WO2010089863A1

WO2010089863A1 - Process for producing tubular structure made of fiber-reinforced resin and tubular structure made of fiber-reinforced resin

Info

Publication number: WO2010089863A1
Application number: PCT/JP2009/051891
Authority: WO
Inventors: 広道佐野; 一長瀬; 隆一藤井
Original assignee: サカイ・コンポジット株式会社
Priority date: 2009-02-04
Filing date: 2009-02-04
Publication date: 2010-08-12
Also published as: CN102282007A; JPWO2010089863A1; JP4827206B2

Abstract

A process for producing a tubular structure made of a fiber-reinforced resin is provided in which a drawing operation in the molding of a molding intermediate is facilitated and wall thickness can be inhibited from increasing. A strength improvement can also be attained. Also provided is a tubular structure made of a fiber-reinforced resin. Solid grip parts (23) are formed integrally with both width-direction edges of a tubular intermediate molding (15), each grip part (23) protruding outward in the width direction and continuously extending in the lengthwise direction. The inner surfaces of a pair of upper and lower holding dies (11, 12) are brought into contact with the surfaces of the intermediate molding (15) which has been cured. The grip parts (23) are sandwiched between the holding dies (11, 12) and this intermediate molding (15) in a compressed state is moved downstream over a given distance. A continuous carbon-fiber woven fabric including carbon fibers as the warp and impregnated with an uncured resin is inserted into the tubular molding space between a molding die and a core, and is drawn over a given distance from the upstream side to the downstream side while heating the impregnated woven fabric and applying a tension thereto. The resultant tubular intermediate molding (15) obtained through thermal curing is successively conveyed downstream and cut into a given length.

Description

Manufacturing method of cylindrical body made of fiber reinforced resin and cylindrical body made of fiber reinforced resin

The present invention relates to a method for manufacturing a fiber reinforced resin tubular body and a fiber reinforced resin tubular body. More specifically, the present invention facilitates a drawing operation when forming a molding intermediate and increases the wall thickness. The present invention relates to a method for manufacturing a cylindrical body made of a fiber reinforced resin and a cylindrical body made of a fiber reinforced resin capable of improving the strength while suppressing.

Conventionally, a cylindrical body made of fiber reinforced resin has been used as a top plate for X-ray photography. In order to produce such a cylindrical body, a core is inserted into a molding die, and a cylindrical molding gap formed between the molding die and the core is impregnated with an uncured resin. The cylindrical intermediate molded body is molded and heat-cured by sequentially pulling out a predetermined length from the upstream side to the downstream side while applying the carbon fiber woven fabric and applying tension, and the cured intermediate molded body is sequentially It is conveyed downstream and cut into a predetermined length (see Patent Document 1).

In this manufacturing process, the drawing operation is performed in a state where the cured intermediate molded body is sandwiched and held from above and below. When a long carbon fiber fabric impregnated with uncured resin is pulled through a molding die, a certain amount of pulling force is required, and the intermediate molded body is sandwiched from above and below accordingly. Need to hold in.

中間 Since the intermediate molded body is hollow, it is easily deformed by the pressure held and held during the drawing operation. In order to prevent this deformation, it is necessary to increase the wall thickness of the hollow part of the intermediate molded body, and the produced fiber-reinforced resin tubular body has a wall thickness that is larger than actually required. There was a problem of becoming a specification.

For example, when the manufactured cylindrical body is used as a top plate for CT or general X-ray photography, the wall thickness becomes larger than necessary, so that X-ray transmission loss increases and precise image data can be obtained. The problem of disappearing arises. Further, if the pressure to hold the intermediate molded body is small, the drawing force cannot be increased, so that the drawing operation becomes difficult, and it becomes difficult to improve the straightness R of the warp yarn of the fiber reinforced resin. It was disadvantageous for improving the strength of the cylindrical body.
Japanese Unexamined Patent Publication No. 2003-319936

An object of the present invention is to provide a method for producing a tubular body made of a fiber-reinforced resin that facilitates a drawing operation when molding a molding intermediate and can improve strength while suppressing an increase in wall thickness, and fiber reinforcement. The object is to provide a cylindrical body made of resin.

In order to achieve the above object, the method for producing a cylindrical body made of fiber reinforced resin according to the present invention inserts a core into a space penetrating the molding die linearly, and between the molding die and the core. By inserting a long carbon fiber woven fabric impregnated with at least uncured resin whose warp is carbon fiber into the formed cylindrical forming gap and pulling it out sequentially from the upstream side to the downstream side while applying tension. A cylindrical intermediate molded body in which the front plate and the back plate are opposed to each other with a space therebetween and the both ends in the width direction are connected to each other is molded and heat-cured, and the cured intermediate molded products are sequentially downstream. To produce a cylindrical body by cutting it to a predetermined length, and to make the straightness R of the warp yarn defined on the basis of the center line passing through the center in the width direction of the cylindrical body to be 90% or more A method of manufacturing a cylindrical body made of resin, wherein the intermediate molded body is formed. In order to cover the surface of the cured intermediate molded body, a solid gripping part protruding outward in the width direction and continuous in the longitudinal direction is integrally formed at both ends in the width direction of the intermediate molded body. Further, the inner surfaces of the upper and lower pair of holding dies are brought into contact with the surface of the intermediate molded body, and the cured gripping portion is sandwiched and compressed by the pair of upper and lower holding dies. By moving a predetermined length downstream from the upstream side to the downstream side while applying a new carbon fiber fabric to the forming gap and applying tension to the forming gap. It is.

