roll is provided which can form a uniform metal layer 6 over a long period of time and has excellent abrasion resistance and scratch resistance.

[0016] The higher the volume content of fibers in carbon fiber reinforced plastics, the better; however, because of the need to develop strength as a composite material, especially when short fibrous carbon fibers are used, the short fibers may be crushed or powdered. It is necessary to keep it as low as possible. Generally, 50% by volume or less is preferred.

It is necessary to provide the bearing hole 4 in the boss 1 (third step), but in the process of manufacturing the boss 1, a deformed mold having a cavity corresponding to the bearing hole 4 is formed. They can also be formed simultaneously by using. Further, following the lamination molding of the boss portion 1, the bearing hole portion 4 is drilled (
It can also be provided on the boss portion 1 by centering).

The carbon fiber reinforced plastic boss portion 1 of the present invention must have a flexural modulus of at least 500 kg/mm 2 . If it is less than this value, it is difficult to maintain the strength to resist the force generated by the moment of inertia due to rotation, especially when used in rotating parts.

(Second step: Integration of boss portion and roll portion) First, a roll portion 2 made of fiber-reinforced plastic is prepared. The fiber-reinforced plastic roll portion 2 is not particularly limited, but generally fiber-reinforced plastic pipes, cylindrical bodies, and rolls obtained by lamination molding techniques can be used. After applying the conductive adhesive 3 to the joint between the boss portion 1 and the roll portion 2 manufactured in the first step, the inner ends of both ends of the roll portion 2 manufactured in the first step are coated with the conductive adhesive 3. The boss portion 1 is fitted and bonded to be integrated. In this case, the roll part 2
The laminated molded body boss portion 1 that fits into the roll is cut into a cylindrical shape as necessary so as to fit inside the roll.

In the case of the present invention, it is better to use a conductive adhesive as the adhesive during the metal plating process in the final step.
The integrated roll as a whole is electrically conductive, and 0.
The volume resistivity (measured according to JIS K-6911) is 1 cm or less, preferably 0.05 Ωcm or less, and metal plating can be easily formed. If the volume resistivity is larger than this value, it is not preferable because it may cause uneven plating or pinholes during electroplating. In order to form a uniform metal plating layer, this process also includes applying a conductive paint to the roll surface or applying electroless plating to make the fiber-reinforced plastic roll conductive and have a volume resistivity of 10 Ωcm or less. You can consider including

[0021] The conductive adhesive and conductive paint are not particularly limited, but include paste adhesives and conductive paints in which a polymer binder or oligomer is generally blended with a large amount of conductive powder. Furthermore, conductive powders include gold, silver, copper, nickel, chromium, palladium,
Metal powders such as aluminum, powders of their metal oxides, inorganic powders or carbon coated with these metals,
Mention may be made of graphite particles. Adhesion and coating resins are not particularly limited, but generally include epoxy resins, acrylic resins or modified products thereof (epoxidized, urethanized, etc.), vinyl resins, and the like.

(Third step; centering the boss portion 1, drilling the bearing hole 4, adjusting the roll outer diameter) The boss portions 1 at both ends of the integrated roll 5 obtained in the second step are , the bearing hole 4 is bored to a predetermined diameter, and the roll outer diameter is adjusted to a level close to the final shape, taking into consideration the thickness of the metal plating layer 6 in the next step, etc., and the roll surface is ground. In the present invention, since the boss portion 1 is bored while being integrated with the roll portion 2, centering accuracy is high and it is also effective for process control such as continuous process.

(Fourth step; metal plating treatment) Next,
Electroplating is applied to the integrated (lightweight) roll 5 to form a metal plating layer 6 on the entire boss portion 1 and roll portion 2, thereby producing the desired lightweight fiber-reinforced plastic roll product 7.
get. Specifically, in the case where the reinforcing fibers and matrix resin are not subjected to conductive treatment or conductive material in the roll part 2, the surface of the roll part 2 is preliminarily coated with copper,
It is preferable to thermally spray a metal such as nickel in order to make the entire roll 5 electrically conductive.

The method for forming the metal plating layer 6 is not particularly limited, but it is generally preferable to apply an electroless plating film of copper, nickel, etc., and then form a hard metal thin film by electroplating with chromium or the like. During this electroplating, it is possible to take electrodes at the boss parts 1 at both ends, or it is preferable to take electrodes at the boss parts 1 at both ends and keep the roll 5 in a level state. A metal plating layer 6 is obtained. In the present invention, since the metal plating layer 6 can be formed over the entire roll 5, the processing steps can be shortened, and a uniform thin metal film can be formed on the obtained lightweight fiber-reinforced plastic roll product 7 with high precision.

