JPH05309792A - Frp composite panel and production thereof - Google Patents

Abstract

PURPOSE:To enhance strength and impact resistance to prevent release by enhancing bending rigidity as an FRP composite panel. CONSTITUTION:In an FRP composite panel obtained by providing FRP panels 4 to both surfaces of foam 2, a large number of small holes 5 are made in the foam 2 in the thickness direction thereof and the pillars 6 integrated with the FRP composite panel 1 are provided in the small holes 5. In the production of the FRP composite panel 1, a glass fiber layer 9 impregnated with a synthetic resin solution is placed on a flat substrate 7 and the foam 2 having a large number of small holes 5 made therein is placed on the glass fiber layer 9 and, further, a glass fiber layer is placed on the foam 2 and the whole is covered with a sheet 11 in an airtight state and the suction port of a vacuum device is connected to a part of the sheet 11 to bring the interior of the sheet 11 to a negative pressure state. By bringing the interior of the sheet to a negative pressure state, the synthetic resin solution is raised through the small holes 5 of the foam 2 to be infiltrated in at least a part of the glass fiber layer on the foam 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an FRP (fiber reinforced plastics) composite plate which can be used for many purposes such as wall materials for buildings, wall materials for tanks other than water tanks, various partition plates, and the like. The present invention relates to a manufacturing method.

[0002]

2. Description of the Related Art FRP with an adhesive on both front and back surfaces of foam
The FRP composite plate formed by adhering the plates can be made to have an arbitrary total thickness by freely selecting the thickness of the foam, and the FRP plates adhered to both front and back surfaces of the foam have sufficient strength. By being obtained, etc., it can be used for a great many purposes. The characteristics of this FRP composite plate are that it is excellent in mechanical strength, has appropriate buffering properties, is excellent in heat resistance, heat insulating properties, and soundproofing properties, is lightweight, and is excellent in workability.

FIG. 8 shows a cross-sectional structure of the FRP composite plate 1 which has been widely used in the past. To explain this,
2 is a foam, for example, a rigid urethane foam. The adhesive 3 is thinly applied to both front and back surfaces of the foam 2, and the FRP plate 4 placed on the upper surface thereof is firmly integrated by adhesion.

[0004]

In the conventional FRP composite plate 1 having such a structure, the adhesive force between the foam 2 and the FRP plate 4 has an important meaning in terms of strength. That is, when this adhesion is peeled off, the synthetic force of the composite plate 1 becomes weak and the performance is remarkably lowered. F
Of the many uses of the RP composite plate 1, when it is used in a usage method in which no external force is applied or a usage method in which even if an external force is applied, it is applied to the entire surface, it is not necessary to consider peeling of the adhesive so much. When used in a method of bending the whole or in a method of partially applying a load from other portions, a displacement force acts between the foam body 2 and the FRP plate 4, which causes peeling. It will be.

The conventional FRP composite plate 1 does not have a special structure against this peeling, and it is dealt with by simply examining the adhesive 3 to increase the adhesive strength. The present invention has been made in view of this point,
It is an object of the present invention to provide an FRP composite plate and a method for manufacturing the FRP composite plate that compensates for this weakness of the conventional FRP composite plate.

[0006]

Means for Solving the Problems As a means for solving the above problems, the present invention provides an FRP composite plate having FRP plates on both front and back surfaces of a foam, and a large number of small FRP plates in the thickness direction of the foam. A FRP composite plate having a structure in which a hole is provided and a column integrally bonded to the FRP plate is provided in the small hole is obtained.

[0007] Then, in this method for producing an FRP plate, a mold release agent and a gel coat are applied, if necessary, on a substrate having a larger area than the FRP composite plate to be produced, and reinforcing fibers are layered on the substrate. Place a reinforced fiber layer to hold a predetermined amount of synthetic resin liquid, and then place a foam with a large number of small holes in the thickness direction on it, and further strengthen it. The fibers are placed, and then the whole is covered with a sheet in an airtight state, and a suction port of a vacuum device is connected to a part of the sheet to bring the inside of the sheet into a negative pressure state. The resin liquid rises in the small holes of the foam to impregnate at least a part of the reinforcing fibers on the top of the foam. Then, the resin liquid oozing into the reinforcing fibers above the foam through the small holes is gelled in this state, and then
The sheet is removed, and the reinforcing fibers in the upper part are impregnated with the synthetic resin to mold the FRP.

