JPWO2013172345A1 - 車両用空調装置のカバーの製造方法 - Google Patents
車両用空調装置のカバーの製造方法 Download PDFInfo
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- 239000011151 fibre-reinforced plastic Substances 0.000 claims abstract description 13
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- 229920005989 resin Polymers 0.000 claims description 43
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- 239000000463 material Substances 0.000 claims description 12
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- 229920001187 thermosetting polymer Polymers 0.000 claims description 6
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 claims description 5
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Abstract
Description
一方で、発泡材をコアとするFRP(繊維強化プラスチック)サンドイッチパネルは、剛性を保ちつつ軽量化が可能であり、かつ断熱性に優れていることが知られている(例えば、特許文献2参照)。
湾曲形状の成形型上に、独立気泡を有するコア及び繊維を両端部で2点支持された状態で中間部が撓んで弾性変形させて腑型する腑型工程と、
前記成形型と前記コアとの間に形成された密閉空間に真空引きにより前記樹脂を注入し、前記繊維に樹脂を含浸させる含浸工程と、
前記樹脂を硬化後、前記成形型から前記カバーを脱型する脱型工程と、を備えている。
また、コアは、湾曲形状に弾性変形されているので、コアが弾性変形していないカバー、即ちコアを予め熱的変形、切削加工または成型金型による変形を施したカバーと比べ、外力に対して反発力が大であり、耐荷重が増大する。
図1はこの発明の実施の形態1による鉄道車両用空調装置のカバー9,10を装着した鉄道車両用空調装置を示す平面図である。但し、図においてカバー9,10の右半分は切り欠かれている。
この鉄道車両用空調装置は、車両の天井部に搭載されており、車両室内側と連通した室内ユニット部1と、室外ユニット部2と、室内ユニット部1及び室外ユニット部2を収納した筐体3と、室内ユニット部1及び室外ユニット部2をそれぞれ覆い、外気に晒された、室内カバー9及び室外カバー10を備えている。
室内カバー9及び室外カバー10は、図2に示すように、矩形状であって上方に曲率1500mm以上2500mm以下で突出した曲面を有する湾曲形状であり、車両限界を考慮すると空間を最大限利用するためには1800mmが適している。
この室内カバー9及び室外カバー10は、室内ユニット部1及び室外ユニット部2からなる空気調和機本体を覆っている。
室内ユニット部1は、室内送風機4及び室内熱交換器5を有している。
室外ユニット部2は、室外送風機6、室外熱交換器7、圧縮機8を有している。
室外カバー10は、真空含浸成形法(VaRTM:Vacuum assist Resin Transfer Molding)で製造されており、断熱性を有する独立気泡を有する発泡材からなるコア11と、この湾曲形状に弾性変形されたコア11の全面を覆った繊維強化プラスチック(FRP 以後FRPと呼ぶ。)からなる表皮部材12と、コア11の上面と表皮部材12との間に介在した樹脂拡散媒体13と、表皮部材12の上面を被覆したゲルコート14とからなり、それぞれは一体化されている。
このFRPは、軽量性、機械的特性、熱的特性、光的特性、成形方法の自由度の点で優れた炭素強化繊維に母材樹脂であるビニルエステル樹脂が含浸されたものである。
なお、強化繊維として、ガラス繊維、アラミド繊維、ケブラー繊維、ボロン繊維、アルミナ繊維等であってもよい。
また、母材樹脂として、ビニルエステル樹脂の代りに、熱硬化性のエポキシ樹脂、不飽和ポリエステル樹脂、フラン樹脂、ポリウレタン樹脂等であってもよい。
繊維は、短繊維、長繊維等があるが、機械的特性の観点から長繊維が用いられ、形態としては織物繊維が用いられている。
コア11の縦弾性率は、後述する製造工程で受ける大気圧での変形を許容範囲に抑えることができ、かつコア11を所定の曲率に変形できるようなものを採用する。
変形は真空引きした際にコア11が受ける大気圧や錘等の外力を用いてもよいが、より好ましくは自重により所定の曲率の湾曲形状に変形するものがよい。
具体的には縦弾性率Eを所定形状の曲率R、長さl、厚さt、幅b、密度ρ、大気圧P、寸法許容差fを用いて下式で得られる値の範囲とする。
