WO2019069639A1

WO2019069639A1 - Fiber-reinforced resin member manufacturing process, fuel tank, and fiber-reinforced resin member

Info

Publication number: WO2019069639A1
Application number: PCT/JP2018/033601
Authority: WO
Inventors: 龍志谷; 鷹志森本
Original assignee: 八千代工業株式会社
Priority date: 2017-10-06
Filing date: 2018-09-11
Publication date: 2019-04-11
Also published as: JP6859448B2; JPWO2019069639A1

Abstract

This fiber-reinforced resin member manufacturing process comprises: a preparation step for preparing a laminated body (40) obtained by forming a laminate of a fiber sheet (41) so as to be sandwiched by resin sheets (42) having a larger size than the fiber sheet (41); and a main molding step for applying pressure and forming the laminated body (40) in such a manner as not to let the fiber sheet (41) be exposed. In the main molding step, it is preferable to have the outer periphery of the fiber sheet (41) pinched by a forming die (K). Further, in the preparation step, when the laminated body (40) is formed with a plurality of fiber sheets (41) and a plurality of resin sheets (42) that are disposed between the respective fiber sheets (41) and at the outermost layers, the resin sheets (42) to be disposed at the outermost layers may be configured to have a size greater than that of the fiber sheets (41).

Description

Method of manufacturing fiber reinforced resin member, fuel tank, and fiber reinforced resin member

The present invention relates to a method for producing a fiber reinforced resin member, a fuel tank and a fiber reinforced resin member.

As a manufacturing method of a fiber reinforced resin (FRP: Fiber-Reinforced Plastics) member, what was described in patent documents 1 is known. The manufacturing method of patent document 1 is making it shape | mold using a shaping | molding die, after laminating a fiber sheet and a resin sheet and forming a laminated body.

Japanese Patent Application Laid-Open No. 7-047596

However, in the conventional manufacturing method, there is a problem that the exposed fibers are fluffed due to the fibers being exposed at the end of the fiber reinforced resin member. The handling of the fiber-reinforced resin member becomes difficult because the worker may tear when touching the fluffed portion. In addition, the fibers may come loose from the fluffed portion, or substances may enter from between the fibers and the resin, which may cause deterioration of the product.

The present invention is created to solve such problems, and it is an object of the present invention to provide a method of manufacturing a fiber reinforced resin member, a fuel tank and a fiber reinforced resin member capable of suppressing the occurrence of fuzzing of fibers. It will be an issue.

In order to solve the above-mentioned subject, the present invention prepares a layered product which laminated so that a fiber sheet may be pinched with a resin sheet larger than the fiber sheet concerned, and the above-mentioned layered product so that the fiber sheet may not be exposed. And a main forming step of pressure forming.

According to this configuration, since the fibers are not exposed to the outside of the fiber reinforced resin member, the generation of fuzzing of the fibers can be suppressed.

Further, in the main forming step, the resin sheet is preferably pinched by a forming die at a position outside the end of the fiber sheet.

According to this configuration, the work of separately cutting the end can be omitted, so the number of working steps can be reduced.

Further, the laminate is composed of a plurality of the fiber sheets and a plurality of the resin sheets disposed between the plurality of fiber sheets and in the outermost layer, and in the preparing step, the laminate is disposed in the outermost layer It is characterized in that the size of only the resin sheet is made larger than the fiber sheet.

According to this configuration, since only the resin sheet of the outermost layer is enlarged, the material cost can be reduced.

Further, the present invention has a tank body, a pair of fiber reinforced resin members sandwiching the outside of the tank body, and a fastening part that fastens both ends of the pair of fiber reinforced resin members, the fiber reinforced resin The member is characterized in that a fiber reinforced layer and a matrix resin layer are laminated, and an unreinforced portion in which the fiber reinforced layer is not interposed is formed at an end portion.