(Fiber-reinforced plastic lightweight roll) The fiber-reinforced plastic lightweight roll product 7 of the present invention consists of a fiber-reinforced plastic roll portion 2 and a carbon fiber-based material fitted to the inner end portions of both ends thereof. The roll part 2 and the boss part 1 are further provided with a metal plating layer 6, making it lightweight, high-strength, To provide an inexpensive roll made of fiber-reinforced plastic that has high rigidity, excellent wear resistance, and scratch resistance.

[0026] Also, carbon fiber reinforced plastic boss portion 1
In order to function effectively as a bearing, its bending elastic modulus must be at least 500 kg/mm2, preferably at least 1500 kg/mm2 (JIS K-70
It is desirable to have a value measured in accordance with 74. 5
If it is less than 00 kg/mm2, sufficient rigidity cannot be exhibited. Furthermore, the fiber-reinforced plastic lightweight roll product 7 of the present invention has no seams on the surface of the roll portion,
Since there are no defects such as voids or uneven thickness in the metal plating layer on the surface, and a uniform and highly accurate metal plating film can be formed over the entire roll, it is particularly effective when applied as a roll used for high-speed rotation.

[0027]

[Function] In the lightweight roll of the present invention, since the fiber layer constituting the boss portion 1 is made of a fibrous material mainly made of carbon fiber, the entire roll portion 2 and boss portion 1, including the roll portion 2, can be made of fiber-reinforced plastic. Furthermore, the metal plating layer 6 can be formed on the roll over the entire roll, resulting in a highly accurate and uniform metal thin film.

According to the method of the present invention, the entire fiber-reinforced plastic roll on which the metal plating layer 6 is formed is configured to be electrically conductive as a whole, and the electrode during plating can be removed from the boss portion 1. Metal plating can be performed smoothly and a uniform thin metal film can be formed.
Moreover, since processing such as dimensional adjustment is not involved, rolls with high precision can be manufactured.

[0029]

EXAMPLES The present invention will be explained in more detail with reference to the following examples, but these are not intended to limit the scope of the invention. Example 1 Pitch-based short fibrous carbon fiber felt with a basis weight of 500 g/m2 was immersed in an impregnating solution prepared by diluting 50 parts by weight of phenolic resin (product name: Pryauchen 5900) manufactured by Dainippon Ink Industries, Ltd. with 50 parts by weight of acetone. It was air-dried in a fume hood overnight. Thereafter, 25 sheets of impregnated and air-dried short fiber felt were laminated, placed in a mold, and cured under pressure at 150° C. for 5 hours. The thus obtained laminated molded body (150 mm x 150 mm x 30 mm) as a boss portion had a fiber volume content of about 22% by volume and a flexural modulus of 2,500 kg/mm 2 .

On the other hand, a bundle of long fiber strands of Carbonic HM-50 (manufactured by Petka) was mixed with 100 parts of bisphenol A type epoxy resin (Epicoat 828, manufactured by Yuka Shell) and a curing agent [methyltetrahydro, manufactured by Hitachi Chemical Co., Ltd.]. Phthalic anhydride (trade name HN2200)] 80 parts, curing accelerator (
It was immersed in an impregnating solution containing 1 part of Shikoku Kasei Co., Ltd. (trade name: 2E4MI), wound onto a mandrel coated with a release agent, molded according to a conventional method, and demolded to an inner diameter of 69φ and a thickness of 3mm. A carbon fiber reinforced plastic pipe with a length of 1 m was obtained.

Next, the boss portion of the laminated molded product was cut into a circular shape so as to fit inside the carbon fiber reinforced plastic pipe, and the bearing hole was centered. Conductive adhesive (Fujikura Kasei Co., Ltd.) is applied to the joint between the cut out cylindrical boss and the inner surface of the carbon fiber reinforced plastic pipe.
XA-262) manufactured by Co., Ltd. was applied and cured at 150° C. for 30 minutes to bond. The volume resistivity between the boss portions of this roll was 0.018 Ωcm.

The boss portion of the carbon fiber-reinforced plastic roll was used as an electrode, and copper plating was applied thereto, followed by chromium plating. The resulting carbon fiber-reinforced plastic roll with a boss-attached metal thin film layer is lightweight, has a small moment of inertia, is extremely easy to rotate, and has high rigidity, high strength, and wear resistance. , it had metal surface characteristics with excellent scratch resistance.

Example 2 A bundle of long fiber strands of Carbonic HM-20 (manufactured by Petka) was used under the same conditions as Example 1, with an inner diameter of 25φ,
It was molded to have an outer diameter of 70 to 75φ and a length of 200 mm, and was ground to a length of 30 mm to form a boss part (fiber volume content: approximately 42 volume %, flexural modulus: 7,600 kg/m
m2), the carbon fiber reinforced plastic pipe used in Example 1 was used as a roll part, and a carbon fiber reinforced plastic roll was produced. The volume resistivity of this roll is 0.02
4 Ωcm, and electroplating as in Example 1 was performed, but there was no problem with the plating layer.

