JPH07148850A - Production of fiber reinforced resin molded object - Google Patents

Abstract

PURPOSE:To continuously produce a fiber reinforced resin molded object having a groove-shaped reinforcing part formed thereto in a direction different from the longitudinal direction thereof and excellent in mechanical strength with good production efficiency. CONSTITUTION:Continuous fibers impregnated with a thermosetting resin are held by closing the respective upper and lower members 9, 10 of a pair of upper and lower rotary endless molds and, after the molds are moved in a take-over direction over a predetermined distance while the impregnated fibers are heated and cured, the respective upper and lower members of the molds are opened to take over a continuous fiber reinforced resin. Protruding parts for shaping groove-shaped reinforcing parts are formed to the closing surfaces with the lower parts of the upper members 9a and the recessed parts in which the protruding parts are fitted are formed to the closing surfaces with the upper members of the lower members 10a forming pairs along with the upper members 9a. By closing the upper and lower members, groove-shaped reinforcing parts are shaped.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a fiber-reinforced resin molded product, which enables high-strength molded products to be obtained with high productivity.

[0002]

2. Description of the Related Art In the continuous production of fiber reinforced resin moldings, there is known a method of shaping by using a rotary mold having a take-up function to flow only an uncured thermosetting resin. (For example, Japanese Patent Laid-Open No. 63-12531).
No. 6 publication).

[0003]

However, in the above manufacturing method, since only the uncured resin is allowed to flow, the formed ribs are not filled with the reinforcing fibers and the strength is insufficient. In addition, the rib shape was limited to the shape of a small protrusion, and the applicable range was narrow.

An object of the present invention is to provide a method for producing a fiber-reinforced resin molded article having a groove-shaped reinforcing portion in a direction different from the longitudinal direction of the molded article and having excellent mechanical strength by continuous production with high production efficiency. To provide.

[0005]

The method for producing a fiber-reinforced resin molded product according to the present invention comprises a method in which continuous fibers impregnated with a thermosetting resin are formed by closing the upper and lower members of a mold which is paired up and down. While squeezing and curing by heating, after moving the mold a predetermined distance in the take-up direction, a groove type reinforcing part is formed in a direction different from the longitudinal direction of the molded body by a molding method that splits the upper and lower members of the mold. In manufacturing the fiber-reinforced resin molded product, a predetermined number of upper and lower members are combined into a rotating endless mold, and the series of closing, moving a predetermined distance, and cleaving steps are repeated. And the fiber-reinforced resin is continuously taken out, and at least one of the predetermined number of upper members is provided with a convex portion or a concave portion on the surface to be closed with the lower member. The lower member that makes a pair has a surface close to the upper member. A concave portion or a convex portion that can be fitted with the convex portion or the concave portion is formed, and by sandwiching the resin-impregnated continuous fiber by closing such upper and lower members, the groove-type reinforcing portion is formed. It is characterized by that.

The manufacturing method of the present invention will be described in detail below.

As the continuous reinforcing fiber, a fiber stable at the temperature of the curing step of the thermosetting resin used is used. Specifically, inorganic fibers such as glass fiber, carbon fiber, silicon / titanium / carbon fiber, boron fiber, and fine metal fiber, aramid fiber, econol fiber, polyester fiber, polyamide fiber, polypropylene fiber, polyethylene fiber, vinylon fiber. Organic fibers such as The diameter of the monofilament is preferably 1 to 50 μm.

As continuous fibers, a roving in which a large number of filaments are bundled, a continuous strand mat in which the strands of the filament bundle are randomly arranged two-dimensionally and bonded with a binder, and a strand bundle in a swirl shape Swirl mats which are arranged in the above and bonded by a binder or needle punching, roving cloths such as plain weaving and satin weaving, and roving cloths are used alone or in combination.

The thermosetting resin used in the present invention is not particularly limited, but specifically, unsaturated polyester resin, vinyl ester (epoxy acrylate) resin, epoxy resin, urethane acrylate resin,
Examples include polyimide resins. Among the above thermosetting resins, unsaturated polyester resins are most preferably used because of their high molding speed and economically low cost.

The ratio of the thermosetting resin to the reinforcing fiber is appropriately determined according to the required physical properties of the fiber-reinforced resin molding, but the reinforcing fiber is 50 to 500 relative to 100 parts by weight of the resin.
It is preferably part by weight. When the amount of the reinforcing fibers is less than 50 parts by weight, the mechanical strength of the molded product is insufficient, and when it exceeds 500 parts by weight, it is difficult to obtain a molded product in which the reinforcing fibers are uniformly dispersed in the resin, and voids are generated. The strength is extremely reduced.