Here, after the cured gripping part is compressed by being sandwiched between a pair of upper and lower holding molds and moved to a downstream side by a predetermined length, the gripping part sandwiched by the pair of upper and lower holding molds may be cut. it can. The portion obtained by cutting the grip portion can be reinforced with a reinforcing material made of fiber reinforced resin. Two pairs of upper and lower holding molds are arranged at an interval in the moving direction of the intermediate molded body, and compressed by sandwiching the cured gripping portion of the intermediate molded body with a pair of upstream upper and lower holding molds A first moving step of moving the pair of downstream upper and lower holding molds upstream by a predetermined length without sandwiching the cured gripping part of the intermediate molded body, Following one moving step, the pair of upper and lower holding molds on the downstream side are compressed while sandwiching the cured gripping part of the intermediate molded body and moved downstream by a predetermined length, and the pair of upper and lower holdings on the upstream side are held. And a second moving step of moving the mold upstream by a predetermined length without sandwiching the cured gripping part of the intermediate molded body, and inserting the new carbon fiber fabric into the molding gap. From the upstream side while applying tension. It may be pulled out successively a predetermined length to the side. Wherein the tension of the carbon fiber woven fabric just prior to insertion into the molding gap, for example, to 5N / mm ² or more 980 N / mm ² or less.

The cylindrical body made of fiber-reinforced resin of the present invention is formed in a cylindrical body in which the long front plate and the back plate are opposed to each other with a gap therebetween, and both ends in the width direction are connected to each other. The front plate and the back plate are made of a fiber reinforced resin having at least a carbon fiber woven fabric whose warp is carbon fiber as a main reinforcing material, and the warp is linearly parallel to the longitudinal direction of the front plate and the back plate. A tubular body made of fiber reinforced resin, wherein the straightness R of the warp yarns is 90% or more, and is defined with reference to a center line passing through the center in the width direction of the tubular body, the width direction of the tubular body Both ends have solid gripping portions that protrude outward in the width direction and are continuous in the longitudinal direction, and the gripping portions are integrally formed of the fiber reinforced resin, and the width of the cylindrical body The width direction length is 1.0% or more and 8.0% or less of the width of the cylindrical body at both ends in the direction. It is characterized in that the solid portions of the is formed.

Further, in another tubular body made of fiber reinforced resin of the present invention, both end portions in the width direction of the tubular body protrude outward in the width direction formed integrally with the fiber reinforced resin in the longitudinal direction. A continuous solid gripping part is formed by cutting.

In the cylindrical body of the present invention, the part obtained by cutting the grip portion can be made to be reinforced with a reinforcing material made of fiber reinforced resin. The carbon fiber woven fabric may be a bamboo woven fabric having a weft density of 1 / cm or less, and the weft of the woven fabric may be made of organic fibers of 50 dtex or more and 350 dtex or less. It is also possible to have a specification in which a plurality of the interwoven fabrics are stacked and a complete carbon fiber fabric in which the warp and weft are both carbon fibers is inserted between any two interwoven fabrics. The complete carbon fiber woven fabric may have a specification that is arranged so as to straddle both sides of the front plate and the back plate. The full carbon fiber fabric having a width wider than the width of the plate may be inserted into one of the front plate and the back plate, and both ends of the complete carbon fiber fabric may be folded back to the other plate side. .

According to the present invention, the front plate and the back plate are opposed to each other with a space therebetween, and projecting outward in the width direction at both ends in the width direction of the cylindrical intermediate molded body in which the both ends in the width direction are connected to each other. Since the grip portion that is continuous in the longitudinal direction is integrally formed and the grip portion is solid, the grip portion cured by the pair of upper and lower holding molds can be firmly sandwiched. As a result, the drawing operation can be performed while holding only the solid gripping portion with a sufficiently large pressure without applying an excessive pressure to the hollow portion of the cured intermediate molded body.

Therefore, it is not necessary to consider the strength when the hollow portion of the intermediate molded body is sandwiched and held between the pair of upper and lower holding molds, and the wall thickness can be minimized. Accordingly, when the manufactured cylindrical body is used for a CT or a general X-ray imaging top plate, X-ray transmission loss can be reduced, and more precise image data can be obtained. Is possible.

Also, since the hardened gripping portion can be sandwiched and held with a large pressure, the pulling force can be increased as compared with the conventional case, and the pulling operation becomes easy. Along with this, it becomes easy to improve the straightness R of the warp of the carbon fiber fabric to 90% or more, which contributes to the improvement of the strength of the produced cylindrical body.

FIG. 1 is an overall schematic diagram illustrating the production process of a fiber-reinforced resin tubular body of the present invention. FIG. 2 is a side view illustrating the drawing device of FIG. 3 is a cross-sectional view taken along the line AA in FIG. 4 is a cross-sectional view taken along the line BB of FIG. FIG. 5 is a side view illustrating a drawing operation (first movement step) by the drawing device of FIG. FIG. 6 is a side view illustrating a drawing operation (second movement step) by the drawing device of FIG. FIG. 7 is a cross-sectional view illustrating an embodiment of the cylindrical body of the present invention. FIG. 8 is a plan view of FIG. FIG. 9 is a cross-sectional view illustrating another embodiment of the cylindrical body of the present invention. FIG. 10 is a cross-sectional view illustrating another embodiment of the cylindrical body of the present invention. FIG. 11 is an explanatory diagram of a method for measuring the straightness R of the warp yarn defined in the present invention. FIG. 12 is a cross-sectional view illustrating the structure of the front and back plates of the cylindrical body of the present invention. FIG. 13 is a cross-sectional view illustrating another structure of the front and back plates of the cylindrical body of the present invention. FIG. 14 is a cross-sectional view illustrating the structure of the cylindrical body of the present invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 2 Resin liquid tank 4 Mold 4a Core 5 Pull-

out apparatus

5a, 5b Puller 6 Vertical moving cylinder 11 Upper holding mold 12 Lower holding mold 15 Intermediate molded body 16 Heating furnace 17 Cutting machine 20 Top plate (tubular body )
21 Front plate 22 Back plate 23 Grip portion 23a Reinforcement material 24 Weave fabric 25 Complete carbon fiber fabric 26 Unidirectional carbon fiber sheet

Hereinafter, the manufacturing method of the cylindrical body made of fiber reinforced resin and the cylindrical body made of fiber reinforced resin of the present invention will be described based on the embodiments shown in the drawings. In the embodiment, a case where the cylindrical body is a top plate used for CT (Computed Tomography) or general X-ray imaging will be described as an example.

