WO2013084552A1 - プリフォームの製造方法および繊維強化プラスチック成形体の製造方法 - Google Patents
プリフォームの製造方法および繊維強化プラスチック成形体の製造方法 Download PDFInfo
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- WO2013084552A1 WO2013084552A1 PCT/JP2012/072743 JP2012072743W WO2013084552A1 WO 2013084552 A1 WO2013084552 A1 WO 2013084552A1 JP 2012072743 W JP2012072743 W JP 2012072743W WO 2013084552 A1 WO2013084552 A1 WO 2013084552A1
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- WIPO (PCT)
- Prior art keywords
- resin
- dry fiber
- preform
- fiber fabric
- fixing resin
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
- B29B11/00—Making preforms
- B29B11/14—Making preforms characterised by structure or composition
- B29B11/16—Making preforms characterised by structure or composition comprising fillers or reinforcement
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
- B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/28—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/36—Moulds for making articles of definite length, i.e. discrete articles
- B29C43/3642—Bags, bleeder sheets or cauls for isostatic pressing
- B29C2043/3644—Vacuum bags; Details thereof, e.g. fixing or clamping
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/44—Compression means for making articles of indefinite length
- B29C43/48—Endless belts
- B29C2043/486—Endless belts cooperating with rollers or drums
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/22—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of indefinite length
- B29C43/30—Making multilayered or multicoloured articles
- B29C43/305—Making multilayered articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/40—Shaping or impregnating by compression not applied
- B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
- B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
- B29C70/443—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding and impregnating by vacuum or injection
Definitions
- the present invention relates to a method for producing a fiber-reinforced plastic molded body under a reduced pressure environment and a method for producing a preform used therefor.
- Fiber reinforced plastic (FRP: Fiber Reinforced Plastics) is attracting attention in various industrial fields as a lightweight and high-strength material.
- VaTM Vacuum assist Resin Transfer Molding
- a dry fiber woven fabric placed in a mold is covered with a bag film, the bag film is vacuum-sucked, a liquid resin is injected into the bag film, and the dry fiber woven fabric is impregnated with the resin and cured.
- Patent Document 1 Japanese Patent Laid-Open No. 60-83826.
- the dry fiber fabric does not have tackiness (adhesiveness)
- the dry fiber fabric itself has a three-dimensional shape forming process (the step of placing the dry fiber fabric on the mold or the dry fiber fabric). In the step of laminating dry fiber fabrics), it cannot be fixed at a position against gravity.
- wrinkles may occur in the fiber during decompression.
- thermoplastic resin A method of preliminarily bonding a plurality of dry fiber fabrics with an adhesive resin made of a mixture of (toughness) and a thermosetting resin, thereby shortening the lamination process of the dry fiber fabrics (for example, Patent Document 3: JP 2004-114586 A). (See the publication).
- Patent Document 2 can be used in the step of placing a dry fiber fabric on a mold, and further in the step of laminating the dry fiber fabric on the dry fiber fabric, and the working time can be shortened.
- the uncured thermoplastic component is exposed on the surface of the fiber-reinforced plastic molded body after demolding, the surface that was in contact with the mold is sticky, There is a problem that the thermoplastic component becomes a white spot and causes poor appearance.
- Patent Document 3 can be used in the process of laminating the dry fiber fabric on the dry fiber fabric, and the working time can be shortened, but the dry fiber fabric is disposed on the mold. It cannot be used in the process.
- a plurality of dry fiber fabrics are integrated in advance, when the number of stacked sheets is large, it becomes difficult to mold the bent portion. Specifically, the tension applied to the fiber is different between the inside and the outside, and the fiber is slackened to cause wrinkles.
