JPH0550438A - Prepreg for resin mold for forming surface layer of resin mold - Google Patents
Prepreg for resin mold for forming surface layer of resin moldInfo
- Publication number
- JPH0550438A JPH0550438A JP3209120A JP20912091A JPH0550438A JP H0550438 A JPH0550438 A JP H0550438A JP 3209120 A JP3209120 A JP 3209120A JP 20912091 A JP20912091 A JP 20912091A JP H0550438 A JPH0550438 A JP H0550438A
- Authority
- JP
- Japan
- Prior art keywords
- resin
- prepreg
- mold
- resin mold
- layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 229920005989 resin Polymers 0.000 title claims abstract description 151
- 239000011347 resin Substances 0.000 title claims abstract description 151
- 239000002344 surface layer Substances 0.000 title claims abstract description 25
- 239000010410 layer Substances 0.000 claims abstract description 39
- 229920000049 Carbon (fiber) Polymers 0.000 claims abstract description 23
- 239000004917 carbon fiber Substances 0.000 claims abstract description 23
- 239000004745 nonwoven fabric Substances 0.000 claims abstract description 19
- 239000000463 material Substances 0.000 claims abstract description 18
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 18
- 239000002356 single layer Substances 0.000 claims abstract description 12
- 239000002184 metal Substances 0.000 claims description 12
- 229910052751 metal Inorganic materials 0.000 claims description 12
- 239000012783 reinforcing fiber Substances 0.000 claims description 8
- 238000000465 moulding Methods 0.000 abstract description 30
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 abstract description 14
- 238000005470 impregnation Methods 0.000 abstract description 2
- 229920005992 thermoplastic resin Polymers 0.000 abstract description 2
- 239000000835 fiber Substances 0.000 description 22
- 239000003822 epoxy resin Substances 0.000 description 11
- 229920000647 polyepoxide Polymers 0.000 description 11
- 238000000034 method Methods 0.000 description 10
- 239000011342 resin composition Substances 0.000 description 8
- 239000012779 reinforcing material Substances 0.000 description 6
- 239000002759 woven fabric Substances 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 238000000576 coating method Methods 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 229920003986 novolac Polymers 0.000 description 4
- 239000004848 polyfunctional curative Substances 0.000 description 4
- 239000000758 substrate Substances 0.000 description 4
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 3
- RAXXELZNTBOGNW-UHFFFAOYSA-N imidazole Natural products C1=CNC=N1 RAXXELZNTBOGNW-UHFFFAOYSA-N 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 239000004033 plastic Substances 0.000 description 3
- 229920003023 plastic Polymers 0.000 description 3
- RTZKZFJDLAIYFH-UHFFFAOYSA-N Diethyl ether Chemical compound CCOCC RTZKZFJDLAIYFH-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- IISBACLAFKSPIT-UHFFFAOYSA-N bisphenol A Chemical compound C=1C=C(O)C=CC=1C(C)(C)C1=CC=C(O)C=C1 IISBACLAFKSPIT-UHFFFAOYSA-N 0.000 description 2
- -1 boron halide amine Chemical class 0.000 description 2
- 230000000052 comparative effect Effects 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 238000009787 hand lay-up Methods 0.000 description 2
- 230000014759 maintenance of location Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 238000010137 moulding (plastic) Methods 0.000 description 2
- 229920006284 nylon film Polymers 0.000 description 2
- XQUPVDVFXZDTLT-UHFFFAOYSA-N 1-[4-[[4-(2,5-dioxopyrrol-1-yl)phenyl]methyl]phenyl]pyrrole-2,5-dione Chemical compound O=C1C=CC(=O)N1C(C=C1)=CC=C1CC1=CC=C(N2C(C=CC2=O)=O)C=C1 XQUPVDVFXZDTLT-UHFFFAOYSA-N 0.000 description 1
- QTWJRLJHJPIABL-UHFFFAOYSA-N 2-methylphenol;3-methylphenol;4-methylphenol Chemical compound CC1=CC=C(O)C=C1.CC1=CC=CC(O)=C1.CC1=CC=CC=C1O QTWJRLJHJPIABL-UHFFFAOYSA-N 0.000 description 1
- 229910015900 BF3 Inorganic materials 0.000 description 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 1
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 1
- 150000008065 acid anhydrides Chemical class 0.000 description 1
- NUFNQYOELLVIPL-UHFFFAOYSA-N acifluorfen Chemical compound C1=C([N+]([O-])=O)C(C(=O)O)=CC(OC=2C(=CC(=CC=2)C(F)(F)F)Cl)=C1 NUFNQYOELLVIPL-UHFFFAOYSA-N 0.000 description 1
- 150000001408 amides Chemical class 0.000 description 1
- 150000001412 amines Chemical class 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- WTEOIRVLGSZEPR-UHFFFAOYSA-N boron trifluoride Substances FB(F)F WTEOIRVLGSZEPR-UHFFFAOYSA-N 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 239000011162 core material Substances 0.000 description 1
- 229930003836 cresol Natural products 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000003733 fiber-reinforced composite Substances 0.000 description 1
- 238000007730 finishing process Methods 0.000 description 1
- 238000010304 firing Methods 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 239000011505 plaster Substances 0.000 description 1
- 229920003192 poly(bis maleimide) Polymers 0.000 description 1
- 229920002239 polyacrylonitrile Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- 229910052709 silver Inorganic materials 0.000 description 1
- 239000004332 silver Substances 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Landscapes
- Reinforced Plastic Materials (AREA)
- Moulds For Moulding Plastics Or The Like (AREA)
- Moulding By Coating Moulds (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、プラスチックの成形、
特に繊維強化複合材料（以下、ＦＲＰという）の成形に
用いられる樹脂型を作成するための、強化材繊維を使用
した樹脂型の表層を形成するための樹脂型用プリプレグ
に関するものである。BACKGROUND OF THE INVENTION The present invention relates to molding of plastics,
In particular, the present invention relates to a resin mold prepreg for forming a resin mold surface for forming a resin mold used for molding a fiber-reinforced composite material (hereinafter, referred to as FRP) using a reinforcing material fiber.