[0008]

With this structure, the FRP composite plate can be filled and hardened in the small holes formed in the foam even if bending stress or partial load acts depending on the application. Since the FRP plate is supported by the pillars formed as described above, it is possible to obtain the one without peeling.

As a manufacturing method, the FRP composite plate having the above structure can be manufactured by means of only sequentially stacking the materials and operating a vacuum device such as a vacuum pump.

[0010]

BEST MODE FOR CARRYING OUT THE INVENTION An embodiment of the present invention will be described below by attaching the same reference numerals to the same members as in FIG. First, what is shown in FIGS. 1 and 2 is an FRP composite plate 1 according to the present invention. The FRP composite plate 1 has a foam body 2 such as a hard urethane foam in the center, and the FRP plates 4 are firmly and integrally laminated on both front and back surfaces of the foam body 2. The most characteristic feature of the present invention is that a large number of small holes 5 are formed in the thickness direction of the foam 2.
And the pillars 6 integrated with the front and back FRP plates 4 are provided in the small holes 5. As a means for integrating the pillar 6 and the FRP plate 4, the material of the pillar 6 is FRP resin,
The reinforcing fibers are impregnated with the FRP resin liquid and filled in the small holes 5, and the columns 6 are formed together with the molding of the FRP plate 4.

When the force in the thickness direction is applied to the entire surface of the FRP composite plate 1 having such a structure, the foam 2 and the FRP plate 4 themselves receive the force as in the conventional case, and the foam 2 also receives the force. The column 6 formed by the hardening of the resin in the small hole 5 formed in the column receives this force. Even when the FRP composite plate 1 is used in a bent portion and bending stress is applied, or even when the FRP composite plate 1 is used in such a way that a partial load is applied, those forces are applied to the small holes 5 formed in the foam 2. The inner pillar 6 surely receives this force, and the foam 2 and the F
It does not give a force to shift between the RP plates 4. Therefore, FR
No peeling occurs between the P plate 4 and the foam 2.

An example of a method of manufacturing the FRP composite plate 1 shown in FIGS. 1 and 2 will be described with reference to FIGS. 3 to 6. In FIG. 3, reference numeral 7 is a workbench (substrate), which is a flat plate having a larger area than the FRP composite plate 1 to be manufactured. In the method of the present invention, a release agent is applied to the surface of the workbench 7 if necessary, and a gel coat 8 is applied as a surface protective layer on the workbench 7 thus formed. A foamed product in which a glass fiber 10 which is a layered reinforcing fiber is impregnated with a predetermined amount of synthetic resin liquid 9 and held thereon, and a large number of small holes 5 are preliminarily formed in the thickness direction thereon. 2 is placed, and the layered glass fiber 10 is further placed thereon to complete the preparation.

Next, as shown in FIG. 4, the sheet 11 is covered with the sheet 11 in an airtight state. As a means for this,
The sheet 11 is sized so that the periphery of the sheet 11 covers the upper surface of the work table 7, and the seal 12 is provided by an appropriate means. The seat 11 is provided with a pipe 13 and the pipe 13
A suction port of a vacuum device composed of a vacuum pump or the like (not shown) is connected to and the inside of the seat 11 is brought into a negative pressure state.

Inside the sheet 11, the synthetic resin liquid before curing, which is a fluid, moves toward the pipe 13 in the process of becoming a negative pressure state by the operation of the vacuum device. As a result, the synthetic resin liquid rises in the small holes 5 of the foam 2 and permeates at least a part of the glass fiber 10 on the upper part of the foam 2. Then, the synthetic resin liquid bleeding into the glass fiber 10 on the top of the foam 2 is gelled in this state, and then the sheet 11 is removed, and the glass fiber 10 on the surface is coated and impregnated with the synthetic resin liquid to make the FRP plate 4 To form. FIG. 5 shows the glass fiber 10 becoming the FRP plate 4, and FIG. 6 shows the glass fiber 10 seen obliquely from above.

If a part of the glass fiber 10 located above the foam 2 is impregnated with the synthetic resin liquid, and further the glass fiber 10 on the surface is impregnated with the synthetic resin liquid, the FR according to the present invention is obtained.
The P composite plate 1 is completed. The FRP composite plate 1 manufactured by such a process is the FRP with the sheet 11 covered.
FR having a rough surface on the plate 4 and formed on the upper surface of the substrate 7.
The surface roughness of the P plate 4 becomes flat because the surface of the substrate 7 is flat. Therefore, when using the FRP composite plate 1, it is preferable to use the flat side as the surface.