- Patent Document 3 uses an adhesive resin whose main component is a thermoplastic resin, heating for fusion is required. Moreover, a thermoplastic resin that melts at a relatively low temperature has a problem in heat resistance. On the other hand, when a thermoplastic resin having a high melting temperature is used, it is possible to laminate dry fiber fabrics, but it is difficult to fix the dry fiber fabrics to the mold. A thermoplastic resin having a high melting temperature has insufficient adhesion to a mold subjected to a release treatment. Moreover, in the method disclosed in Patent Document 3, it is not easy to cut a dry fiber fabric into a target shape.
- an object of the present invention is to provide a method for producing a preform and a method for producing a fiber-reinforced plastic molded body that can be continuously produced in a roll form without requiring heating.
- the present invention is a method for producing a preform for producing a fiber-reinforced plastic molded article comprising a dry fiber fabric and a resin-coated film
- the film with resin includes a release film, and a fixing resin including a thermosetting resin in a semi-cured state having tackiness at room temperature, which is fixed to one surface thereof,
- the release film is fixed on the surface of the dry fiber woven fabric that has been rolled out in a roll shape, by fixing the film with resin that has been rolled out from the rolled state via the fixing resin.
- a first step of obtaining a first dry fiber fabric having a fixing resin Separately, on the surface of the dry fiber fabric fed out from the state wound in a roll shape, the film with resin fed out from the state wound in a roll shape is fixed via the fixing resin,
- a cutting step in which the surface of the preform on the side of the release film is vacuum-adsorbed by a cutting machine and then cut into a target shape.
- the preform is preferably pre-pressurized at a pressure of atmospheric pressure or higher using a roll press.
- the fixing resin has a dot shape, and the area of each dot is smaller than the area of each sparse portion where the fibers of the dry fiber fabric do not overlap each other.
- the pitch of the dot-like fixing resin is larger than the pitch of the fibers of the dry fiber fabric and is not an integral multiple of the pitch of the fibers constituting the dry fiber fabric.
- the fixing resin is linear.
- variety of the linear said resin for fixing is smaller than the pitch of the fiber which comprises the said dry fiber fabric.
- the angle formed by the linear arrangement direction of the fixing resin and the direction of the fibers constituting the dry fiber fabric is other than 45 °.
- the position of the linear fixing resin differs between each of the first dry fiber fabric and the second dry fiber fabric.
- the present invention is a molding step of fixing the preform to the mold via a fixing resin while peeling off the release film of the preform.
- the present invention also relates to a method for producing a fiber-reinforced plastic molded body, which comprises a demolding step of demolding the fiber-reinforced plastic molded body from the mold.
- a film with a resin wound in a roll shape including a release film and a fixing resin including a thermosetting resin in a semi-cured state having tackiness at room temperature, which is attached to one surface thereof, a peel ply and It is preferable to include a step of fixing the flow media on the fiber woven fabric with resin of the preform from which the release film has been peeled off.
- the fiber-reinforced plastic molded body has a foam core material between the dry fiber fabrics, Using a film with a resin wound in a roll shape, including a release film and a fixing resin including a thermosetting resin in a semi-cured state having tackiness at room temperature, which is attached to one side of the release film. It is preferable to include a step of crimping the fiber fabric and the foamed core material.
- the fixing resin used in the present invention (a semi-cured thermosetting resin having tackiness at room temperature) does not contain a thermoplastic component, so even if it is used on the surface in contact with the mold, it may become sticky or white. A fiber-reinforced plastic molded article having a good appearance is obtained.
- the preform of the present invention includes the fixing resin, the position can be fixed without being affected by gravity, and a molding process into a three-dimensional shape (a dry fiber fabric is formed on the mold).
- the step of arranging and the step of laminating the dry fiber fabric on the dry fiber fabric) can be simplified and the productivity can be improved.
- the preform of the present invention can be continuously produced in roll form without requiring heating. Further, since the preform of the present invention has a release film on one side and can be adsorbed, it can be easily processed into a predetermined shape by a cutting machine such as a cutting plotter.
- (A) is a cross-sectional schematic diagram which shows an example of the film with resin of this invention.
- (B) is a cross-sectional schematic diagram which shows another example of the film with resin of this invention.