In addition to the above resins, stabilizers, lubricants, processing aids,
Additives such as plasticizers and colorants, and fillers such as calcium carbonate and metal oxides may be blended.

The method for impregnating the reinforcing fibers with these thermosetting resin compositions is a conventional method, that is, a method in which the reinforcing fibers are passed through a resin tank, or a resin is injected into a mold through which the reinforcing fibers are passed. Any method may be used. In addition, when the viscosity of the resin is slightly high and it is difficult to impregnate the fiber, the viscosity of the resin may be lowered by heating to a temperature at which the initiator is not decomposed.

The pair of upper and lower molds used in the present invention is an endless rotary type in which a predetermined number of upper members and lower members are combined. Then, at least one of the predetermined number of upper members is formed with a convex portion or a concave portion for shaping the groove type reinforcing portion on the surface to be closed with the lower member, and forms a pair with the upper member. The lower member is formed with a concave portion or a convex portion that can be fitted to the convex portion or the concave portion on the surface closed with the upper member, and has such a convex portion and a concave portion, respectively. By sandwiching the resin-impregnated continuous fiber by closing the upper and lower members, the groove type reinforcing portion is formed. No convex portion or concave portion for imprinting the groove type reinforcing portion is formed on the closed surfaces of the upper member and the lower member other than this. Further, the arrangement of the pair of upper and lower members each having the convex portion and the concave portion and the pair of the upper and lower members in which the convex portion and the concave portion are not formed are arranged in the fiber-reinforced resin molded body in terms of the number of grooves. It can be appropriately determined depending on whether or not the mold reinforcing portion is desired to be formed.

Further, the mold has means for heating the fiber reinforced resin. The heating temperature is equal to or higher than the decomposition temperature of the initiator. Also, as a method of thermosetting the molding material,
High-frequency heating or photo-curing may be used.

The apparatus and process used in the method for producing a fiber-reinforced resin molding of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram showing an outline of an apparatus used in the manufacturing method of the present invention. In the following description, the term “front” means the right direction in FIG. 1.

In FIG. 1, only two continuous reinforcing fiber bundles (F1) and two continuous reinforcing fiber mats (f2) are shown for the sake of convenience. , Mats are used in parallel.

This device comprises a roving stand (1) for a reinforcing fiber bundle (F1) for reinforcing fibers arranged in one direction and a random arrangement on a plane. Thermosetting resin composition impregnation tank (3) equipped with a rewinding roll (2) for rewinding a continuous strand mat (f2) for reinforcing fibers and a jacket through which a heating medium (water) for heating passes , A guide (4) for guiding and taking out the reinforcing fibers into the impregnation tank (3), a dipper (4a) and an infeed (5), and a resin liquid adhered to the reinforcing fiber bundle (F1) and the mat (f2). The temperature of the drawing die (6) and the fiber-reinforced resin molding material that passed through the drawing die (6), which has both the scraper function for adjusting the amount of Cold air circulation chamber (7) for collecting and take-up roll (8) for collecting reinforcing fibers , A pair of mold top member (9) and a set of lower mold member forming a pair therewith (10)
And a cutter (11) for cutting the molded product.

The pair of mold upper members (9) are alternately arranged with a convex portion formed on the closing surface of the lower member (9a) and a flat closing surface (9b). Has been done. And, the pair of mold lower members (10) has a flat closed surface with the concave member (10a) which can be fitted with the convex member of the upper member (9a).
(10b) and are arranged alternately. In this way
A set of mold upper members (9) and a set of mold lower members (10) are paired as a whole, and are rotated in the arrow direction in the figure by a motor drive (not shown). Also, these upper members
Each of the lower member (9) and the lower member (10) is provided with a heater so that the resin can be heat-cured.

The method of the present invention can be carried out as follows using the apparatus having the above structure. From the roving stand (1) and the rewind roll (2), pick up roll
The reinforcing fiber bundle (F1) fed out by the drive of (8), the continuous strand mat (f2) is impregnated with the thermosetting resin composition (a) by the guide (4) and the dipper (4a). Guided into tank (3). The reinforcing fiber soaked here is further guided from the outside of the tank into the drawing die (6) by the infeed (5). Here, the resin attached excessively is removed by the clearance of the drawing die (6).

In this example, the method of immersing the reinforced fiber in the resin impregnation tank for impregnation is used, but a method of using a dipping die to inject and supply a certain amount of resin from the middle of the die for impregnation may be used. .