【０００２】[0002]
【従来の技術】従来、熱可塑性樹脂あるいは熱硬化性樹
脂等のプラスチックの成形型として、金属製のいわゆる
金型が多く用いられてきた。この金型は型の寸法精度が
高く耐久性に優れている反面、重量が大きく取扱が困難
であった。そして、この金型を用いて成形した成形物は
その金型と熱膨張率が違うために、そのような成形物の
精度を所定の範囲に仕上げるには高度の技術を必要とし
た。また、この金型は熱容量が大きいため、均一加熱・
冷却が困難であった。2. Description of the Related Art Conventionally, a so-called metal mold has been widely used as a mold for plastic such as thermoplastic resin or thermosetting resin. Although this mold has high dimensional accuracy and excellent durability, it is heavy and difficult to handle. Since the molded product molded using this mold has a coefficient of thermal expansion different from that of the mold, a high level technique is required to finish the accuracy of such molded product within a predetermined range. Also, since this mold has a large heat capacity, uniform heating
It was difficult to cool.
【０００３】最近ではこの金型に代わる成形型として、
ＦＲＰ製の成形型（以下、樹脂型という）が採用される
ようになった。ＦＲＰに用いることのできる強化材繊維
には、ガラス繊維、炭素繊維、金属被覆炭素繊維等があ
り、特に炭素繊維からなる織物を強化材繊維に使用した
樹脂型としては、例えば、特開昭６０−２２２２１０号
公報にて既に提案されている。この公報に記載の樹脂型
は強化材繊維として炭素繊維を用いているため剛性、耐
久性に優れ、また組織が織物であるため母型に対するド
レープ性に優れている。Recently, as a mold replacing the mold,
FRP molds (hereinafter referred to as resin molds) have been adopted. Reinforcing material fibers that can be used in FRP include glass fibers, carbon fibers, metal-coated carbon fibers, and the like, and as a resin type in which a woven fabric made of carbon fibers is used as the reinforcing material fibers, for example, Japanese Patent Laid-Open Publication No. -222210 has already been proposed. The resin mold described in this publication has excellent rigidity and durability because it uses carbon fiber as the reinforcing material fiber, and has excellent drape property with respect to the mother mold because the structure is a woven fabric.
【０００４】ＦＲＰ製の樹脂型の製造は、通常次のよう
にして行なわれていた。即ち、木型や石膏型等の母型に
離型剤を塗布した後、成形中間素材である、例えば、強
化材繊維からなる基材シートを載せ、樹脂を塗り込みな
がら含浸させ（ハンドレイアップ処理）、若しくはプリ
プレグをレイアップして、各々の操作を何度も繰り返し
て樹脂型のバックアップ層を形成し、さらに、離型クロ
ス或いはブリーダークロスを載せ、オートクレーブ成
形、又は真空バッグ成形等により成形されていた。The resin mold made of FRP is usually manufactured as follows. That is, after applying a mold release agent to a mother mold such as a wooden mold or a plaster mold, a molding intermediate material, for example, a base material sheet made of reinforcing material fiber is placed and impregnated while applying resin (hand lay-up). Processing) or laying up the prepreg and repeating each operation many times to form a resin type backup layer, and then placing a release cloth or bleeder cloth on it and molding by autoclave molding, vacuum bag molding, etc. It had been.
【０００５】このようにして製造された樹脂型は、素材
として繊維を含有した樹脂材を使用しているため、繊維
目が樹脂型の表面に出てしまっていた。そのために、こ
の樹脂型を用い、レイアップ等により樹脂成形した場
合、得られた成形物の表面に繊維目が転写してしまい、
成形物の表面が荒れ、表面仕上げ工程を必要としてい
た。このような樹脂型では、高度な表面平滑性が求めら
れる製品の成形には使用できず、表面平滑性が求められ
ない一部の製品用に使用されていた。Since the resin mold produced in this way uses a resin material containing fibers as a raw material, the fibers of the fiber are exposed on the surface of the resin mold. Therefore, when this resin mold is used and resin molding is performed by lay-up or the like, fibers are transferred to the surface of the obtained molded product,
The surface of the molded product was rough and required a surface finishing process. Such a resin mold cannot be used for molding a product that requires a high degree of surface smoothness, and has been used for some products that do not require a surface smoothness.
【０００６】そのため、従来、高度な表面平滑性が求め
られる製品の成形用の樹脂型には、その樹脂型の表層と
なる部分にゲルコート層が形成されていた。そのゲルコ
ート層を有する樹脂型の製造方法は、例えば、次のよう
にしていた。母型に、ゲルコート用樹脂を塗布等により
形成してゲルコート層部分を形成する。次に、前記の成
形方法と同様にハンドレイアップ処理又はプリプレグの
レイアップ処理による方法で同様に成形し、樹脂型を製
造していた。Therefore, conventionally, in a resin mold for molding a product which is required to have a high degree of surface smoothness, a gel coat layer is formed in a portion which is a surface layer of the resin mold. The method for producing the resin mold having the gel coat layer is as follows, for example. A gel coat resin is formed on the mother die by coating or the like to form a gel coat layer portion. Next, similar to the above-mentioned molding method, the resin mold was manufactured by carrying out molding in the same manner by a method of hand lay-up treatment or prepreg lay-up treatment.