- (A) is a top view which shows an example of the film with resin of this invention.
- (B) is a top view which shows another example of the film with resin of this invention.
- (A) is a cross-sectional schematic diagram which shows an example of the preform of this invention.
- (B) is a cross-sectional schematic diagram which shows another example of the preform of this invention. It is a cross-sectional schematic diagram for demonstrating an example of the manufacturing method of the preform of this invention.
- the resin-coated film 3 of the present invention is used for producing a preform 5 and a fiber-reinforced plastic molded body.
- FIG. 1 the cross-sectional schematic diagram of the film 3 with resin is shown.
- the film 3 with resin equips the mold release film 1 with the resin 2 for fixing containing the thermosetting resin of the semi-hardened state which has tack property at room temperature.
- both sides of the release film 1 may be covered with the release film 1 as shown in FIG.
- the manufacturing method of a film with resin is not specifically limited, Screen printing is preferable.
- the fixing resin is not particularly limited as long as it is a semi-cured thermosetting resin having tackiness at room temperature, and is, for example, an epoxy resin, a polyimide resin, or a phenol resin, and preferably the same resin. It is a vinyl ester resin having both a (meth) acryloyl group and an epoxy group in the skeleton.
- the fixing resin may contain a pigment such as carbon black.
- the fixing resin may contain a trace amount of tackifier such as rosin ester. Moreover, you may use release paper etc. instead of the said release film.
- FIG. 2 shows a top view of the film 3 with resin.
- the fixing resin 2 is preferably a dot-shaped fixing resin 2a so as not to prevent resin impregnation.
- FIG. 2 (b) not only the dot-like fixing resin 2a but also a line with an interval (about 100 mm) that does not affect the resin impregnation in order to prevent twisting and fraying of the dry fiber fabric.
- a fixing resin 2b in the form of a plate is disposed.
- the preform is a member that includes a dry fiber fabric and the resin-coated film that is pressure-bonded to the surface of the preform via a fixing resin, and is used for manufacturing a fiber-reinforced plastic molded body.
- the “surface” of the dry fiber fabric means that it does not include the inner surface in the voids inside the dry fiber fabric.
- Fig. 3 shows a schematic cross-sectional view of the preform.
- the preform of the present invention is a preform 5 in which a dry fiber fabric 4 and a release film 1 are pressure-bonded via a fixing resin 2.
- the preform 5 may be one in which a plurality of dry fiber fabrics 4 are pressure-bonded via the fixing resin 2.
- dry fiber fabric 4 examples include fabrics such as carbon fiber, glass fiber, Zylon fiber, and Kepler fiber. Preferably, it is a carbon fiber.
- the preform of the present invention can be continuously produced in a roll shape.
- FIG. 4 the cross-sectional schematic diagram for demonstrating an example of the manufacturing method of the preform of this invention is shown.
- two roll-shaped resin-attached films 3b each having a release film 1 on both surfaces of the fixing resin 2 are prepared.
- the release film 1 on one side of one of the resin-coated films 3b is removed and pressure-bonded to the dry fiber fabric 4 fed out from the roll state to obtain a preform 5a.
- the release film 1 on the other surface of the preform 5a is wound up. In this way, a second dry fiber fabric having the fixing resin 2 is obtained.
- the release film 1 on one side of the other resin-coated film 3b (lower side in FIG. 4) is removed, and it is pressure-bonded to the dry fiber fabric 4 fed out from the roll state, and fixed with the release film 1
- a first dry fiber woven fabric (preform 5a) having the resin 2 is obtained.
- the second dry fiber fabric is laminated on the first dry fiber fabric (preform 5a).
- the obtained preform laminate 5b is pressurized (10 kgf / cm 2 ) with a roll press, and the release film surface is vacuum-adsorbed by a cutting machine, and then cut into a desired shape. Since pressurization (about 10 kgf / cm 2 ) is performed by a roll press, a preform that is a fiber-reinforced plastic having a thin plate thickness, that is, a high fiber content can be obtained.