Next, the reinforcing fiber material to which a constant tension is applied by the drawing die (6) is a cooling chamber (7) for adjusting the temperature of the thermosetting resin composition and controlling the resin viscosity. Guided inside. In the case of this example, the cooling chamber (7) was a cold air circulation, but it may be in contact with a cooling medium. The fiber reinforced molding material that has passed through the temperature control area is taken up by the take-up roll (8).
After that, it is fed to the rotary endless die imprinting area.

A set of mold upper members (9) composed of mold upper members (9a) and (9b), and a set of mold lower members composed of mold lower members (10a) and (10b) (10) forms a pair of upper and lower molds, and the pair of upper and lower molds (9) and (10) are closed and
It keeps the closed state while moving horizontally forward for a while. During this time, the unsaturated polyester resin as the matrix is heated and cured. After the resin is cured to form a molded body, the upper and lower members (9) and (10) are split vertically and returned to the closed position while rotating. Then, the upper member (9a) and the lower member (10
A groove type reinforcing portion is formed in the portion which is closed and shaped by a).

Next, the time-dependent movements of the pair of upper and lower molds (9) and (10) at the time of meshing (closing) and releasing (cleaving) will be described with reference to FIGS. 4 and 5, respectively. . In both FIG. 4 and FIG. 5, the molded body is transferred to the right.

In FIG. 4, in FIG. 4A, the mold upper and lower members (9a) (10a) on the right side in the figure are closed to mold the molding material into a groove shape.

In the "I" diagram, (9a) and (10a) are moved horizontally to the right while being closed, and the mold upper and lower members (9b) (10b) are moved.
) Moves to the right and closes vertically while holding the flat plate horizontally.

In the "u" diagram, (9b) and (10b) are in a closed state.

In the "E" figure, the closed (9b) (10b)
Moves horizontally as it is, and the next mold upper and lower members (9a) (10a
) Moves to the right while holding the horizontal part horizontally and closes in the vertical direction.

As described above, the upper member (9) moves obliquely downward and the lower member (10) moves obliquely upward while the horizontal surface of each mold is kept horizontal. Next, when the clearance moves diagonally downward and upward to reach the predetermined position, the pair of upper and lower members (9)
While (10) closes and molds, it continuously moves to the right at a constant speed while maintaining the closed state. In this way, at the time of meshing, the molding material is sequentially meshed by the upper and lower members (9) and (10) for the length of the molded body corresponding to the mold width, and the mold is moved horizontally to the right continuously. By doing so, a molded body can be obtained.

The molding material thus shaped is heat-cured into a molded body while being horizontally moved by the mold upper and lower members (9) and (10).

When the upper and lower members (9) (10) of the mold are closed,
Keeping the horizontal surfaces of the upper and lower members (9) and (10) horizontal by closing them vertically means that the upper member and the lower member interfere with each other in the case of a deep groove shape with the horizontal surface inclined. This is because extra force is applied and molding becomes difficult.

In FIG. 5, when passing the horizontal moving part as shown in the "ka" figure, the mold upper and lower members (9a) (10a)
Will start kaiwari. At this time, as in the case of closing,
While moving the right part while keeping the horizontal part of the upper and lower parts of the mold horizontal, split the parts vertically as shown in the figure.

In the "ku" figure, move further to the right and select (9
a) (10a) completely releases the molded body, and then the mold upper and lower members (9b) (10b) similarly start the splitting.

In this way, the molded body continuously moves horizontally as shown in the "ke" figure, and then the mold upper and lower members (9
a) (10a) starts the splitting.

In this way, the upper and lower members (9) and (10) are moved diagonally upward and downward so that the horizontal members are kept horizontal while the upper and lower members (9) and (10) are released vertically while moving to the right. The member (10) moves diagonally downward.

When the mold is split, it is necessary to split it vertically to maintain the horizontal surfaces of the upper and lower members (9) and (10) horizontally.
In the case of a deep groove shape having an inclined horizontal surface, the upper member and the lower member interfere with each other, and an excessive force is applied to not only the mold but also the molded body, which makes molding difficult.

Molding resistance is moved horizontally rightward and cut at a certain length to obtain a molded body.

In order to drive the mold upper and lower members (9) (10) in this way, for example, each mold is provided with a plurality of pins and the like, and the pins are guided along a guide having a number of pins. , Can be performed by a mechanism that moves each mold in an oblique direction.