この材質は、熱的、機械的な観点から炭素繊維が用いられている。
なお、樹脂拡散媒体13の材質は、ガラス繊維、アラミド繊維、ケブラー繊維、ボロン繊維、アルミナ繊維、熱硬化性のエポキシ樹脂、不飽和ポリエステル樹脂、ビニルエステル樹脂、フラン樹脂、ポリウレタン樹脂、熱可塑性のナイロン、PBT,ABS等であってもよい。
なお、ゲルコート14の材質は、熱硬化性のエポキシ樹脂、ビニルエステル樹脂、フラン樹脂、ポリウレタン樹脂等でもよい。
先ず、テフロン(登録商標)コーティングで離型処理された成形型15の上にゲルコート樹脂を、スプレーガンを用いて塗布してゲルコート14を形成する。
次に、ゲルコート14の上に織物繊維16を所定の方向に所定の枚数、積層する。
この後、樹脂拡散媒体13を積層する。この樹脂拡散媒体13は、織物繊維16とゲルコート14の間や織物繊維間に積層してもよいが、意匠性の点から織物繊維16とコア11との間に配置する。
こうして、成形型15上に、織物繊維16、樹脂拡散媒体13及びコア11を順に腑型する腑型工程では、図4に示すように、コア11は、自重により1800mmの曲率の成形型15に沿うように変形する。
その上にピールプライ17を積層し、その上に樹脂拡散媒体13を配置する。
次に、真空ポンプの空気の吸引口18と樹脂タンク(図示せず)からの注入される樹脂の注入口19をそれぞれ成形型15に取り付け、全体をバギングフィルム20で覆い、空気が漏れないようにバギングフィルム20の周囲を、シーラント21で成形型15に接着させる。
この後、真空ポンプを用いてバギングフィルム20で覆われた織物繊維16を含めた内部を、真空状態にしたのち、バルブを解放して樹脂を注入する。
この含浸工程の後、バルブを閉口し樹脂を硬化させる。
なお、室内カバー9についても、室外カバー10と同じ方法で製造される。
また、コア11は、自重による弾性変形で湾曲形状に変形されているので、コアが弾性変形していないカバー、即ちコアを予め熱的変形、切削加工または成型金型による変形を施したカバーと比べ、外力に対して反発力が大であり、耐荷重が増大する。
また、成形型15上に、コア11を腑型する腑型工程では、コア11は、常温で、自重により湾曲に変形され、コア11を変形するに際して熱的加工、切削工程が不要となり、カバー9,10の生産性が向上し、また金型コストが高い曲面形状を有する成型金型を用いずに湾曲形状に形成されており、低コストで生産される。
錘を用いた場合には、目的の曲率まで変形させても破損しない材料を用いればよい。
また、ここでは錘を例に外力を説明したが、真空引きやオートクレーブ等の圧力、磁力、粘着力などの外力を用いても実現できる。
湾曲形状の成形型上に、独立気泡を有するコア及び繊維を両端部で2点支持された状態で中間部が撓んで弾性変形させて腑型する腑型工程と、
前記成形型と前記コアとの間に形成された密閉空間に真空引きにより前記樹脂を注入し、前記繊維に樹脂を含浸させる含浸工程と、
前記樹脂を硬化後、前記成形型から前記カバーを脱型する脱型工程と、を備えている。
Claims (11)
- 車両の天井部に搭載される、室内ユニット部及び室外ユニット部からなる空気調和機本体を覆う、車両用空調装置のカバーであって、
前記カバーは、断熱性を有する発泡材からなるコアと、このコアの全面を覆った繊維に樹脂が含浸した繊維強化プラスチックからなる表皮部材と、を備え、
前記コアは、弾性変形で湾曲形状に変形されている車両用空調装置のカバー。 - 前記繊維は、炭素繊維である請求項1に記載の車両用空調装置のカバー。
- 前記表皮部材及び前記コアは、難燃性である請求項1または2に記載の車両用空調装置のカバー。
- 前記コアは、熱硬化性樹脂で構成されている請求項1〜3の何れか1項に記載の車両用空調装置のカバー。
- 前記車両用空調装置は、鉄道車両用空調装置である請求項1〜4の何れか1項に記載の車両用空調装置のカバー。
- 前記表皮部材及び前記コアは、鉄道車両用材料燃焼試験における難燃性の合格基準を超えている請求項5に記載の車両用空調装置のカバー。
- 請求項1に記載の車両用空調装置のカバーを製造する製造方法であって、
湾曲形状の成形型上に、独立気泡を有する前記コア及び前記繊維を両端部で2点支持された状態で中間部が撓んで弾性変形させて腑型する腑型工程と、
前記成形型と前記コアとの間に形成された密閉空間に真空引きにより前記樹脂を注入し、前記繊維に樹脂を含浸させる含浸工程と、
前記樹脂を硬化後、前記成形型から前記カバーを脱型する脱型工程と、を備えている車両用空調装置のカバーの製造方法。 - 前記腑型工程において、前記コアを常温で、自重により弾性変形させる請求項7に記載の車両用空調装置のカバーの製造方法。
- 前記腑型工程において、前記コアを常温で、外力により弾性変形させる請求項7に記載の車両用空調装置のカバーの製造方法。
- 前記コアは、その縦弾性率が9〜33MPaである請求項9に記載の車両用空調装置のカバーの製造方法。
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