- FIG. 5 shows the relationship between the dry fiber fabric 4 and the dot-like fixing resin 2a.
- the area of the dot-like fixing resin 2a is larger than the portion 41a in which the fibers 41 of the dry fiber fabric 4 are sparse. Small is preferable.
- the arrangement pitch of the dot-shaped fixing resins 2a is regular and larger than the pitch of the dry fiber fabric. It is preferable that the pitch is not an integral multiple of the pitch of the dry fiber fabric.
- the dot diameter is preferably 0.75 mm or less.
- this value is preferably not the state of the film with resin, but the state when the fixing resin is pressure-bonded to the dry fiber fabric, that is, the collapsed state. Therefore, it is preferable that the dot diameter in the state of the film with resin is further 1 ⁇ 4 to ⁇ ⁇ ⁇ of the dot diameter in the state of being pressure-bonded.
- the arrangement pitch of the dot-shaped fixing resins 2a is regular and larger than the pitch of the dry fiber fabric. It is preferable that the pitch is not an integral multiple of the pitch of the dry fiber fabric.
- the arrangement pitch of the dot-like fixing resin is preferably a value that is not an integer multiple of 7.6 mm or more.
- a value obtained by adding a further sparse part of 0.75 mm to the pitch of the fiber fabric, 7.6 mm, that is, 8.35 mm is preferable.
- the fixing resin 2a can be obtained by hot air treatment.
- a gap for resin impregnation can be generated in the fixing resin 2a.
- the hot air treatment at this time is preferably carried out after completion of shaping into the mold and fixation of the fibers by vacuum suction.
- the dot-like fixing resin is in an uncured or semi-cured state, the viscosity is lowered by the heat treatment. For this reason, the film-like fixing resin in the sparse part penetrates into the fiber by capillary action. By doing in this way, the flow path of liquid thermosetting resin is securable.
- FIG. 7 shows the relationship between the dry fiber fabric 4 and the linear fixing resin 2b.
- the width of the linear fixing resin 2b is preferably smaller than the pitch of the fibers 41, and more preferably smaller than the width of the fibers 41.
- the line width in the state of the film with resin is preferably 1 ⁇ 4 to 3 of the fiber width of 6.85 mm in consideration of the state when pressure bonding is performed as in the case of the dots.
- the arrangement direction of the linear fixing resin 2b is preferably different from the fiber direction.
- the angle ⁇ formed by the fiber direction and the linear fixing resin arrangement direction is preferably an inclination other than 0 °, 45 °, and 90 °.
- the position of the linear fixing resin 2b is different among the dry fiber fabrics 4 as shown in FIG.
- the fixing resin does not prevent the liquid fiber thermosetting resin described later from impregnating the dry fiber fabric. Further, by preparing the preform laminate in advance, it is not necessary to mold all the dry fiber fabrics with fixing resin one by one on the mold. Note that the fixing resin can be appropriately used in a necessary amount in a necessary portion.
- the method for producing a fiber-reinforced plastic according to the present invention includes a molding step of fixing the preform to the molding die via a fixing resin while peeling the release film of the preform.
- FIG. 9 an example of a method for manufacturing a fiber-reinforced plastic molded body will be described.
- a molding die 6 whose surface is released with a Teflon (registered trademark) coating 7 is prepared, and the preform laminate 5 b is brought into contact with the molding die 6 through the fixing resin 2. Fix it.
- the dry fiber fabric 4 is also fixed to the Teflon (registered trademark) coating 7 on the surface of the mold 6 by the fixing resin 2, and the position is not shifted due to gravity.
- the peel ply 8 and the flow media 9 are arranged on the preform laminate 5b, and the whole is covered with the bagging film 10 and sealed.
- Teflon (registered trademark) tubes 101a and 101b are provided at two end portions of the sealed space, plugged with valves, and the Teflon (registered trademark) tube 101a is connected to a vacuum pump. ) Connect the tube 101b to the resin tank.