【０００７】[0007]
【発明が解決しようとする課題】しかし、従来のゲルコ
ート層を有する樹脂型では、そのゲルコート層は１〜２
ｍｍ程度の厚みの有る単独層で、何も補強されていない
層となっており、しかも、その樹脂は、プリプレグの含
浸樹脂と組成が異なり粘度が高く、そのようなゲルコー
ト層を有する樹脂型は、耐久性に乏しかった。そのため
に、ゲルコート層を有する樹脂型を用いて、ＦＲＰ成形
のためのオートクレーブ成形等をある期間行なっている
と、圧力等により、樹脂型の表面のゲルコート層部分に
亀裂、陥没等が生じていた。したがって、そのような欠
陥が生じた場合、その都度、樹脂型の表面補修を行う必
要があった。However, in the conventional resin mold having the gel coat layer, the gel coat layer has 1 to 2 parts.
It is a single layer with a thickness of about mm and is not reinforced at all, and the resin has a high viscosity because of its different composition from the impregnating resin of the prepreg, and the resin type having such a gel coat layer is , Was poor in durability. Therefore, when autoclave molding or the like for FRP molding is performed for a certain period using a resin mold having a gel coat layer, cracks, depressions, etc. occur in the gel coat layer portion on the surface of the resin mold due to pressure or the like. .. Therefore, when such a defect occurs, it is necessary to repair the surface of the resin mold each time.
【０００８】そこで本発明は、樹脂型表面にゲルコート
層を形成させる必要がなく、しかも、耐久性に優れ、表
面が平滑性に優れた、樹脂型の表層を形成するための樹
脂型用プリプレグを提供することを目的とする。Therefore, the present invention provides a resin mold prepreg for forming a resin mold surface layer which does not require formation of a gel coat layer on the resin mold surface and has excellent durability and smooth surface. The purpose is to provide.
【０００９】[0009]
【課題を解決するための手段】本発明の樹脂型の表層を
形成するための樹脂型用プリプレグを図１によって説明
する。図１は、本発明のプリプレグの一例を示す断面図
である。図１において１は強化材繊維からなるシート状
基材に樹脂を含浸してなる層、２はプリプレグ上部の樹
脂単独層、３はプリプレグ下部の樹脂単独層をそれぞれ
示す。上部の樹脂単独層２は下部の樹脂単独層３に比べ
て厚くなっている。この樹脂型用プリプレグは、強化材
繊維からなるシート状基材に対し、熱硬化性樹脂含有率
を９０〜９８重量％とし、好ましくは９３〜９６重量％
とする。熱硬化性樹脂含有率が９０重量％未満である
と、プリプレグ表面に繊維の凹凸が表れて、表面平滑な
樹脂型用プリプレグが得られにくい。また９８重量％を
超えるとこのプリプレグを製造するときに樹脂フローの
コントロールが困難となる。このように、本発明の樹脂
型用プリプレグの熱硬化性樹脂含有率は、９０〜９８重
量％とかなり高く、従来のプリプレグの熱硬化性樹脂含
有率の３０〜６０重量％と比べて、はるかに熱硬化性樹
脂含有率が高いものである。A resin mold prepreg for forming a surface layer of a resin mold of the present invention will be described with reference to FIG. FIG. 1 is a sectional view showing an example of the prepreg of the present invention. In FIG. 1, 1 is a layer obtained by impregnating a sheet-shaped base material made of reinforcing fibers with a resin, 2 is a resin single layer above a prepreg, and 3 is a resin single layer below a prepreg. The upper resin single layer 2 is thicker than the lower resin single layer 3. This resin mold prepreg has a thermosetting resin content of 90 to 98% by weight, preferably 93 to 96% by weight, based on the sheet-like base material made of reinforcing fiber.
And When the thermosetting resin content is less than 90% by weight, the prepreg surface has irregularities of fibers, and it is difficult to obtain a prepreg for a resin mold having a smooth surface. If it exceeds 98% by weight, it becomes difficult to control the resin flow when producing this prepreg. As described above, the thermosetting resin content of the resin mold prepreg of the present invention is considerably high at 90 to 98% by weight, which is much higher than the thermosetting resin content of conventional prepregs of 30 to 60% by weight. It has a high thermosetting resin content.
【００１０】本発明の樹脂型用プリプレグに用いるシー
ト状基材としては、不織布、朱子織、平織、一方向性織
物等の各種織物があげられる。不織布はドレープ性に優
れ、樹脂含浸性及び形態保持性が良いことからシート状
基材に特に好適に用いることができる。ドレープ性に欠
けるシート状基材を用いると、特に、コーナー部付近で
しわが生じ、そのようなシート状基材を樹脂型の表層材
として用いた場合、成形して得られた樹脂型の表面は平
滑にならない。また、成形された樹脂型の表面を平滑に
するために、シート状基材に含浸する樹脂の繊維に対す
る目付量を好ましくは１０〜８０ｇ／ｍ2 、さらに好ま
しくは３０〜６０ｇ／ｍ2 とする。Examples of the sheet-like base material used for the resin mold prepreg of the present invention include various woven fabrics such as non-woven fabric, satin weave, plain weave and unidirectional woven fabric. Nonwoven fabrics have excellent drapeability, resin impregnation properties, and shape retention properties, and thus can be used particularly suitably for sheet-shaped substrates. When a sheet-like base material lacking drape is used, wrinkles particularly occur near the corners, and when such a sheet-like base material is used as the surface layer material of the resin mold, the surface of the resin mold obtained by molding Does not become smooth. Further, in order to make the surface of the molded resin mold smooth, the basis weight of the resin with which the sheet-shaped substrate is impregnated is preferably 10 to 80 g / m 2 , and more preferably 30 to 60 g / m 2 . ..