FIG. 7 shows an application example of the FRP composite plate according to the present invention. Explaining this, this FRP composite plate is obtained by superimposing two sheets each having a thickness of 25 mm, and the density of the silencing glass wool 15 located in the middle is "30". .. As a result, the sound transmission loss could be reduced to 25 decibels at 400 hertz and 30 decibels at 1000k hertz, and sufficient results as a soundproofing material could be obtained. For the structure of each part, refer to the reference numeral of each part.

In the present invention, the reinforcing fibers used may be those generally used in the field of FRP, such as glass fibers and carbon fibers. The reinforcing fibers may be preliminarily formed into a sheet shape such as a roving cloth or a chipped strand mat, or may be formed by stacking the chipped strands to have an appropriate thickness during manufacturing. Also, the resin for FRP is not particularly limited,
In addition to a resin having an appropriate fluidity such as a polyester resin used in this type of field, a molten resin or the like can be used depending on the case. Depending on the FRP resin, it goes without saying that the application of a surface protective agent such as a gel coat can be omitted.

When a curable resin such as polyester resin is used, a curing agent is used if necessary, and after suction molding, it is transferred to a heating furnace or the like in that state or in a semi-cured state to be cured by heating. You may let me.

As the foam, any one having a hardness that does not deform during vacuum can be used, and hard or semi-rigid polyurethane foam, polystyrene foam, acrylic resin, etc. can be used. For the purpose of the present invention, the foam is preferably a closed cell.

Although a flat plate is used as the substrate in the above embodiment, a plate having an appropriate uneven pattern or curvature on the surface may be used if desired. Further, in the above example, by placing a flat plastic plate on the glass fiber on the upper surface of the foam, it is possible to obtain an FRP composite plate having flat surfaces on both sides.

By using a plate which has been subjected to a release treatment such as silicone processing or fluororesin processing as the substrate, the application of the release agent at the time of manufacture can be omitted.

[0022]

EFFECT OF THE INVENTION The present invention is the FRP composite plate and the method of manufacturing the FRP composite plate constructed as described above.
As for the composite plate, the columns formed in the small holes formed in the foam material will significantly improve the bending rigidity of the FRP composite plate, so that the strength and impact resistance of the composite plate will be improved. It is possible to prevent the peeling between the FRP plate and the foam, which has occurred, from occurring. Further, in the method for producing the FRP composite plate of the present invention,
By simply stacking the members and drawing a vacuum,
Since the pillar, which is an important part of the FRP composite plate according to the present invention, can be formed, no special equipment or the like is required.

[Brief description of drawings]

FIG. 1 is a sectional view of an FRP composite plate according to the present invention.

FIG. 2 is a perspective view of the device shown in FIG. 1 as viewed obliquely from above.

FIG. 3 is a cross-sectional view showing the first step of the method of the present invention.

FIG. 4 is a cross-sectional view showing the next step of FIG.

FIG. 5 is a cross-sectional view showing the next step of FIG.

FIG. 6 is a perspective view showing a state in which an FRP composite plate is formed by the final step of the method of the present invention.

FIG. 7 is a cross-sectional view showing an application example of the FRP composite plate according to the present invention.

FIG. 8 is a sectional view of a conventional FRP composite plate.

[Explanation of symbols]

 1 FRP composite plate 2 Foam 4 FRP plate 5 Small hole 6 Column 7 Working table 8 Gel coat 9 Glass fiber impregnated with synthetic resin solution 10 Glass fiber 11 Sheet 12 Seal 13 Pipe

Claims (2)

[Claims] 1. An FRP composite plate comprising FRP plates on both front and back surfaces of a foam, wherein a large number of small holes are formed in the thickness direction of the foam, and the small holes are integrated with the FRP plate. An FRP composite board characterized by having columns. 2. A reinforcing fiber is placed in layers on a substrate having a larger area than the FRP composite plate to be manufactured, and the synthetic resin liquid is held on the reinforcing fiber, and a large number of small holes are previously formed in the thickness direction on the reinforcing fiber. Place the foam that has been perforated, further place the reinforcing fibers on it, then cover all of them with a sheet in an airtight state and connect the suction port of the vacuum device to a part of the sheet An FRP comprising a negative pressure inside and raising the synthetic resin liquid into the small holes of the foam by making the negative pressure so that at least a part of the reinforced fibers on the top of the foam is impregnated. Manufacturing method of composite plate.