As illustrated in FIGS. 7 and 8, the top plate (tubular body) 20 of the present invention is made of fiber reinforced resin, and the long front plate 21 and the back plate 22 are opposed to each other with a space therebetween. It has a hollow shape in which both end portions in the width direction are connected to each other. The front plate 21 and the back plate 22 are made of a fiber reinforced resin having at least a carbon fiber fabric whose warp is carbon fiber as a main reinforcing material, and the warp is linearly parallel to the longitudinal direction of the front plate 21 and the back plate 22, respectively. Are arranged in a shape. And the straightness R of the warp defined with reference to the center line CL passing through the center of the top plate 20 in the width direction is 90% or more. In FIG. 8, the warp is schematically shown by a solid line, and the weft is schematically shown by a broken line.

In the present invention, the straightness R refers to the total average value of the values measured and calculated at 10 locations on one side of the top board 20 by the following measurement method.

That is, as shown in FIG. 11, each of the front plate 21 and the back plate 22 of the top plate 20 is divided into 10 equal parts in the width direction, and is centered in the width direction and at the center position in the longitudinal direction, When the center line passing through the center in the width direction of the body 20 is a reference line CL, two straight lines S1 and S2 having a length of 1 m parallel to the reference line CL are drawn at an interval of 40 mm, and the straight lines S1 and S2 are drawn. A long and narrow rectangle A is cut out by connecting both ends of each of the two by short lines T1 and T2.

Next, after cutting out the section of the rectangle A (10 pieces in total) of each band having a size of 1 m × 40 mm cut out in this way to remove the resin component, either one of the short lines T1 and T2 at both ends (For example, T1) is clamped, and the carbon fiber bundle that is in an unconstrained state at the unclamped portion is shaken off. Next, the number N1 of carbon fiber bundles (warps) constrained by the clamp portion and the number N2 of carbon fiber bundles (warps) remaining in the portion of the short line (T2) on the opposite side are counted, and N1 and N2 To calculate the straightness defined by the following equation.
(N2 / N1) x 100 (%)

This measurement and calculation are performed on the above ten intercepts, and the total average value of the ten straightnesses is defined as straightness R in the present invention.

The top plate 20 has solid gripping portions 23 protruding outward in the width direction and continuous in the longitudinal direction at both ends in the width direction, and the gripping portions 23 are integrally formed of fiber reinforced resin. By forming the grip portion 23, solid portions having a width direction length W1 of 5 mm or more and 30 mm or less are formed at both ends of the top plate 20 in the width direction. The thickness T of the solid portion is, for example, 4 mm or more and 20 mm or less.

The top plate 20 is formed in a rectangular shape in plan view, but when used for CT or X-ray imaging, the cross-sectional shape orthogonal to the longitudinal direction is a flat tube that is curved in an arc shape to place the human body in a stable state. The shape is preferred. The size of the top plate 20 is generally in the range of 190 to 350 cm in the longitudinal direction and 35 to 50 cm in the width direction in plan view.

The cross section perpendicular to the longitudinal direction of the top plate 20 has a crescent shape in which the upper side of both the front plate 21 and the back plate 22 is curved in a concave arc shape, and both ends in the width direction are connected to each other. Further, sealing lids are attached to both ends of the top plate 20 in the longitudinal direction.

As shown in FIG. 12, the front plate 21 and the back plate 22 are formed between two

interwoven fabrics

24, 24 each consisting of a carbon fiber bundle in which the warp is substantially untwisted (twist number is 5 T / m or less). Both the warp and the weft are made of a fiber reinforced resin in which a complete carbon fiber woven fabric 25 composed of carbon fiber bundles is inserted and heat-cured in a state where these woven fabrics are impregnated with a thermosetting resin. The warp of the weave fabric 24 and the warp of the complete carbon fiber fabric 25 are arranged in parallel to the longitudinal direction of the front plate 21 and the back plate 22, respectively, and the straightness R is 90% or more.

The fiber reinforced resin constituting the front plate 21 and the back plate 22 is not limited to the laminated structure of FIG. 12, but may be in the form as shown in FIG. In the form of FIG. 13, the unidirectional carbon fiber sheet 26 is laminated on the surface of the outermost layer of the laminated structure of the carbon fiber fabric of FIG. Since the unidirectional carbon fiber sheet 26 does not have a weft, it is excellent in flatness and smoothness, and the top plate 20 can have a good appearance by being disposed on the outermost side.

The top plate 20 of the present invention may be a complete carbon fiber fabric 25 arranged as shown in FIG. In FIG. 14, one full carbon fiber fabric 25 is inserted between the two

braid fabrics

24, 24 of the back plate 22. The complete carbon fiber fabric 25 has a width wider than the width of the back plate 22, and both

end portions

25e and 25e of the wide width are folded back to the front plate 21 side. In the front plate 21, both

end portions

25 e and 25 e of the complete carbon fiber fabric 25 are overlapped with each other while being sandwiched between the two

bamboo fabrics

24 and 24. Further, both the front plate 21 and the back plate 22 have a unidirectional carbon fiber sheet 26 laminated on the outermost layer.

In the top plate 20 of FIG. 14, the shape stability is improved by the insertion of the complete carbon fiber fabric 25, and warpage and bending are less likely to occur. Furthermore, since both ends 25e and 25e of the complete carbon fiber fabric 25 are folded back so as to straddle between the back plate 22 and the front plate 21, the rigidity of the top plate 20 is improved. Moreover, the external appearance property is improving by arrange | positioning the unidirectional carbon fiber sheet 26 in the outermost layer.

In the top plate 20 of the present invention, when the straightness R is 90% or more, preferably 95% or more, the strength utilization rate of the warp in the carbon fiber fabric used as the main reinforcing material can be improved. As a result, the strength and rigidity (particularly bending rigidity) of the top plate 20 can be improved while reducing the amount of carbon fiber used. In addition, warping and twisting can be reduced, and the top plate 20 having excellent dimensional accuracy can be obtained. Furthermore, the fiber content of the carbon fiber in the fiber reinforced resin can be set to 60% by volume or more, which cannot be achieved with the conventional hand-attached top plate, and only the strength and rigidity of the top plate 20 are improved. In other words, the X-ray transmittance of the top plate 20 is improved, and the captured image can be made clear.