【００１１】不織布には、製造方法によって湿式法によ
る不織布、乾式法による不織布があり、いずれの不織布
も採用することができるが、特に湿式法である抄紙法に
よる不織布は、密度が高く均一な厚みで平滑性に優れ、
取扱性に優れて好適である。乾式法による不織布は、バ
インダーを使用したものが密度が高く、平滑性に優れ好
適である。The non-woven fabric includes a non-woven fabric by a wet method and a non-woven fabric by a dry method depending on the manufacturing method, and any of the non-woven fabrics can be adopted. In particular, the non-woven fabric by a papermaking method which is a wet method has a high density and a uniform thickness. Has excellent smoothness,
It is suitable because it is easy to handle. The non-woven fabric produced by the dry method is preferably a non-woven fabric using a binder because of its high density and excellent smoothness.
【００１２】本発明における強化材繊維とは、炭素繊
維、ガラス繊維、金属被覆炭素繊維、アラミド繊維等が
あげられる。炭素繊維には、ポリアクリルニトリル（Ｐ
ＡＮ）系炭素繊維、ピッチ系炭素繊維等があり、さらに
焼成温度により高強度タイプと高弾性タイプとがあり何
れも使用できる。高強度タイプの炭素繊維よりも、いわ
ゆる黒鉛繊維と称される高弾性タイプの炭素繊維の方が
熱伝導率が高い。したがって、熱伝導率が高い強化材繊
維を使用して製造された樹脂型でＦＲＰ成形を行なう場
合には、加熱するときに均一に加熱されやすく、また成
形サイクルが速くなる利点がある。Examples of the reinforcing fiber in the present invention include carbon fiber, glass fiber, metal-coated carbon fiber, aramid fiber and the like. Polyacrylonitrile (P
AN) -based carbon fibers, pitch-based carbon fibers, and the like, and depending on the firing temperature, there are a high-strength type and a high-elasticity type, and both can be used. High-elasticity type carbon fibers, so-called graphite fibers, have higher thermal conductivity than high-strength type carbon fibers. Therefore, when FRP molding is performed with a resin mold manufactured using a reinforcing material fiber having a high thermal conductivity, there is an advantage that heating is easily performed uniformly and a molding cycle is accelerated.
【００１３】また、前記金属被覆炭素繊維とは、炭素繊
維芯材の外層に銀、銅、ニッケルなどの金属層を有する
繊維である。この金属被覆炭素繊維における金属層の厚
さは、炭素繊維の太さによっても変わるが、炭素繊維の
直径５〜１０μｍの場合０．１〜１．０μｍ程度であ
る。このような金属被覆炭素繊維は、市場において容易
に入手することができる。金属被覆炭素繊維の熱伝導性
は、金属層の厚さによって、指数関数的に高くなるの
で、目的に応じ必要な熱伝導性を有するものを使用す
る。The metal-coated carbon fiber is a fiber having a metal layer of silver, copper, nickel or the like on the outer layer of the carbon fiber core material. The thickness of the metal layer in the metal-coated carbon fiber varies depending on the thickness of the carbon fiber, but is about 0.1 to 1.0 μm when the diameter of the carbon fiber is 5 to 10 μm. Such metal-coated carbon fibers are easily available on the market. The thermal conductivity of the metal-coated carbon fiber increases exponentially depending on the thickness of the metal layer, so that the one having the required thermal conductivity according to the purpose is used.
【００１４】本発明の樹脂型用プリプレグに使用可能な
熱硬化性樹脂としては、エポキシ樹脂、ポリイミド樹
脂、ビスマレイミド樹脂、不飽和ポリエステル樹脂、フ
ェノール樹脂等が用いられる。エポキシ樹脂は、ビスフ
エノールＡ型エポキシ樹脂、フェノールノボラック型エ
ポキシ樹脂、クレゾールノボラック型エポキシ樹脂、ト
リスヒドロキシフェニルメタン・トリグリシジルエーテ
ル型エポキシ樹脂、テトラグリシジルアミン型エポキシ
樹脂等の多官能性エポキシ樹脂並びにこれらの変性樹脂
である。これらの熱硬化性樹脂は単独又は混合して用い
ることができる。特に耐熱性が要求される樹脂型に用い
るプリプレグとしてフェノールノボラック型エポキシ樹
脂が好適に用いられる。As the thermosetting resin usable in the resin mold prepreg of the present invention, epoxy resin, polyimide resin, bismaleimide resin, unsaturated polyester resin, phenol resin and the like are used. The epoxy resin is a polyfunctional epoxy resin such as bisphenol A type epoxy resin, phenol novolac type epoxy resin, cresol novolac type epoxy resin, trishydroxyphenylmethane / triglycidyl ether type epoxy resin, tetraglycidyl amine type epoxy resin and the like. It is a modified resin of. These thermosetting resins can be used alone or in combination. Particularly, a phenol novolac type epoxy resin is preferably used as a prepreg used for a resin type which is required to have heat resistance.