[0038]

According to the method for producing a fiber-reinforced resin molded product of the present invention, a series of closing and moving for a predetermined distance is performed by using a mold in which a predetermined number of upper members and lower members are combined with each other to form an endless rotary type. , And the splitting process are repeatedly performed to continuously draw out the fiber reinforced resin, and at least one of the predetermined number of upper members has a groove-shaped reinforcing portion formed on the surface to be closed with the lower member. A convex part or a concave part for forming a concave part or a convex part that can be fitted to the convex part or the concave part on the closing surface with the upper member, in the lower member forming a pair with the upper member. Since the groove-shaped reinforcing portion is formed by sandwiching the resin-impregnated continuous fiber by closing the upper and lower members like this, the groove-shaped reinforcing portion is filled with the reinforcing fiber. The groove-shaped reinforcing portion has a sufficient effect of reinforcing the molded body, and It is possible to manufacture the production with good moldings.

[0039]

【Example】

[Example 1] A molded body was manufactured by the above method for manufacturing a molded body as follows.

As the thermosetting resin, a styrene: diallyl phthalate = 1: 1 mixed monomer solvent was added to a three-component copolymer of maleic anhydride, propylene glycol and isophthalic acid so that the total amount thereof was 45% by weight. What added 1 part by weight of t-butyl perbenzoate to 100 parts by weight of the saturated polyester resin was used.

As the reinforcing fiber (F1), 4450 tex G
^Two hundred F rovings were used, and as the mat material (f1), ^two continuous strand mats having a basis weight of 450 g / m ² and a width of 500 mm were used as the outermost layers on the front and back.

The resin composition was placed in the resin impregnation tank (3), and the jacket around the impregnation tank (3) was water-cooled so that the resin temperature was kept constant at 23 ° C. This impregnation tank (3)
Guide the reinforcing fiber bundle (F1) and the reinforcing fiber mat (f1)
(4) (5), guide dipping with dipper (4a), draw die
By (6), the total glass content was adjusted to about 40 wt%. The fiber reinforced resin molding material adjusted in this way is passed through the take-up machine (8) and then the rotary endless shaping die (9).
It was supplied to (10) at 2.1 m / min.

In this embodiment, the upper and lower members (9a) and (9b) shown in FIG. 2 are used as the mold upper and lower members (9) and (10), and the lower members (10a) and (10b) which can be fitted to these members, respectively. ) Was used.
Then, these are alternately the upper member (9a) and (9b), the lower member
Alternating (10a) and (10b), 50 pairs each are shown in FIG.
It was installed in the rotary drive system as shown in.

The horizontal moving speed of the mold is 2 m / mi.
n and the temperature was set to 145 ° C., and heat curing was performed. In this way, a molded product having a groove-shaped reinforcing portion having the shape shown in FIG.
I got (20).

This molded body was cut out in a lengthwise direction of 1.5 m and subjected to a bending test with a span of 1 m. As a result, the load resistance was 29 kgf. Thus, the strength of the molded body was sufficient.

[Comparative Example 1] In the same manner as in Example 1, the matrix resin and the reinforcing fiber were molded into a flat plate-shaped molded product having no groove type reinforcing portion by the same method as in Example 1. That is, without using the mold upper member (9a) and the lower member (10a) of Example 1, all the molds were replaced by the upper member (9b) and the lower member (10a).
b)

In this case, when the thickness of the molded body is the same as that of the first embodiment, the bending withstand load is 23 kgf,
The strength was insufficient. In order to obtain the same strength as in Example 1, it was necessary to increase the thickness by 1.1 times.

Further, even if an attempt was made to form a reinforcing portion of the same shape by the flow of only the resin, the resin did not flow in the same shape and it was impossible to perform the molding.

[Example 2] As thermosetting resins, maleic anhydride, neopentyl glycol and phthalic anhydride were used.
Unsaturated polyester obtained by adding 5 parts by weight of hexamethylenediamine and 1 part by weight of t-butylperbenzoate to 100 parts by weight of unsaturated polyester resin added to the component copolymer so that styrene accounts for 40% by weight of the whole. A resin composition was used.

As the reinforcing fiber (F1), 4450 tex G
350 pieces of F roving and two pieces of continuous strand mat having a basis weight of 450 g / m ² were used as the outermost layers of the front and back as the mat material (f1).

The resin composition was placed in the resin impregnation tank (3), and the jacket around the impregnation tank (3) was water-cooled so that the resin temperature was kept constant at 23 ° C. This impregnation tank (3)
Guide the reinforcing fiber bundle (F1) and the reinforcing fiber mat (f1)
(4) (5), guide dipping with dipper (4a), draw die
By (6), the total glass content was adjusted to about 40 wt%. The fiber-reinforced resin molding material thus adjusted is guided through a take-up machine (8) on a Teflon block cut out in a U shape for pre-molding, and a rotary endless molding die (9). It was supplied to (10) at 2.1 m / min.