The carbon fiber fabric used in the present invention is a fabric in which at least the warp is made of carbon fiber, and the carbon fiber bundle of the warp is preferably substantially untwisted.

The carbon fiber woven fabric used in the present invention is preferably a blind fabric 24. The weave fabric 24 is characterized in that the weft density is remarkably rough compared to the warp density, whereas the warp density is 5 / cm or more, whereas the weft density is 1 / cm or less, Those having a range of 0.2 to 0.5 / cm 2 are preferably used. When the weft density is higher than 1 / cm, the number of crimps per unit length (number of waveform bends) formed on the warp due to the intersection with the weft increases, and the strength utilization factor of the warp decreases. On the other hand, when it is less than 0.2 pieces / cm, the effect of preventing cracks generated between warp yarns is reduced, and the uniform alignment effect (uniform dispersion effect) on the warp yarns is reduced.

For the weft used in the weave fabric 24, the same carbon fiber as that of the warp may be used, and preferably organic fiber is used. In other words, the weft yarn in the weave fabric 24 used in the present invention suppresses cracks between adjacent warps and prevents the cracks from propagating and growing, thereby reinforcing the reinforcing function of the carbon fiber fabric. This is because it is not necessary to have high strength and high elastic modulus. Although it does not specifically limit as an organic fiber used for a weft, For example, a polyamide fiber, a polyvinyl alcohol fiber, a polyester fiber, an aramid fiber etc. can be used.

When using organic fiber for the weft of the weave fabric 24, the fineness is preferably in the range of 50 to 350 dtex. When the fineness is larger than 350 dtex, a large crimp is formed on the carbon fiber of the warp, so that the strength utilization rate is lowered. On the other hand, if it is smaller than 50 dtex, the effect of suppressing cracks on the warp and the effect of imparting uniform dispersibility of the warp are reduced.

When using the brazing fabric 24 as the carbon fiber fabric, it is preferable to use a plurality of laminated layers. In addition, when a plurality of interlacing fabrics 24 are laminated, at least one complete carbon fiber fabric 25 in which both warps and wefts are composed of carbon fibers may be inserted between any two interlacing fabrics 24. By inserting this complete carbon fiber fabric 25, the shape stability of the top plate 20 is improved, and the occurrence of twisting and warping can be suppressed.

Moreover, it is preferable to arrange | position so that the complete carbon fiber fabric 25 inserted and arrange | positioned between the interwoven fabrics 24 as mentioned above may straddle the width direction both ends of the front board 21 and the back board 22, and may continue between both boards. . Thus, by arrange | positioning so that the front board 21 and the back board 22 may be straddled, the rigidity of the top plate 20 can increase and shape stability can be improved. Further, when inserting the complete carbon fiber fabric 25 in this way, the complete carbon fiber fabric 25 having a width wider than the plate width is inserted into one of the front plate 21 and the back plate 22 on the other plate side. It is preferable to have a structure in which both ends extending on both sides of the plate are folded back to the other plate side and overlapped.

The complete carbon fiber fabric 25 used in combination with the bamboo fabric 24 is not particularly limited in structure as long as both the warp and the weft are made of carbon fiber bundles. Further, both the warp density and the weft density may be 5 pieces / cm or more.

When a plurality of carbon fiber woven fabrics are laminated, particularly when a plurality of interwoven fabrics 24 are laminated, a unidirectional carbon fiber sheet 26 may be laminated on the outermost surface. The unidirectional carbon fiber sheet 26 mainly aims at improving the appearance, and may be a nonwoven fabric or paper made of organic fibers such as polyester fibers and nylon fibers.

Carbon fiber fabric, unidirectional carbon fiber sheet 26, organic fiber non-woven fabric and paper are impregnated with resin to make fiber reinforced resin. As the resin, a thermosetting resin is preferably used. In the case of the present invention, as described above, the strong utilization rate of the warp in the carbon fiber fabric is improved, and therefore, an unsaturated polyester resin, a vinyl ester resin, or the like can be used in addition to the epoxy resin.

Unsaturated polyester resins and vinyl ester resins can easily impart flame retardancy compared to epoxy resins. In addition, since unsaturated polyester resins and vinyl ester resins can be easily made to have low shrinkage as compared with epoxy resins, it is possible to obtain a top plate having further excellent dimensional stability.

Hereinafter, a method of manufacturing the top plate (tubular body) 20 illustrated in FIGS. 7 and 8 using the manufacturing method of the present invention will be described. The manufacturing method of the present invention uses pultrusion molding, and the top plate 20 can be manufactured efficiently and continuously.

As illustrated in FIG. 1, in the manufacturing process, a plurality of reinforcing sheet rolls 18 are supported on a creel stand, and a brake is attached to a support shaft of the creel stand. Thereby, a braking force is applied to the reinforcing sheet drawn out from each roll 18.

One of the two rolls 18 group (the lower side in FIG. 1) is provided with a reinforcing sheet group for forming the front plate 21, and two rolls 18 each wrapped with a carbon fiber tinting fabric 24 are provided. One piece and one roll 18 around which the unidirectional carbon fiber sheet 26 is wound are disposed. Both the blind fabric 24 and the unidirectional carbon fiber sheet 26 are formed to have substantially the same width as the front plate 21. Further, the interwoven fabric 24 is a carbon fiber bundle in which the warp is substantially untwisted, and organic fibers such as polyamide fibers are used for the weft, and the weft density is 1 / cm or less.