【００１５】前記熱硬化性樹脂に含むことのできる硬化
剤成分は、アミド系硬化剤、イミダゾール系硬化剤、酸
無水物系硬化剤、ハロゲン化ホウ素アミン錯体等であ
る。つぎに、本発明のプリプレグを製造する方法は、前
記したプリプレグ用の樹脂組成物をフィルムとし、この
フィルム上に強化材繊維からなるシート状基材を載せ、
前記フィルムをさらに積層し、含浸成形してプリプレグ
を得るものである。このようなプリプレグは通常知られ
ているホットメルト法、例えば、ホットローラー間（約
１〜５Ｋｇ／ｃｍ2 、約５０〜８０℃）を通すことによ
って作製することができる。これらの圧力、温度条件は
用いる樹脂組成物によって変化する。また、プリプレグ
の厚みの調整は、ホットローラーに一定のクリアランス
を設けることによって行なうことができる。また、基材
シート上の樹脂単独層の厚みの調整は、供給する樹脂シ
ートの厚み又は樹脂シートの積層枚数によって調整する
ことができる。The hardener component that can be contained in the thermosetting resin is an amide hardener, an imidazole hardener, an acid anhydride hardener, a boron halide amine complex, or the like. Next, the method for producing a prepreg of the present invention, the resin composition for the prepreg described above as a film, a sheet-shaped substrate made of reinforcing fiber on the film,
The film is further laminated and impregnated and molded to obtain a prepreg. Such a prepreg can be produced by a generally known hot melt method, for example, by passing it between hot rollers (about 1 to 5 Kg / cm 2 , about 50 to 80 ° C.). These pressure and temperature conditions vary depending on the resin composition used. The thickness of the prepreg can be adjusted by providing the hot roller with a certain clearance. The thickness of the resin single layer on the substrate sheet can be adjusted by the thickness of the resin sheet to be supplied or the number of laminated resin sheets.
【００１６】本発明のプリプレグを用いて樹脂型を成形
するには、樹脂型のバックアップ層となる部分のプリプ
レグを別に用意しておく。このプリブレグは、炭素繊維
織物からなる基材シートに、前記本発明の表層を形成す
るための樹脂型用プリプレグに用いた同じ樹脂組成物を
含浸している。このように、樹脂型の表層とバックアッ
プ層の樹脂組成を同じにすることにより、接着性・耐久
性に優れた型を得ることができる。In order to mold a resin mold using the prepreg of the present invention, a prepreg of a portion which will be a backup layer of the resin mold is prepared separately. In this prepreg, a base sheet made of a carbon fiber woven fabric is impregnated with the same resin composition used for the resin mold prepreg for forming the surface layer of the present invention. Thus, by making the resin composition of the surface layer and the backup layer of the resin mold the same, it is possible to obtain a mold having excellent adhesiveness and durability.
【００１７】これらのプリプレグを用いて樹脂型を成形
する方法を図３に基づいて説明する。図３は、樹脂型を
成形する際のレイアップの概念を示した断面図である。
図３において、４は、樹脂型を成形するための母型であ
る。この母型４に樹脂型の素材となるべきプリプレグを
レイアップし、即ち、最初に樹脂型の表層を形成するた
めのプリプレグをレイアップし次いで樹脂型のバックア
ップ層を形成するためのプリプレグをレイアップし、プ
リプレグ層５を形成する。次いで、その外層に穴あき離
型フィルム６、ブリーダークロス７、穴あき離型フィル
ム８、ブレーザークロス９、ナイロンフィルム１０の順
序で積層し、ナイロンフィルム１０の外端部はシーラン
ト１１にてシールし、真空バッグを形成する。A method of molding a resin mold using these prepregs will be described with reference to FIG. FIG. 3 is a cross-sectional view showing the concept of layup when molding a resin mold.
In FIG. 3, 4 is a mother die for molding a resin die. A prepreg to be a resin type material is laid up on the mother die 4, that is, a prepreg for forming a resin type surface layer is first laid up, and then a prepreg for forming a resin type backup layer is laid up. And the prepreg layer 5 is formed. Then, a perforated release film 6, a bleeder cloth 7, a perforated release film 8, a blazer cloth 9, and a nylon film 10 are laminated on the outer layer in this order, and the outer end portion of the nylon film 10 is sealed with a sealant 11. Form a vacuum bag.
【００１８】この真空バッグを、オートクレーブ内に載
置し、真空バッグ成形を行なう。この際のキュアースケ
ジュールは、樹脂によって異なる。先ず、真空下で６０
〜７０℃にて保持したのち、９０〜１００℃にて３〜５
時間保持して樹脂を硬化し、脱型する。次いで、１７０
〜１９０℃まで２〜６時間かけて昇温し、この温度にて
１〜３時間保持しキュアーを完了する。This vacuum bag is placed in an autoclave and vacuum bag molding is performed. The cure schedule at this time varies depending on the resin. First, 60 under vacuum
Hold at ~ 70 ° C, then 3 ~ 5 at 90 ~ 100 ° C
Hold for time to cure the resin and demold. Then 170
The temperature is raised to 190 ° C over 2 to 6 hours, and the temperature is maintained for 1 to 3 hours to complete the curing.