- the vacuum pump is operated, and the space sealed with the bagging film 10 is decompressed.
- the valve of the Teflon (registered trademark) tube 101b on the resin tank side is opened, and the liquid thermosetting resin 11 is sucked into the decompressed sealed space.
- the liquid thermosetting resin 11 is impregnated in the dry fiber fabric 4 while spreading through the coarse flow media 9.
- the valve of the Teflon (registered trademark) tube 101b on the resin supply side is closed.
- the liquid thermosetting resin 11 is not particularly limited as long as it is a low-viscosity thermosetting resin such as an epoxy resin, a polyester resin, or a vinyl ester resin, but is preferably a vinyl ester resin.
- the curing conditions for the fixing resin are preferably not different from the curing conditions for the liquid thermosetting resin.
- the fixing resin is a vinyl ester resin having both a (meth) acryloyl group and an epoxy group in the same resin skeleton, and is a semi-cured resin in which only the epoxy group is reacted, and the above liquid thermosetting resin
- the fixing resin and the liquid thermosetting resin can be simultaneously cured in the curing step. Thereby, a manufacturing process can be skipped and there exists an advantage which can improve manufacturing efficiency.
- Step cure consists of a pre-stage process (Precure) and a post-process process (Aftercure, Postcure).
- Pre-cure is a pretreatment stage in the curing of the thermosetting resin, is cured to such an extent that the final strength is not obtained, and is mainly intended to form a stable shape.
- pre-curing is performed at a temperature slightly below the glass transition point.
- After-cure is a curing stage for obtaining the final strength, and is generally performed in an environment at a higher temperature and longer time than pre-cure.
- the fixing resin is completely cured during the after-curing of the liquid thermosetting resin. This is to prevent a decrease in strength due to uncured resin.