The other roll 18 group (upper side in FIG. 1) is a group of reinforcing sheets for forming the back plate 22, and is composed of two rolls 18 each wrapped with a carbon fiber tint fabric 24, and a complete carbon fiber fabric. One roll 18 wound with 25 and one roll 18 wound with the unidirectional carbon fiber sheet 26 are arranged. The blind fabric 24 has the same configuration as that set in one group of rolls 18. Further, the brazing fabric 24 and the unidirectional carbon fiber sheet 26 are formed to have the same width as that of the back plate 22, but the complete carbon fiber fabric 25 is formed to have a width that is twice or more that of the back plate 22. .

On the downstream side of each roll 18 group,

resin liquid tanks

2 and 2 filled with an uncured thermosetting resin liquid are disposed. On the downstream side of the

resin liquid tanks

2 and 2, an impregnation processing unit 3, a molding die 4, a drawing device 5, a heating furnace 16, a cutting machine 17, and a conveyor are installed in this order.
The core 4 a is a long body whose cross section is formed in a crescent shape, and one end in the longitudinal direction is connected to the cylinder 19. The core 4a is configured to move horizontally forward and backward by the operation of the cylinder 19 upstream and downstream.

First, reinforcing sheet groups of a weave fabric 24, a complete carbon fiber fabric 25, and a unidirectional carbon fiber sheet 26, which are pulled out from the respective rolls 18 by applying a brake to the

resin liquid tanks

2 and 2 by a drawing operation of the drawing device 5. To pass an uncured thermosetting resin liquid.

Next, the weave fabric 24 on the side of one of the rolls 18 is placed along the surface (the lower side in FIG. 1) of the core 4a through the guide 14a. Next, the wide carbon fiber fabric 25 with a wide width drawn out from the other roll 18 group side is folded back by the folding guide 14c at both ends, and the surface of the core 4a ( 1 is folded on the surface of the weave fabric 24 along the lower side of FIG.

Next, at the entrance of the impregnation treatment unit 3, the interwoven fabric 24 and the unidirectional carbon fiber sheet 26 on the one side of the roll 18 group are placed on the folded portion of the complete carbon fiber fabric 25 with the interwoven fabric 24 side inside. Is laminated. Further, the reinforcing sheet group of the interwoven fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 on the other roll 18 group side is along the opposite side (the upper surface side in FIG. 1) of the core 4a.

The impregnation processing section 3 is composed of an upper mold and a lower mold, and a crescent-shaped space is penetrated linearly in the front and rear direction inside. When the core 4a passes through the space, an annular throttle gap is formed around the core 4a. The gap width of the narrowing gap is formed to be slightly wider than the gap width of the molding gap of the downstream molding die 4.

When the impregnation processing unit 3 passes the interlining fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26, to which the resin liquid is adhered in the

resin liquid tanks

2 and 2, along the surface of the core 4a, and passes through the narrowing gap. Then, the resin liquid is impregnated inside each. Then, on the outlet side of the impregnation processing unit 3, the interwoven fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 are formed into a laminated state having a crescent-shaped cross section. In this preform, each of the weave fabric 24 and the complete carbon fiber fabric 25 has weft yarns, so that these weft yarns provide lateral displacement resistance with respect to the warp yarn group and are uniformly distributed in the width direction. It is in a state of being aligned parallel to the.

The molding die 4 is composed of an upper die 4 and a lower die, like the impregnation processing section 3, and a crescent-shaped space in the cross section penetrates linearly in the front and rear, and a heating means (heater) is incorporated. ing. When the core 4a passes through this space, an annular forming gap is formed around the core 4a. The core 4 a passes through the molding die 4, and the tip of the core 4 a reaches a position slightly beyond the downstream end surface of the molding die 4.

In the molding die 4, a laminated body of a braid fabric 24, a complete carbon fiber fabric 25, and a unidirectional carbon fiber sheet 26 preformed in a crescent cross section is passed through a molding gap so as to be along the core 4 a and drawn. By pulling out with the apparatus 5 and heat-curing with a heater, it is formed into a flat cylindrical intermediate formed body 15 having a crescent cross section as shown in FIGS.

In this way, a long carbon fiber fabric impregnated with at least uncured resin whose warp is carbon fiber is inserted into the molding gap of the molding die 4, and a predetermined length is sequentially applied from the upstream side to the downstream side while applying tension. Pull out. Thereby, the cylindrical intermediate molded body 15 in which the front plate and the back plate are opposed to each other with a space therebetween and the both ends in the width direction are connected to each other is molded and heat-cured. At both ends in the width direction of the intermediate molded body 15, gripping

portions

23, 23 that protrude outward in the width direction and continue in the longitudinal direction are integrally formed.

When this molding, the tension of the carbon fiber woven fabric just prior to insertion into the molding gap may 5N / mm ² or more 980 N / mm ² to less than. That is, the cord fabric 24 at the inlet side of the molding die 4, complete carbon fiber fabric 25, tension 5 ~ 980N / mm ² of unidirectional carbon fiber sheet 26, preferably 10 ~ 490 N / mm ² or less, more preferably 10 It is good to set it to ˜300 N / mm ² or less. By applying such tension, the interwoven fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet, which are preformed in a crescent cross section in the impregnation processing section 3 between the impregnation processing section 3 and the molding die 4. The straightness R of the warp yarn when the carbon fiber bundles in 26 are straightly arranged to form the top plate 20 can be 90% or more.

When the solder fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 are initially set in the impregnation processing unit 3 and the molding die 4, the core 4 a is upstream from the molding die 4 and the impregnation processing unit 3. If the core 4a is inserted after passing through the interwoven fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet 26 into the space penetrating them, the core 4a can be easily set.

The drawing device 5 is for continuously pulling the cured intermediate molded body 15, and the weaving fabric 24, the complete carbon fiber fabric 25, and the unidirectional carbon fiber sheet on the upstream side of the molding die 4 by the drawing operation. A high tension is generated at 26 so that warps and the like extending in the longitudinal direction are straightened.