【００１９】[0019]
【実施例１】樹脂型の表層を形成するための樹脂型用プ
リプレグの製造方法は次のようにして行なった。下記の
組成Ａ〜Ｃからなるプリプレグ用樹脂組成物を混合し
た。 〔Ａ〕フェノールノボラック型エポキシ樹脂 ９０重量部 〔Ｂ〕テトラグリシジルアミン型エポキシ樹脂 １０重量部 〔Ｃ〕３弗化硼素アミン系硬化剤 ６重量部 この樹脂組成物を用いてフィルムコーターで、樹脂目付
２５０ｇ／ｍ2 の樹脂フィルムを作成した。このフィル
ム上に、繊維目付５０ｇ／ｍ2 の炭素繊維からなる不織
布を載せ、６０℃に加熱されたホットローラー間（約３
Ｋｇ／ｃｍ2 ）を通し、不織布に樹脂を含浸させた。さ
らに、同じ樹脂フィルムを片面に２層積層し、同様にホ
ットローラーで含浸させ、繊維目付５０ｇ／ｍ2 、樹脂
含有率９４重量％のプリプレグａを得た。Example 1 A resin mold prepreg for forming a resin mold surface layer was manufactured as follows. Resin compositions for prepreg comprising the following compositions A to C were mixed. [A] Phenol novolac type epoxy resin 90 parts by weight [B] Tetraglycidylamine type epoxy resin 10 parts by weight [C] Boron trifluoride amine curing agent 6 parts by weight Using this resin composition, a resin coating weight is obtained. A resin film of 250 g / m 2 was prepared. A non-woven fabric made of carbon fiber having a fiber areal weight of 50 g / m 2 was placed on this film, and the space between the hot rollers heated to 60 ° C. (about 3
The non-woven fabric was impregnated with the resin by passing through Kg / cm 2 ). Further, two layers of the same resin film were laminated on one side and impregnated with a hot roller in the same manner to obtain a prepreg a having a fiber areal weight of 50 g / m 2 and a resin content of 94% by weight.
【００２０】このプリプレグａの断面を顕微鏡での観察
の結果、不織布の両面に樹脂単独の層を有し、一方の樹
脂層の厚さは、他方の樹脂層の厚さに比較し３倍以上の
厚さを有していた。このようにして、本発明の樹脂型の
表層を形成するための樹脂型用プリプレグを得た。つぎ
に、同じ樹脂組成物を３５重量％含浸した炭素繊維平織
物プリプレグ（繊維目付２００ｇ／ｍ2 ）ｂを樹脂型の
バックアップ層として別に用意した。As a result of observing the cross section of this prepreg a with a microscope, it has a layer of resin alone on both sides of the nonwoven fabric, and the thickness of one resin layer is three times or more as large as the thickness of the other resin layer. Had a thickness of. In this way, a resin mold prepreg for forming the resin mold surface layer of the present invention was obtained. Next, a carbon fiber plain weave prepreg (fiber basis weight 200 g / m 2 ) b impregnated with the same resin composition by 35% by weight was separately prepared as a resin type backup layer.
【００２１】前記プリプレグａを厚い方の樹脂単独層が
表層となるように母型上に１枚積層し、その上に前記プ
リプレグｂを３０枚積層してオートクレーブ成形した。
成形条件は、６０℃にて１．５時間保持後、９８℃にて
４時間保持した後、母型から外した。次いで、加熱炉中
で、６５℃、９５℃、及び１３５℃に順次昇温しつつ各
温度で各々１時間保持した後、１８０℃に昇温して、２
時間保持して樹脂の硬化を完了し、図２に示すような厚
み５．７ｍｍのチャンネル型の成形型を作成した。この
成形型は繊維目が表に出ておらず、平滑な表面を有して
いた。One prepreg a was laminated on a mother mold so that the thicker resin single layer was a surface layer, and 30 prepregs b were laminated on the mother prepreg a and autoclaved.
The molding conditions were as follows: holding at 60 ° C. for 1.5 hours, holding at 98 ° C. for 4 hours, and then removing from the mother mold. Next, in a heating furnace, the temperature was raised to 65 ° C., 95 ° C., and 135 ° C. in sequence, each temperature was held for 1 hour, and then the temperature was raised to 180 ° C.
Curing of the resin was completed by holding for a period of time to prepare a channel mold having a thickness of 5.7 mm as shown in FIG. The mold had no smooth fibers and had a smooth surface.
【００２２】このようにして得られた成形型を用いて、
１３５℃硬化タイプのプリプレグを成形型にレイアップ
し、オートクレーブにて８０℃で３０分保持した後、昇
温速度３℃／分にて１３５℃まで昇温し、９０分、４Ｋ
ｇ／ｃｍ2の圧力下でプラスチックの成形を１００回繰
り返し行なった後、型の表面を観察した。また、比較の
ため、プリプレグｂのみを３０枚積層した以外は、本実
施例１と同様にしてチャンネル型の成形型を作製した。
この成形型は、繊維目が表に出ている箇所があり、この
まま使用すると成形物の表面を荒らしてしまうおそれが
あった。一方、母型にゲルコート層を形成させた後、プ
リプレグｂを３０枚積層した以外は本実施例１と同様に
してゲルコート付きの成形型を作製した。この成形型は
平滑な表面を有していた。これらのゲルコートなしとゲ
ルコート付きの２つの成形型を用いて、それぞれ本実施
例１と同様にしてプラスチックの成形を行った後、表面
の観察を行った。以上各々の結果を次の表１に示す。Using the mold thus obtained,
Lay-up a 135 ° C-curing type prepreg into a molding die, hold it in an autoclave at 80 ° C for 30 minutes, then raise it to 135 ° C at a heating rate of 3 ° C / minute, and then 90 minutes, 4K
After molding the plastic 100 times under a pressure of g / cm 2 , the surface of the mold was observed. For comparison, a channel mold was manufactured in the same manner as in Example 1 except that only 30 prepregs b were laminated.
This molding die has a part where the fiber mesh is exposed, and if it is used as it is, the surface of the molding may be roughened. On the other hand, a molding die with a gel coat was prepared in the same manner as in Example 1 except that 30 prepregs b were laminated after forming the gel coat layer on the mother die. This mold had a smooth surface. Plastic molding was carried out in the same manner as in Example 1 using these two molding dies without gel coating and gel coating, and the surface was observed. The results of each of the above are shown in Table 1 below.
