JPS605454B2 - Composite manufacturing method - Google Patents

Description

[Detailed description of the invention] The present invention relates to a method for manufacturing composite materials.

Composite materials such as plates and rods made of glass fiber reinforced plastic (FRP) have high strength and rigidity, as well as excellent electrical insulation and corrosion resistance, so they are becoming popular for various uses.

The method for manufacturing this composite material involves uniformly and continuously advancing preheated glass fibers in a molding channel, and filling the molding channel with a thermosetting resin to impregnate the glass with the resin. A method is known in which the composite material is continuously manufactured by integrally curing these materials while progressing through a heat-curing section of a forming path.

Methods using such injection molding methods have advantages such as scales that can set the cross-sectional shape arbitrarily and good molding accuracy, but conventional methods use resin A and reinforcing fibers from the outer periphery of the member to the inside. Fill B uniformly over the entire cross section (
(See FIG. 1) Therefore, it is difficult to manufacture products with large cross sections, and there are also restrictions on the selection of resin, which depends on strength and weight.

On the other hand, a manufacturing method by winding is also known, but this method has the disadvantage of poor molding accuracy. The present invention maintains the advantages of the injection molding method, divides the member into an inner core part and an outer layer part, and forms a fiber-reinforced resin layer around the outer periphery of the core material to produce a composite material, which improves strength and weight. It enables the optimum combination of core material and resin for molding, etc., and significantly improves the versatility and economic efficiency of composites.The structure is such that the molding path is provided with a child heating section and a heat curing section according to the direction of movement, and the molding While the reinforcing fibers are made to advance continuously in the passage, a thermosetting resin is filled in the passage in the preheating section, and this is integrally cured while it advances through the heat curing section, so that the fiber reinforcement material is continuously made. In the manufacturing method, the core material is continuously advanced into the molding passage, reinforcing fibers are uniformly advanced into the gap between the core material and the molding passage and integrally with the core village, and the reinforcing fibers are made to advance uniformly into the gap between the preheating section. filled with thermosetting resin,
The core material is characterized in that it is integrally heated and cured while it progresses through the heat-curing section, and a resin layer is continuously formed to cover the outer periphery of the core material.

A method for manufacturing a composite material according to the present invention will be explained in detail based on an embodiment shown in the drawings. In this example, a round bar material is manufactured. First, the configuration of an apparatus embodying the present invention will be explained.

A cylindrical mold 5 is installed substantially horizontally, and the inside of the mold 5 forms a molding passage 20. The first half of the molding path 20 is preheated to preheat the reinforcing fibers, and the second half is maintained at a temperature higher than the curing temperature of the resin by a heater 7 embedded in the mold 5 to harden the thermosetting resin. Ru. That is, the first half of the molding passage 20 becomes the child heating section 30, and the second half becomes the heating hardening section 31. Note that the mold 5 is held by an external support (not shown). The rod-shaped core material 1 is fed coaxially and continuously to the molding path 201.

The core material 1 is always held at a fixed position, that is, coaxially with the forming path 20, by a feed roller 2 that rolls into contact with the outer peripheral surface of the core material 1. In addition, when the formation of the core village 1 and the production of the composite material of the present invention are performed continuously, the core material 1 is continuously fed by, for example, an extrusion molding line (not shown) in the previous step. be done. The core village 1 has a substantially smaller diameter than the molding passage 20, so that a gap of a constant width is formed between the outer peripheral surface of the core material 1 and the inner peripheral surface of the mold 5. This gap is the outer layer 10
This becomes the outer layer passage 21 that forms the outer layer. The width of the outer layer passage 21 is the thickness of the outer layer 10, and the cross-sectional shape of the core material 1 is the same as the cross-sectional shape of the inner core, so the width of the gap and the core material 1 are the same.
The cross-sectional shape of is set appropriately. A glass woven roving 3 along the axial direction is continuously introduced into the outer layer passage 21 as an outer layer fiber, integrally with the core material 1.

The roving 3 is arranged at a predetermined position by a silk-like or hole-like guide 4, that is, so as to be uniformly supplied into the outer layer passage 21. The fibers for the outer layer are not limited to fibers along the axial direction, for example, the fibers for the outer layer may be formed by wrapping the fibers around the core material 1 using a winding device or the like alone or together with the fibers along the mari direction. It's okay. In addition to roving, strand, mat, and cross-like fibers may be used alone or in combination, and not only glass fiber but also other inorganic or organic fibers such as carbon fiber,
Asbestos fibers, nylon fibers, etc. may be used in combination or as a whole. Note that the guide 4 is made of iron, plastic, ceramic, or the like. The mold 5 is provided with an injection port 22 for injecting a thermosetting resin, that is, an unsaturated polyester resin, which will become the outer layer into the outer layer passage 21 of the child heating section 30, and the resin is provided inside the mold 5. supply path 23
The resin is then fed at high pressure from the resin feeding device 8.

The injection ports 22 are preferably arranged along the circumference of the outer layer passage 21 so that the resin is uniformly injected into the outer layer passage 21. Further, a cooling device 6 is provided at the boundary between the peak preheating section 30 and the heat curing section 31, and the mold 4 for molding the composite material is provided with a cooling device 6.
The cooling device 6 in which 0 is formed prevents the high heat of the heat curing section 31 from being transmitted to the child heat section 30' and hardening the resin in the child heat section 30, particularly in the vicinity of the injection port 22. . A take-off device 9 is provided in front of the outlet of the mold 40 for molding the composite material, and the take-off device 9 has a roller that rolls into contact with the outer peripheral surface of the molded composite material, and the take-off device 9 has a roller that rolls into contact with the outer peripheral surface of the molded composite material.
1, the composite material in which the resin layer and the core material 1 have been integrally heat-molded is continuously pulled out from the composite material molding die 40, and the outer layer fibers and the core material are pulled together by the drawing, and the molding is performed. Introduced into the passage 20. The outer layer fibers drawn into the forming passage 20 are preheated while traveling through the outer layer passage 21 of the child heating section 30.