2 to 4, the drawing device 5 has a configuration in which a pair of front and

rear pullers

5a and 5b are arranged at intervals in the moving direction of the intermediate molded body 15. Each

puller

5a, 5b is provided with a moving roller 13a on the bottom surface of the lower plate 10, and the upstream puller 5a reciprocates along the upstream half of the stroke at the midpoint of the base 13 in the front-rear direction. The puller 5b reciprocates along the downstream half stroke.

Each of the

pullers

5a and 5b has four support columns 8 erected on the lower plate 10, and a holding plate 7 is fixed to the upper end of each support column 8. A vertical movement cylinder 6 is attached to the holding plate 7, and an upper plate 9 is connected to the tip of a cylinder rod extending downward. Four struts 8 are inserted into the upper plate 9, and the upper plate 9 moves up and down by the operation of the vertical movement cylinder 6.

The upper holding mold 11 is mounted on the lower surface of the upper plate 9, and the lower holding mold 12 is mounted on the upper surface of the lower plate 10. The cross-sectional shape of the lower surface of the upper holding mold 11 is substantially the same arc shape as the outer shape of the cured intermediate molded body 15 on the back plate side (the upper surface side in FIGS. 3 and 4). The cross-sectional shape of the upper surface of the lower holding mold 12 is substantially the same arc shape as the outer shape of the cured intermediate molded body 15 on the front plate side (lower surface side in FIGS. 3 and 4).

The pair of upper and lower holding

molds

11 and 12 are arranged with their arc-shaped surfaces facing each other. By the operation of the vertical movement cylinder 6, the upper holding mold 11 moves so as to be close to the lower holding mold 12 and also moves so as to be separated. Therefore, when the upper holding mold 11 and the lower holding mold 12 are brought into contact with each other, a crescent-shaped space substantially the same as the cured intermediate molded body 15 is formed by the inner surfaces of the pair of upper and lower holding

molds

11 and 12. It is formed.

When performing the drawing operation, first, as illustrated in FIG. 5, the upper holding mold 11 attached to the upstream puller 5 a is moved downward, and the intermediate is cured on the inner surfaces of the pair of upper and lower holding

molds

11, 12. The inner surfaces of the pair of upper and lower holding

molds

11 and 12 are brought into contact with the surface so as to cover the surface of the molded body 15 annularly, and the cured gripping

portions

23 and 23 are held by the pair of upper and lower holding

molds

11 and 12. Put in a compressed state.

At this time, the surface of the hollow portion of the intermediate molded body 15 is such that the inner surfaces of the pair of upper and lower holding

molds

11 and 12 are in light contact with each other, and is substantially free of pressure. . In this state, the puller 5a is moved downstream by a predetermined length. For example, the downstream end of the puller 5a is moved to the intermediate point in the front-rear direction of the base 13.

The compression force by the vertical movement cylinder 6 that moves the upper holding die 11 downward is, for example, about 2200 kgf, and this compression force is applied in plan view when the upper holding die 11 (lower holding die 12) contacts the intermediate molded body 15. average pressure calculated by dividing the area will extent ^{12 × 10 4 Pa ~ 15 ×} 10 4 Pa (1.2kgf / cm 2 ~ 1.5kgf / cm 2). Actually, a larger pressure acts on the

grip portions

23 and 23 than the other portions, so that the

grip portions

23 and 23 are compressed by a pressure larger than the average pressure.

Further, when the upstream puller 5a moves as described above, the upper holding mold 11 mounted on the downstream puller 5b is moved upward and cured by the pair of upper and lower holding

molds

11 and 12 of this puller 5b. The gripping

portions

23 and 23 are kept in a state where they are not sandwiched. In this state, the puller 5b is moved upstream by a predetermined length. For example, the upstream end of the puller 5b is moved to the intermediate point of the base 13 in the front-rear direction.

The operations of the upstream side puller 5a and the downstream side puller 5b are the first moving step. By the operation of the upstream side puller 5a in the first moving step, a new carbon fiber fabric impregnated with an uncured thermosetting resin liquid is inserted into the drawing gap of the impregnation processing unit 3 and the molding gap of the molding die 4. Thus, a predetermined length is pulled out from the upstream side to the downstream side while applying tension.

The second movement process is performed following the first movement process. First, as illustrated in FIG. 6, the upper holding mold 11 of the downstream puller 5 b is moved downward so that the surface of the intermediate molded body 15 cured by the inner surfaces of the upper and lower holding

molds

11 and 12 is annularly covered. In addition, the inner surfaces of the pair of upper and lower holding

molds

11 and 12 are brought into contact with the surface, and the cured gripping

portions

23 and 23 are sandwiched between the pair of upper and lower holding

molds

11 and 12 and compressed. At this time, the surface of the hollow portion of the intermediate molded body 15 is such that the inner surfaces of the pair of upper and lower holding

molds

11 and 12 are in light contact with each other, and is substantially free of pressure. . In this state, the puller 5b is moved downstream by a predetermined length. For example, the downstream end of the puller 5 b is moved to the end of the base 13 in the front-rear direction.

Further, when the downstream puller 5b moves as described above, the upper holding mold 11 mounted on the upstream puller 5a is moved upward and cured by the pair of upper and lower holding

molds

11 and 12 of the puller 5a. The gripping

portions

23 and 23 are kept in a state where they are not sandwiched. In this state, the puller 5a is moved upstream by a predetermined length. For example, the upstream end of the puller 5 b is moved to the end of the base 13 in the front-rear direction.

The operation of the upstream side puller 5a and the downstream side puller 5b is the second moving step. By the operation of the downstream puller 5b in the second moving step, a new carbon fiber fabric impregnated with an uncured thermosetting resin liquid is inserted into the drawing gap of the impregnation processing unit 3 and the molding gap of the molding die 4. Then, a predetermined length is pulled out from the upstream side to the downstream side while applying tension. The drawing speed at this time is, for example, about 0.2 m / min to 0.5 m / min.

A new carbon fiber woven fabric in which the first moving step and the second moving step are alternately performed, and an uncured thermosetting resin liquid is impregnated in the drawing gap of the impregnation processing unit 3 and the forming gap of the molding die 4. Are sequentially pulled out from the upstream side to the downstream side while applying tension and applying tension.