【００２３】[0023]
【表１】 [Table 1]
【００２４】表１によれば、本発明の樹脂型の表層を形
成するための樹脂型用プリプレグを用いて製造された樹
脂型では、１００回のプラスチック成形を行なっても、
成形された成形品の樹脂表面は滑らかであるのに対し
て、比較例１のゲルコートなしの樹脂型では、成形され
た全ての成形品の樹脂表面に多少繊維目が出でいた。ま
た、比較例２のゲルコートを有する樹脂型では、成形を
重ねる毎にゲルコート層に亀裂、陥没等が発生し、その
樹脂型を用いて成形した成形品の表面に傷や荒れが発生
していた。According to Table 1, in the resin mold manufactured using the resin mold prepreg for forming the surface layer of the resin mold of the present invention, even if the plastic molding is performed 100 times,
While the resin surface of the molded molded product was smooth, in the resin mold without the gel coat of Comparative Example 1, some resin fibers appeared on the resin surface of all molded products. In addition, in the resin mold having the gel coat of Comparative Example 2, cracks, depressions, etc. occurred in the gel coat layer each time molding was repeated, and the surface of the molded product molded using the resin mold was scratched or roughened. ..
【００２５】[0025]
【実施例２】実施例１で用いたのと同一の樹脂組成物を
実施例１と同様にして、フィルム上に繊維目付５０ｇ／
ｍ2 の炭素繊維からなる不織布を載せ、６０℃に加熱さ
れたホットローラー間を通し、不織布に樹脂を含浸させ
た。さらに、同じ樹脂フィルムを前記処理された不織布
の両面に各１層積層し、同様に６０℃に加熱されたホッ
トローラー間（約３ｋｇ／ｃｍ2 ）を通して含浸させ、
繊維目付５０ｇ／ｍ2 、樹脂含有率９４重量％のプリプ
レグｃを得た。Example 2 The same resin composition used in Example 1 was used in the same manner as in Example 1 to give a fiber basis weight of 50 g /
A nonwoven fabric made of m 2 of carbon fiber was placed and passed through a hot roller heated to 60 ° C. to impregnate the nonwoven fabric with resin. Further, the same resin film was laminated on both sides of the treated non-woven fabric, and impregnated through hot rollers (about 3 kg / cm 2 ) similarly heated to 60 ° C.,
A prepreg c having a fiber basis weight of 50 g / m 2 and a resin content of 94% by weight was obtained.
【００２６】このプリプレグｃの断面を顕微鏡観察する
と、不織布の両面に樹脂単独の層が形成され、両面の各
々の樹脂層の厚さはほぼ等しかった。プリプレグａに代
えてプリプレグｃを用いた以外は、実施例１と同様にし
て樹脂型を製作した。この樹脂型は、実施例１の樹脂型
に比べ、表面の平滑性はやや劣るものの、耐久性におい
ては同等であった。When the cross section of this prepreg c was observed under a microscope, layers of the resin alone were formed on both surfaces of the nonwoven fabric, and the resin layers on both surfaces were approximately equal in thickness. A resin mold was manufactured in the same manner as in Example 1 except that the prepreg c was used instead of the prepreg a. This resin mold was slightly inferior to the resin mold of Example 1 in surface smoothness, but was equivalent in durability.
【００２７】[0027]
【発明の効果】本発明の樹脂型の表層を形成するための
樹脂型用プリプレグは、熱硬化性樹脂含有率が９０〜９
８重量％と高いためプリプレグ表面に繊維目が出る恐れ
がなく、樹脂型の表層を形成するために好適に使用する
ことができる。従来、表面が平滑な樹脂型にはゲルコー
ト層が設けられており、そのゲルコート層は樹脂単独で
厚みも１〜２ｍｍと厚く耐久性に乏しかったが、本発明
の樹脂型の表層を形成するための樹脂型用プリプレグ
は、樹脂単独層からなる表層が非常に薄く、そのために
通常のプリプレグの中間層と同等の耐久性を有してい
る。The resin mold prepreg for forming the surface layer of the resin mold of the present invention has a thermosetting resin content of 90 to 9.
Since it is as high as 8% by weight, there is no fear that fibers will appear on the prepreg surface, and it can be suitably used for forming a resin type surface layer. Conventionally, a resin mold having a smooth surface is provided with a gel coat layer, and the gel coat layer is thick and has a thickness of 1 to 2 mm and is poor in durability alone. However, since the surface layer of the resin mold of the present invention is formed. The resin mold prepreg has a very thin surface layer consisting of a resin single layer, and therefore has the same durability as the intermediate layer of a normal prepreg.
【００２８】そして、本発明のプリプレグを樹脂型の表
層材として用いた樹脂型は表面平滑性・耐久性に優れた
ものとなる。また、本発明の樹脂型の表層を形成するた
めの樹脂型用プリプレグは、樹脂型の表層部分を別体と
し、非常に薄い表層材としたものであるが、それ自体で
形態保持性があり、その取扱性に優れている。The resin mold using the prepreg of the present invention as the surface layer material of the resin mold has excellent surface smoothness and durability. Further, the resin mold prepreg for forming the resin-type surface layer of the present invention is a very thin surface layer material in which the resin-type surface layer portion is a separate body, but has a shape retention property by itself. , Its handleability is excellent.
【００２９】さらに、本発明の樹脂型の表層を形成する
ための樹脂型用プリプレグには、強化材繊維からなるシ
ート状基材として金属被覆炭素繊維を含んだ不織布を用
いたので、そのプリプレグから製造された樹脂型は熱伝
導性の良いものとなる。Further, the resin mold prepreg for forming the resin-type surface layer of the present invention uses a non-woven fabric containing metal-coated carbon fibers as a sheet-like base material made of reinforcing fiber. The manufactured resin mold has good thermal conductivity.