- the film 3 with resin can also be used for the process of fixing auxiliary materials such as peel ply 8 and flow media 9. Furthermore, it is used also for the process of fixing the foam core material 13 required when forming a lightweight and highly rigid sandwich structure on the dry fiber fabric 4 and the process of fixing the dry fiber fabric 4 to the foam core material 13. be able to.
- the inner medium 12 is a flow medium for integrally forming a sandwich structure, and remains in the molded body.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Moulding By Coating Moulds (AREA)
- Reinforced Plastic Materials (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
Abstract
Description
前記樹脂付きフィルムは、離型フィルムと、その片面に固定された、室温でタック性を有する半硬化状態の熱硬化性樹脂を含む固定用樹脂とを含み、
ロール状に巻かれた状態から繰り出された前記ドライ繊維織物の表面に、ロール状に巻かれた状態から繰り出された前記樹脂付きフィルムを前記固定用樹脂を介して固定することで、離型フィルムおよび固定用樹脂を有する第1のドライ繊維織物を得る第1の工程と、
別途、ロール状に巻かれた状態から繰り出された前記ドライ繊維織物の表面に、ロール状に巻かれた状態から繰り出された前記樹脂付きフィルムを前記固定用樹脂を介して固定し、
前記ドライ繊維織物に圧着された樹脂付きフィルムから、前記離型フィルムを剥離することで、固定用樹脂を有する1つ以上の第2のドライ繊維織物を得る第2の工程と、
前記第1のドライ繊維織物の固定用樹脂が固定されていない面に、前記第2のドライ繊維織物の固定用樹脂を介して前記第2のドライ繊維織物を積層する積層工程とを備える、プリフォームの製造方法。
前記成形型に固定された前記プリフォーム中の前記ドライ繊維織物に、液状の熱硬化性樹脂を含浸する含浸工程と、
前記液状の熱硬化性樹脂および前記固定用樹脂を硬化させることにより、繊維強化プラスチック成形体を形成する硬化工程と、
前記成形型から前記繊維強化プラスチック成形体を脱型する脱型工程と
をこの順で備える、繊維強化プラスチック成形体の製造方法にも関する。
離型フィルムと、その片面に付着された、室温でタック性を有する半硬化状態の熱硬化性樹脂を含む固定用樹脂とを含む、ロール状に巻かれた樹脂付きフィルムを用いて、前記ドライ繊維織物と前記発泡コア材とを圧着する工程を含むことが好ましい。
本発明の樹脂付きフィルム3は、プリフォーム5および繊維強化プラスチック成形体の製造に用いられる。図1に、樹脂付きフィルム3の断面模式図を示す。図1(a)に示すように樹脂付きフィルム3は、離型フィルム1上に、室温でタック性を有する半硬化状態の熱硬化性樹脂を含む固定用樹脂2を備える。ロール供給を可能とするため、図1(b)に示すように、離型フィルム1の両面を離型フィルム1で覆っても良い。樹脂付きフィルムの製造方法は、特に限定されるものではないが、スクリーン印刷が好ましい。
プリフォームは、ドライ繊維織物と、その表面に固定用樹脂を介して圧着された上記樹脂付きフィルムとを備える部材であり、繊維強化プラスチック成形体の製造に用いられる。なお、ここでのドライ繊維織物の「表面」とは、ドライ繊維織物内部の空隙における内表面は含まない意味である。
本発明のプリフォームは、ロール状で連続生産することができる。図4に、本発明のプリフォームの製造方法の一例を説明するための断面模式図を示す。まず、固定用樹脂2の両面に離型フィルム1を備えたロール状の樹脂付きフィルム3bを2つ準備する。
図5に、ドライ繊維織物4とドット状の固定用樹脂2aとの関係を示す。繊維強化プラスチック成形体を製造する際に液状の熱硬化性樹脂の含浸を妨げないようにするため、ドット状の固定用樹脂2aの面積は、ドライ繊維織物4の繊維41が疎な部分41aより小さいことが好ましい。また、ドライ繊維織物と固定用樹脂との密着性や機械的強度の安定性の観点から、ドット状の固定用樹脂2aの配列ピッチは、規則性があり、かつドライ繊維織物のピッチよりも大きいことが好ましく、ドライ繊維織物のピッチの整数倍でないことがより好ましい。
本発明の繊維強化プラスチックの製造方法は、上記のプリフォームの離型フィルムを剥がしながら、成形型に固定用樹脂を介して前記プリフォームを固定する賦型工程と、
成形型に固定されたプリフォーム中のドライ繊維織物に、液状の熱硬化性樹脂を含浸する含浸工程と、