The intermediate molded body 15 that has been drawn, molded, and cured in such a manner as to pass through the molding gap of the molding die 4 is sequentially conveyed to the downstream side, and the first moving step and the second moving by the drawing device 5. After passing through the process, it is conveyed to the heating furnace 16. The heating furnace 16 is not particularly limited, and any known furnace can be used. In the heating furnace 16, the intermediate molded body 15 cured by the molding die 4 is reheated and subjected to a finishing process, so that the curing of the intermediate molded body 15 is almost completed and internal distortion is removed to stabilize the form. Let

The finished intermediate molded body 15 is sequentially transported to the downstream side, cut into a predetermined length by a cutting machine 17, and carried out by a transport conveyor. The intermediate molded body 15 cut to a predetermined length becomes the top plate 20, and sealing lids are attached to both ends in the longitudinal direction.

In the present invention, when the cylindrical intermediate molded body 15 is molded,

solid grip portions

23 and 23 that protrude outward in the width direction and are continuous in the longitudinal direction are integrally formed at both ends in the width direction. ing. Therefore, the cured gripping

portions

23 and 23 can be firmly sandwiched between the pair of upper and lower holding dies 11 and 12 attached to the

pullers

5a and 5b of the drawing device 5. As a result, it is possible to carry out the drawing operation while holding only the solid

gripping portions

23 and 23 with a sufficiently large pressure without applying excessive pressure to the hollow portion of the cured intermediate molded body 15. become.

Therefore, the hollow portion of the intermediate molded body 15 does not need to consider the strength when being held between the pair of upper and lower holding

molds

11, 12, and the intermediate molded body 15, and consequently the wall of the top plate 20. The thickness can be minimized. Therefore, when the manufactured top plate 20 is used as a top plate for CT or general X-ray photography, X-ray transmission loss can be reduced. Thereby, precise image data can be obtained, and a more precise and clear image can be captured.

In the narrowing gap of the impregnation processing part 3 and the molding gap of the molding die 4, the air existing in the member to be inserted is also removed, so that the member to be inserted is drawn out so as to narrow down. Therefore, the drawing work requires a certain amount of drawing force, but according to the present invention, the hardened

gripping portions

23 and 23 are compressed and held by a pair of upper and lower holding dies 11 and 12 with a large pressure. Therefore, it becomes possible to increase the pulling force as compared with the conventional case, and the pulling operation becomes easy. Along with this, it becomes easy to improve the straightness R of the warp of the carbon fiber fabric to 90% or more, which contributes to the improvement of the strength of the manufactured top plate 20.

The length in the width direction of the solid portion formed at both ends in the width direction of the intermediate molded body 15 (top plate 20) in order to sandwich and compress the grip portion 23 firmly and stably by the pair of upper and lower holding dies 11, 12. The height is preferably 1.0% to 8.0%, more preferably 1.0% to 6.5% of the width of the intermediate molded body 15 (top plate 20).

Further, when the pair of upper and lower holding

molds

11 and 12 mounted on the

pullers

5a and 5b are brought into contact with each other and combined, both end portions in the width direction in the space formed by the inner surfaces of the pair of upper and lower holding

molds

11 and 12 The height dimension of the space (the space corresponding to the gripping portions 23, 23) may be set to about 80% to 99% of the thickness of the cured gripping

portions

23, 23. Thereby, it becomes easy to reliably hold only the

solid grip portions

23 and 23 with a large pressure without applying an excessive pressure to the hollow portion of the cured intermediate molded body 15.

FIG. 9 illustrates another embodiment of the tubular body of the present invention. This embodiment is different from the embodiment illustrated in FIGS. 7 and 8 only in the specifications at both ends in the width direction, and the other specifications are the same, so only the differences will be described.

In this embodiment, both end portions in the width direction of the top plate 20 of FIGS. 7 and 8 are cut by a cutting device and the grip portion 23 is removed. That is, after the intermediate molded body 15 is moved to the downstream side while being compressed by being sandwiched and compressed by the pair of upper and lower holding

molds

11 and 12 attached to the

pullers

5a and 5b of the drawing device 5, the pair of upper and lower holding molds 11 are moved. , 12, the gripping

portions

23, 23 are cut.

The length W2 of the solid portions at both ends of the top plate 20 is about 2 mm to 7 mm by this cutting process. Therefore, when used as the top plate 20 for CT, there is an advantage that the adverse effect of the artifact is reduced.

Artifacts are the top plate 20 (the front plate 21 and the back plate) through which X-rays traveling straight due to the difference in the circumferential position pass when the subject on the top plate 20 is photographed from the outer peripheral side over the entire circumferential direction. This is a phenomenon caused by the difference in the total thickness 20 of 22). That is, at the circumferential position where the total thickness of the top plate 20 (the front plate 21 and the back plate 22) through which the straight X-rays pass increases, the X-ray transmission loss increases and a part of the top plate 20 becomes a virtual image. An image is taken. For this reason, if there is a solid portion such as the gripping portion 23 at the end in the width direction of the top plate 20, the X-ray transmission loss increases at a certain circumferential position, so that a virtual image can be easily captured and a precise image can be obtained. Image shooting becomes difficult.

9, the adverse effect of the artifact is reduced, but the weft of the carbon fiber woven fabric is divided, so that the strength of the top plate 20 is somewhat lowered. Therefore, as illustrated in FIG. 10, a portion obtained by cutting the grip portion 23 can be reinforced by a reinforcing material 23 a made of a fiber-reinforced resin that is attached later. The reinforcing material 23a can be a fiber reinforced resin of the same specification used for the top plate 20, or a fiber reinforced resin of a different specification.

The thickness of the reinforcing material 23a is about 0.5 mm to 1.0 mm, which is smaller than the cutting width of the grip portion 23. Thereby, the bad influence by an artifact can be reduced, improving the intensity | strength of the top plate 20. FIG.

In the case of the top plate 20 for CT, since the size restriction is large, the embodiment of FIGS. 9 and 10 is very useful.