【図１】本発明のプリプレグの一例を示す断面図であ
る。FIG. 1 is a sectional view showing an example of a prepreg of the present invention.
【図２】本発明のプリプレグを用いて成形した樹脂型の
一例を示す斜視図である。FIG. 2 is a perspective view showing an example of a resin mold molded using the prepreg of the present invention.
【図３】樹脂型を成形する際のレイアップの概念を示し
た断面図である。FIG. 3 is a cross-sectional view showing the concept of lay-up when molding a resin mold.
１ 強化材繊維からなるシート状基材に樹脂を含浸し
てなる層 ２ プリプレグ上部の単独樹脂層 ３ プリプレグ下部の単独樹脂層1 A layer obtained by impregnating a sheet-shaped base material made of reinforcing fiber with a resin 2 A single resin layer above the prepreg 3 A single resin layer below the prepreg
───────────────────────────────────────────────────── フロントページの続き (51)Int.Cl.5 識別記号 庁内整理番号 ＦＩ 技術表示箇所 Ｂ２９Ｋ 105:08 ─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. 5 Identification code Office reference number FI technical display location B29K 105: 08
Claims (3)
化性樹脂を含浸してなり、該熱硬化性樹脂含有率が９０
〜９８重量％であることを特徴とする樹脂型の表層を形
成するための樹脂型用プリプレグ。1. A thermosetting resin is impregnated into a sheet-shaped base material made of reinforcing fiber, and the thermosetting resin content is 90%.
A resin mold prepreg for forming a resin mold surface layer, wherein the resin mold prepreg is about 98% by weight.
化性樹脂を含浸してなる層の両側に熱硬化性樹脂の単独
層を有し、しかも一側の熱硬化性樹脂の単独層が他側の
熱硬化性樹脂の単独層よりも厚い積層構造であり、全体
の熱硬化性樹脂含有率が９０〜９８重量％である請求項
１記載の樹脂型の表層を形成するための樹脂型用プリプ
レグ。2. A single layer of thermosetting resin is provided on both sides of a layer obtained by impregnating a sheet-like base material made of reinforcing fibers with a thermosetting resin, and one layer of thermosetting resin is provided on one side. Is a laminated structure thicker than a single layer of thermosetting resin on the other side, and the total thermosetting resin content is 90 to 98% by weight. Resin for forming a surface layer of a resin type according to claim 1. Mold prepreg.
被覆炭素繊維を含んだ不織布である請求項１または２記
載の樹脂型の表層を形成するための樹脂型用プリプレ
グ。3. The resin-type prepreg for forming a resin-type surface layer according to claim 1, wherein the base sheet constituting the prepreg is a nonwoven fabric containing metal-coated carbon fibers.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3209120A JP2767329B2 (en) | 1991-08-21 | 1991-08-21 | Prepreg for resin mold to form surface layer of resin mold |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP3209120A JP2767329B2 (en) | 1991-08-21 | 1991-08-21 | Prepreg for resin mold to form surface layer of resin mold |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0550438A true JPH0550438A (en) | 1993-03-02 |
| JP2767329B2 JP2767329B2 (en) | 1998-06-18 |
Family
ID=16567622
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP3209120A Expired - Fee Related JP2767329B2 (en) | 1991-08-21 | 1991-08-21 | Prepreg for resin mold to form surface layer of resin mold |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP2767329B2 (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0642904A1 (en) * | 1993-09-13 | 1995-03-15 | R. ALKAN & Cie. | Process for making a mould, particularly of bismaleimide resin |
| JP2015507100A (en) * | 2011-12-07 | 2015-03-05 | トウホウ テナックス ユーロップ ゲゼルシャフト ミット ベシュレンクテル ハフツングＴｏｈｏ Ｔｅｎａｘ Ｅｕｒｏｐｅ ＧｍｂＨ | Carbon fiber for composites with improved conductivity |
| CN108883584A (en) * | 2015-12-11 | 2018-11-23 | 奥钢联钢铁公司 | Method for manufacturing the semi-finished product or component that are made of metal and fibre composites |
Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5417787A (en) * | 1977-07-11 | 1979-02-09 | Dainippon Ink & Chemicals | Method and apparatus for complete coincidence of color |
-
1991
- 1991-08-21 JP JP3209120A patent/JP2767329B2/en not_active Expired - Fee Related
Patent Citations (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5417787A (en) * | 1977-07-11 | 1979-02-09 | Dainippon Ink & Chemicals | Method and apparatus for complete coincidence of color |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP0642904A1 (en) * | 1993-09-13 | 1995-03-15 | R. ALKAN & Cie. | Process for making a mould, particularly of bismaleimide resin |
| FR2710000A1 (en) * | 1993-09-13 | 1995-03-24 | Alkan R & Cie | Process for manufacturing tools for molding synthetic resin parts, in particular bismaleimide resin. |
| JP2015507100A (en) * | 2011-12-07 | 2015-03-05 | トウホウ テナックス ユーロップ ゲゼルシャフト ミット ベシュレンクテル ハフツングＴｏｈｏ Ｔｅｎａｘ Ｅｕｒｏｐｅ ＧｍｂＨ | Carbon fiber for composites with improved conductivity |
| CN108883584A (en) * | 2015-12-11 | 2018-11-23 | 奥钢联钢铁公司 | Method for manufacturing the semi-finished product or component that are made of metal and fibre composites |
Also Published As
| Publication number | Publication date |
|---|---|
| JP2767329B2 (en) | 1998-06-18 |
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|---|---|---|---|
| LAPS | Cancellation because of no payment of annual fees |