[0034]

Effects of the Invention The lightweight roll made of fiber-reinforced plastic of the present invention uses a fibrous material mainly made of carbon fiber as the fiber layer constituting the boss part, so that the roll part and the boss part are all made of fiber-reinforced plastic. Furthermore, the metal plating layer can be formed on the roll over the entire roll, resulting in a highly accurate and uniform metal thin film.

The lightweight fiber-reinforced plastic roll of the present invention is lightweight, has a small moment of inertia, is very easy to rotate, and has high rigidity, high strength, and excellent abrasion resistance and scratch resistance. Since we have various rotating machinery parts,
Effective for use in calender rolls for plastic molding, mangle rolls for deliquification, air shafts for bobbin support, rolls for film conveyance, etc.

According to the method of the present invention, the fiber-reinforced plastic roll on which the metal plating layer is formed is configured to conduct as a whole, so that the metal plating process can be performed smoothly and with uniformity and precision. A good metal thin film can be formed.

[Brief explanation of the drawing]

FIG. 1 is a typical schematic diagram showing the process of manufacturing a lightweight fiber-reinforced plastic roll of the present invention.

[Explanation of symbols]

1 Boss part 2 Roll part 3 Conductive adhesive 4 Bearing hole 5 (lightweight) roll 6 Metal plating layer

Claims (10)

[Claims] [Claim 1] A fiber-reinforced plastic roll part;
It is composed of carbon fiber reinforced plastic boss parts reinforced with reinforcing fibers mainly composed of carbon fibers, which are fitted into the inner end parts of the roll at both ends, and the roll parts and boss parts are further metal plated. A fiber-reinforced plastic roll characterized by having layers. 2. The fiber-reinforced plastic boss portion comprises a long fiber strand mainly composed of carbon fibers and/or an aggregate layer thereof (a), a fibrous material layer (b), or a layer thereof (
The fiber-reinforced plastic roll according to claim 1, characterized in that it is reinforced by a combination of a) layer and (b) layer. 3. The fibrous material layer (b) constituting the carbon fiber-reinforced plastic boss portion is a fibrous sheet material or paper material such as a mat, felt, or nonwoven fabric mainly made of short fibrous carbon fibers. Claim 2, characterized in that
The fiber-reinforced plastic roll described. 4. The fiber-reinforced plastic roll according to claim 1, wherein the carbon fiber-reinforced plastic boss has a bending modulus of at least 500 kg/mm 2 . 5. In manufacturing a roll made of fiber-reinforced plastic, (a) long fiber strands mainly composed of carbon fibers and/or an aggregate layer thereof (a), a fibrous material layer (b), or (a) (b) a combination of layers, formed into a predetermined shape and then impregnated with resin and cured, or impregnated with resin and molded into a predetermined shape and then cured, or impregnated with resin. a first step of forming a fiber-reinforced plastic boss into a predetermined shape and curing it to form a fiber-reinforced plastic boss; (b) fitting and bonding the carbon fiber-reinforced plastic boss to both ends of the fiber-reinforced plastic roll; The second step is to integrate the
c) A third step of subjecting the fiber-reinforced plastic roll integrated with the boss portion to a desired process such as grinding; (d) electroplating the fiber-reinforced plastic roll to form the roll portion and the boss. A method for manufacturing a fiber-reinforced plastic roll, comprising a fourth step of providing a metal layer on the portion. [Claim 6] A carbon fiber-reinforced plastic boss is made by laminating prepregs, which are resin-impregnated fibrous sheet materials mainly made of carbon fibers, in a mold and then heating and pressurizing them. The method for manufacturing a fiber-reinforced plastic roll according to claim 5. 7. The fiber-reinforced plastic roll according to claim 5, wherein the fiber-reinforced plastic boss is made by a filament winding method using long fiber strands mainly composed of carbon fibers. manufacturing method. 8. In the fiber-reinforced plastic roll before being coated with a metal plating layer consisting of a fiber-reinforced plastic roll portion and boss portions at both ends, the volume resistivity between the boss portions at both ends is at least 0.1 Ωcm or less. 6. The method for manufacturing a fiber-reinforced plastic roll according to claim 5. 9. The fiber-reinforced plastic according to claim 5, characterized in that the fiber-reinforced plastic boss portion is fitted and bonded to both ends of the fiber-reinforced plastic roll portion via a conductive adhesive to integrate the fiber-reinforced plastic roll portion. Method of manufacturing plastic rolls. 10. A fiber-reinforced plastic roll with the fiber-reinforced plastic boss still attached is subjected to desired processing such as grinding to bring it close to the final shape, and then electroplated to give the roll and boss parts a final shape. 6. The method for manufacturing a fiber-reinforced plastic roll according to claim 5, characterized in that the metal layer is provided up to.