Due to this thermal heating, the air held by the fibers expands, separates from the fibers, and is discharged from the passage entrance. Unsaturated polyester resin is injected and filled into the outer layer passage 21 from the injection port 22, and the outer layer fibers are impregnated with the resin. Of course, the temperature in the preheating section 30 is maintained lower than the curing temperature of the thermosetting resin, but it is in a temperature range that allows sufficient impregnation of the resin and removal of the air contained therein. If preheating is performed sufficiently, the viscosity of the resin will be low, so the fibers will not be misaligned in the passage during injection, and the impregnation of the fibers will proceed quickly, and the air held by the fibers will be reduced. can be easily discharged, and the length of the heat-curing section 31 can also be shortened. Note that the pressure for injecting the resin is set to such a level that the resin does not spray out from the passage entrance. The resin filled into the outer layer passage 21 forms the outer layer 10 integrally with the outer layer fibers while remaining uncured, and advances in the molding passage 20 integrally with the core village 1 to enter the heat-curing section 31. . While proceeding through the heat-curing section 31, the uncured outer layer 10 is integrally cured, and by the time it reaches the exit of the heat-curing section 31, it is completely cured to form a composite with the core material 1 as the inner core. material is manufactured. The composite material is continuously pulled out from the composite material molding die 40 by the dealing device 9. Note that if the composite material is not completely cured even after being pulled out from the mold 40, it is heated by irradiation with far infrared rays or the like to completely cure the composite material. Further, in this embodiment, an FRP layer is used for the outer layer 10, but the present invention is not limited to this, and other inorganic or organic fiber-reinforced plastic layers may be used. In addition to the wood used in this embodiment, the core material 1 may be made of a wood composite, a synthetic resin molded product, a foamed resin molded product, a resin mortar molded product, iron, copper, aluminum, or the like. Furthermore, since the core material 1 is supported before and after the molding path 20 by the feed rollers 2 and the take-up device 9, it does not necessarily require high strength, so it can be used even with thick powder solidified with a binder. Since curing takes place within the passage within a short time, even materials that are not very heat resistant or insect resistant to resin can be used as the core.
Furthermore, the surface of the core material 1 does not need to be smooth, so the wood or the like may be mirror-polished, and it is also possible to add lip-like protrusions or vertical stripes to the surface.
On the other hand, when manufacturing a product with a large cross section, the inner core can be divided into several parts as shown in FIG. 3b. As described above, in the present invention, the selection range of the core material is extremely wide. Next, the present invention can also be applied to surface treatment of metal materials.

That is, it is carried out in the same manner as in the case of manufacturing the above-mentioned composite material using steel, copper, or aluminum as the core material. In this case, since the surface of the metal material is coated with a fiber reinforced resin layer, corrosion resistance, coin resistance, chemical resistance, insulation properties, etc. are imparted, and mechanical strength is also improved. In the present invention, since the hardened resin is continuously pulled out from the molding passage together with the core material, the resin and the core material in the molding passage advance integrally and continuously.
Therefore, composite materials of arbitrary length can be manufactured.

Furthermore, since the outer layer is heat-formed while in contact with the surface of the mold, a composite material with a smooth outer circumferential surface and dimensional accuracy can be manufactured. In addition, since the component is divided into an outer layer and an inner core, and the outer layer is coated on the outer peripheral surface of the core material, a wide variety of resins can be selected for the core and outer layer. As a result of being able to select and roughly match the most suitable core material and resin, strength, weight, heat resistance, and other physical properties can be significantly improved. In addition, the cross-sectional shape can be arbitrarily set, and by changing the thickness of the inner and outer layers, there is a great deal of room for designing rational properties depending on the application. Several examples of such cross-sectional shapes are shown in FIG. However, only figure f shows a state in which the reinforcing fibers are uniformly arranged, and the same is true for figures a to e and g.

[Brief explanation of drawings]

Fig. 1 is a cross-sectional diagram of a conventional composite material, Fig. 2 is a schematic diagram of an embodiment of the method for manufacturing a composite material according to the present invention, and Fig. 3 a to g.
is a cross-sectional shape diagram of a composite material. In the drawing, 1 is a core material, 1 is a feed roller, 3 is a glass fiber roping, 4 is a guide, 5 is a cylindrical mold, 6 is a cooling device, 7 is a heater, 8 is a resin feeding device, 9 is a take-up device , 10
is an outer layer, 20 is a molding passage, 21 is an outer layer passage, 22 is a resin outlet, 23 is a resin supply passage, 30 is a child heating section, 31 is a heat curing section, A is a thermosetting resin, and B is a reinforcing fiber. . Figure 2 Figure 3

Claims (1)

[Claims] 1. A preheating section and a heat curing section are provided in the molding path according to the direction of movement, and reinforcing fibers are made to advance continuously in the molding path, while a thermosetting resin is filled in the path of the preheating section,
In a method for continuously manufacturing a fiber reinforcing material by integrally curing the fiber reinforcement material while progressing through the heating and curing section, the core material is continuously advanced into the forming path, and the core material and the forming path are bonded together. The reinforcing fibers are advanced uniformly into the gaps and integrally with the core material, while the gaps in the preheating section are filled with a thermosetting resin, and while the reinforcing fibers are advancing through the heat curing section, they are heated and cured integrally. A method for manufacturing a composite material, which comprises continuously forming a resin layer around the outer periphery of a core material.