In this embodiment, the upper and lower members (9a) and (9b) shown in FIG. 6 are used as the mold upper and lower members (9) and (10), and the lower members (10a) and (10b) which can be fitted to these members, respectively. ) Was used.
The size of each of these members (9a) (9b) (10a) (10b) can be changed as appropriate, but those used in this example are the members (9a) (9b) (10
a) (10b) length (l1) is 500mm, width (l2) is 250mm
belongs to. The thickness (l3) of the plate-shaped parts of the members (9a) and (9b) is 3m.
m, which is the height (l of the convex portion protruding from the U-shaped portion of the member (9a) (l
4) is 2 mm. And these are upper members (9a) and (9b)
Alternately, the lower members (10a) and (10b) were alternately arranged, and 50 sets each were installed in the rotary drive system in the same manner as in the first embodiment.

The horizontal moving speed of the mold is 2 m / mi.
n and the temperature was set to 145 ° C., and heat curing was performed. In this way, a molded body having a groove-shaped reinforcing portion having the shape shown in FIG.
I got (21).

When the end of this molded body 1m was sealed and the No. 6 sand was packed up to the upper end, the expansion degree of the upper end was 2.1 mm.
Met. Thus, the strength of the molded body was sufficient.

[Comparative Example 2] A matrix resin and a reinforcing fiber were formed in the same manner as in Example 2, and a molded article having a U-shaped cross section without a groove type reinforcing portion was molded by the same method as in Example 2.
That is, the die upper member (9a) and the lower member (10) of the second embodiment.
Without using a), all molds were used as the upper member (9b) and the lower member (10b).

In this case, if the thickness of the molded body is the same as that of the second embodiment, the expansion opening of the upper end when the No. 6 silica sand is packed up to the upper end is 3.1 mm and the strength is insufficient. It was In order to make the opening degree equivalent to that of the second embodiment, the thickness is set to 2
Had to double.

Further, even if an attempt was made to form a groove type reinforcing portion of the same shape by the flow of only the resin, the resin did not flow in the same shape and it was impossible to perform the molding.

[0058]

According to the method for manufacturing a fiber-reinforced resin molded product of the present invention, it is possible to continuously manufacture a fiber-reinforced resin molded product having groove-shaped reinforcing portions formed in a direction different from the longitudinal direction of the molded product. It is possible to obtain a molded product which is excellent in strength and rigidity and is lightweight, with high productivity.

The molded product obtained by the manufacturing method of the present invention can be effectively used, for example, as a U-shaped groove replacing a cement material, a slab roofing material, and the like.

[Brief description of drawings]

FIG. 1 is a diagram schematically showing an example of an apparatus used in a manufacturing method of the present invention.

FIG. 2 is a perspective view showing an example of a pair of upper and lower molds.

FIG. 3 is a perspective view of a molded body that is molded using the mold of FIG.

FIG. 4 is a view showing how the mold upper and lower members are closed.

FIG. 5 is a diagram showing how the upper and lower mold members are split.

FIG. 6 is a perspective view showing a modified example of a pair of upper and lower molds.

7 is a perspective view of a molded body that is molded using the mold of FIG.

[Explanation of symbols]

(1): Roving stand for reinforcing fiber bundle (2): Rewinding roll for rewinding continuous string mat (3): Resin impregnation tank (4): Guide (5): Infeed (6) : Die mold (7): Cold air circulation chamber (8): Take-up rolls (9) (10): Pair of upper and lower molds (9a) (9b): Upper mold member (10a) (10b): Lower mold Material (11): Cutter

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Claims (1)

[Claims] 1. A continuous fiber impregnated with a thermosetting resin,
By a molding method in which the upper and lower members of the mold are clamped by closing the upper and lower members of the mold that are paired up and down and the mold is moved by a predetermined distance in the pulling direction, and then the upper and lower members of the mold are split. When manufacturing a fiber reinforced resin molded product in which a groove type reinforcing portion is formed in a direction different from the longitudinal direction of the molded product, a predetermined number of upper and lower members are respectively combined into a rotating endless mold, By repeating the above-mentioned series of closing, moving for a predetermined distance, and splitting process, the fiber reinforced resin is continuously taken up, and at least one of the predetermined number of upper members has a closing surface with the lower member. In addition, a convex portion or a concave portion is formed, and the lower member paired with the upper member has a concave portion or a convex portion which can be fitted with the convex portion or the concave portion on the closing surface with the upper member. Part is formed, and by closing such upper and lower members By sandwiching the fat-impregnated continuous fibers, characterized by shaping the groove-shaped reinforcing portion, method for producing a fiber-reinforced resin molded body.