Examples of the cylindrical body of the present invention include an accommodation case for accommodating a film for sensing X-rays transmitted through a human body in addition to CT and a general X-ray imaging top plate. An element for sensing X-rays is disposed on the film, and image data is created based on the sensing data of the element, and an X-ray image is displayed on a monitor.

Claims

A core is inserted into a space penetrating the molding die, and a cylindrical molding gap formed between the molding die and the core is impregnated with at least uncured resin whose warp is carbon fiber. By pulling out a predetermined length sequentially from the upstream side to the downstream side while inserting a long carbon fiber woven fabric and applying tension, the front and back plates are opposed to each other with a gap between each other and both ends in the width direction. A cylindrical intermediate formed body is formed and heated and cured, and the cured intermediate molded body is sequentially conveyed to the downstream side and cut into a predetermined length to produce a cylindrical body. A method for manufacturing a cylindrical body made of fiber reinforced resin, wherein the straightness R of the warp yarn defined on the basis of a center line passing through the center in the width direction of the body is 90% or more,
When the intermediate molded body is molded, a solid grip part protruding outward in the width direction and continuous in the longitudinal direction is integrally formed at both ends in the width direction of the intermediate molded body, and the cured intermediate molding is formed. The inner surfaces of a pair of upper and lower holding molds are brought into contact with the surface of the intermediate molded body so as to cover the surface of the body, and the cured gripping portion is sandwiched and compressed by the pair of upper and lower holding molds, By moving the pair of upper and lower holding dies downstream by a predetermined length, a new length of carbon fiber fabric is inserted through the forming gap and pulled out from the upstream side to the downstream side while applying tension. A method for producing a fiber-reinforced resin tubular body.
2. The gripped portion sandwiched between the pair of upper and lower holding molds is cut after the cured gripped portion is sandwiched and compressed by a pair of upper and lower holding molds and moved downstream by a predetermined length. Of manufacturing a cylindrical body made of fiber reinforced resin.
The method for producing a fiber-reinforced resin tubular body according to claim 2, wherein the portion obtained by cutting the grip portion is reinforced by a fiber-reinforced resin reinforcing material.
Two pairs of upper and lower holding molds are arranged at an interval in the moving direction of the intermediate molded body, and compressed by sandwiching the cured gripping portion of the intermediate molded body with a pair of upstream upper and lower holding molds A first moving step of moving the pair of downstream upper and lower holding molds upstream by a predetermined length without sandwiching the cured gripping part of the intermediate molded body, Following the one moving step, the pair of downstream upper and lower holding molds are compressed while sandwiching the cured gripping portion of the intermediate molded body and moved to the downstream side by a predetermined length. A second moving step of moving the holding mold upstream by a predetermined length without sandwiching the cured gripping part of the intermediate molded body, and performing a new carbon fiber fabric in the molding gap. While upstream, applying tension Fiber-reinforced method for producing a resin-made cylindrical body according to any of claims 1 to 3 as pulled out successively a predetermined length toward the downstream side.
The method for producing a fiber-reinforced resin tubular body according to any of claims 1 to 4, the tension of the carbon fiber woven fabric to 5N / mm 2 or more 980 N / mm 2 or less immediately before the insertion into the forming gap.
The long front plate and the back plate are opposed to each other with a space therebetween, and are formed in a cylindrical body in which both ends in the width direction are connected to each other. The front plate and the back plate are made of carbon fiber at least. A center composed of a fiber reinforced resin whose main reinforcing material is a certain carbon fiber fabric, and the warps are arranged linearly in parallel to the longitudinal direction of the front plate and the back plate, and pass through the center of the cylindrical body in the width direction. A cylindrical body made of fiber reinforced resin having a straightness R of the warp defined on the basis of a line of 90% or more,
At both ends in the width direction of the cylindrical body, there are solid gripping portions protruding outward in the width direction and continuous in the longitudinal direction, and the gripping portions are integrally formed of the fiber reinforced resin. A tubular body made of fiber reinforced resin, in which a solid portion having a width direction length of 1.0% or more and 8.0% or less of the width of the tubular body is formed at both ends in the width direction of the tubular body.
The long front plate and the back plate are opposed to each other with a space therebetween, and are formed in a cylindrical body in which both ends in the width direction are connected to each other. The front plate and the back plate are made of carbon fiber at least. A center composed of a fiber reinforced resin whose main reinforcing material is a certain carbon fiber fabric, and the warps are arranged linearly in parallel to the longitudinal direction of the front plate and the back plate, and pass through the center of the cylindrical body in the width direction. A cylindrical body made of fiber reinforced resin having a straightness R of the warp defined on the basis of a line of 90% or more,
Both ends in the width direction of the cylindrical body are formed by cutting a solid gripping portion that protrudes outward in the width direction and is continuously formed in the longitudinal direction, which is integrally formed with the fiber reinforced resin in advance. A cylindrical body made of fiber-reinforced resin.
The tubular body made of fiber reinforced resin according to claim 7, wherein a portion obtained by cutting the grip portion is reinforced by a reinforcing material made of fiber reinforced resin.
The fiber-reinforced resin tube according to any one of claims 6 to 8, wherein the carbon fiber woven fabric is a bamboo woven fabric having a weft density of 1 / cm or less, and the weft yarn of the woven fabric is made of organic fibers of 50 dtex or more and 350 dtex or less. The state.
A tubular body made of fiber-reinforced resin according to claim 9, wherein a plurality of the interwoven fabrics are laminated, and a complete carbon fiber fabric in which warps and wefts are both carbon fibers is inserted between any two interwoven fabrics. .
The tubular body made of fiber reinforced resin according to claim 10, wherein the complete carbon fiber woven fabric is disposed so as to straddle both sides of the front plate and the back plate.
The complete carbon fiber fabric having a width wider than the plate width is inserted into one of the front plate and the back plate, and both ends of the complete carbon fiber fabric are folded back to the other plate side. A cylindrical body made of fiber-reinforced resin.