液状の熱硬化性樹脂および固定用樹脂を硬化させることにより、繊維強化プラスチック成形体を形成する硬化工程と、
成形型から繊維強化プラスチック成形体を脱型する脱型工程と
をこの順で備える。
Claims (13)
- ドライ繊維織物(4)と樹脂付きフィルム(3)とを備えた繊維強化プラスチック成形体の製造用のプリフォーム(5)の製造方法であって、
前記樹脂付きフィルム(3)は、離型フィルム(1)と、その片面に固定された、室温でタック性を有する半硬化状態の熱硬化性樹脂を含む固定用樹脂(2)とを含み、
ロール状に巻かれた状態から繰り出された前記ドライ繊維織物(4)の表面に、ロール状に巻かれた状態から繰り出された前記樹脂付きフィルム(3)を前記固定用樹脂(2)を介して固定することで、離型フィルム(1)および固定用樹脂(2)を有する第1のドライ繊維織物(4)を得る第1の工程と、
別途、ロール状に巻かれた状態から繰り出された前記ドライ繊維織物(4)の表面に、ロール状に巻かれた状態から繰り出された前記樹脂付きフィルム(3)を前記固定用樹脂(2)を介して固定し、
前記ドライ繊維織物(4)に圧着された樹脂付きフィルム(3)から、前記離型フィルム(1)を剥離することで、固定用樹脂(2)を有する1つ以上の第2のドライ繊維織物(4)を得る第2の工程と、
前記第1のドライ繊維織物(4)の固定用樹脂(2)が固定されていない面に、前記第2のドライ繊維織物(4)の固定用樹脂(2)を介して前記第2のドライ繊維織物(4)を積層する積層工程とを備える、プリフォーム(5)の製造方法。 - さらに、前記プリフォーム(5)の前記離型フィルム(1)側の面を、切断機に真空吸着させた後、目的の形状に切断する切断工程を含む、請求項1に記載のプリフォーム(5)の製造方法。
- 前記プリフォーム(5)は、ロールプレスを用いて予め大気圧以上の圧力で加圧されている、請求項1に記載のプリフォーム(5)の製造方法。
- 前記固定用樹脂(2)がドット状であり、各々のドットの面積が、前記ドライ繊維織物(4)の繊維同士が重ならない疎な部分の各々の面積よりも小さい、請求項1に記載のプリフォーム(5)の製造方法。
- ドット状の前記固定用樹脂(2)のピッチが、前記ドライ繊維織物(4)の繊維のピッチよりも大きく、かつ、前記ドライ繊維織物(4)を構成する繊維のピッチの整数倍でない、請求項4に記載のプリフォーム(5)の製造方法。
- ドット状の前記固定用樹脂(2)を加熱処理することにより、ドット状の前記固定用樹脂(2)の面積を、前記ドライ繊維織物(4)の繊維同士が重ならない疎な部分の面積よりも小さくする工程を含む、請求項4に記載のプリフォーム(5)の製造方法。
- 前記固定用樹脂(2)の少なくとも一部が線状である、請求項1に記載のプリフォーム(5)の製造方法。
- 線状の前記固定用樹脂(2)の幅が、前記ドライ繊維織物(4)を構成する繊維のピッチよりも小さい、請求項7に記載のプリフォーム(5)の製造方法。
- 線状の前記固定用樹脂(2)の配置方向と前記ドライ繊維織物(4)を構成する繊維の方向とのなす角度が45°以外である、請求項7に記載のプリフォーム(5)の製造方法。
- 前記第1のドライ繊維織物(4)および前記第2のドライ繊維織物(4)の各々の間で、線状の前記固定用樹脂(2)の位置が異なる、請求項7に記載のプリフォーム(5)の製造方法。
- 請求項1に記載のプリフォーム(5)の前記離型フィルム(1)を剥がしながら、成形型に固定用樹脂(2)を介して前記プリフォーム(5)を固定する賦型工程と、
前記成形型(6)に固定された前記プリフォーム(5)中の前記ドライ繊維織物(4)に、液状の熱硬化性樹脂を含浸する含浸工程と、
前記液状の熱硬化性樹脂および前記固定用樹脂(2)を硬化させることにより、繊維強化プラスチック成形体を形成する硬化工程と、
前記成形型(6)から前記繊維強化プラスチック成形体を脱型する脱型工程と
をこの順で備える、繊維強化プラスチック成形体の製造方法。 - 前記賦型工程はさらに、離型フィルム(1)と、その片面に付着された、室温でタック性を有する半硬化状態の熱硬化性樹脂を含む固定用樹脂(2)とを含む、ロール状に巻かれた樹脂付きフィルム(3)を用いて、ピールプライ(8)および/またはフローメディア(9)を固定用樹脂(2)が付着したドライ繊維織物(4)上に固定する工程を含む、請求項11に記載の繊維強化プラスチック成形体の製造方法。
- 前記繊維強化プラスチック成形体は、前記ドライ繊維織物(4)の間に発泡コア材を有し、
離型フィルム(1)と、その片面に付着された、室温でタック性を有する半硬化状態の熱硬化性樹脂を含む固定用樹脂(2)とを含む、ロール状に巻かれた樹脂付きフィルム(3)を用いて、前記ドライ繊維織物(4)と前記発泡コア材(13)とを圧着する工程を含む、請求項11に記載の繊維強化プラスチック成形体の製造方法。
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