According to this configuration, the end portion of the fiber reinforced resin member is covered with the unreinforced portion, so that the fiber is not exposed. As a result, it is possible to easily carry out the work of assembling the carbon reinforced resin member to the tank body.

Furthermore, the present invention is characterized in that a fiber reinforced layer and a matrix resin layer are laminated and an unreinforced portion in which the fiber reinforced layer is not interposed is formed at an end portion.

According to the method for producing a fiber-reinforced resin member, the fuel tank, and the fiber-reinforced resin member of the present invention, the occurrence of fuzzing of fibers can be suppressed.

It is a perspective view showing a fuel tank concerning a first embodiment of the present invention. It is a sectional view showing the circumference of a fiber reinforced resin member of a first embodiment. It is a perspective view which shows a fiber reinforced resin member. It is a side view showing a fiber reinforced resin member. It is a principal part expanded sectional view of A part of FIG. It is a principal part expanded sectional view of B part of FIG. It is a perspective view which shows the preparatory process of the manufacturing method of the fiber reinforced resin member concerning 1st embodiment. It is sectional drawing which shows the arrangement | positioning process and the formation process of the manufacturing method of the fiber reinforced resin member concerning 1st embodiment. It is a perspective view which shows the preparatory process of the manufacturing method of the fiber reinforced resin member of 2nd embodiment. It is a schematic plan view which shows the fiber reinforced resin member completed by the manufacturing method of the fiber reinforced resin member of 2nd embodiment.

Hereinafter, a method of manufacturing a fiber reinforced resin member according to an embodiment of the present invention will be described on the assumption that the method is applied to a method of manufacturing a fuel tank. In the following description, when referring to “front and rear”, “left and right”, and “upper and lower”, the direction shown in FIG. 1 is used as a reference. Each direction is set for convenience in describing the fuel tank T, and is not intended to limit the direction when the fuel tank T is mounted on a vehicle.

First Embodiment
As shown in FIGS. 1 and 2, the fuel tank T is mounted on moving means such as a car, a motorcycle, or a ship, and includes the tank body 1 and a plurality of fiber reinforced resin members 21 (8 in the present embodiment). Mainly consists of

The tank main body 1 is a hollow container made of resin for storing fuel such as gasoline, and has, for example, a multilayer structure including a barrier layer. The tank body 1 is mainly made of, for example, a thermoplastic resin such as polyethylene or high density polyethylene. The tank body 1 is formed by, for example, blow molding.

The tank body 1 is composed of a lower wall 11, an upper wall 12, a first side wall 13, a second side wall 14, a third side wall 15 and a fourth side wall 16. The lower wall 11, the upper wall 12, the third side wall 15 and the fourth side wall 16 of the tank body 1 are formed with a continuous recess 3 over the entire circumference. In the present embodiment, four recesses 3 are arranged in parallel in the front-rear direction with intervals. As shown in FIG. 2, the recess 3 has a bottom and a pair of side walls rising from the bottom, and is formed to be open to the outside. The recess 3 is formed with a constant cross section along the entire circumference. The number of recesses 3 is not limited.

The fiber reinforced resin member 21 is a member that reinforces the tank body 1 and is provided in parallel in the front-rear direction with an interval on the outer surface of the tank body 1. The fiber reinforced resin member 21 is a fiber reinforced resin (FRP) formed by impregnating a fiber sheet (carbon fiber sheet, glass fiber sheet or the like) with a resin. The fiber reinforced resin member 21 is a thin belt-like member as shown in FIGS. 3 and 4, and has a band portion 21a covering one semi-periphery side along the outer surface of the tank main body 1 (see FIG. 1) It is comprised by

extension part

21b, 21b extended in the outward direction from the both ends of 21a. The shape of the band portion 21 a is formed to correspond to the shape of the outer surface of the tank body 1. Mounting holes 21c for fastening portions 22 (for example, bolts and nuts) are formed in both extension portions 21b.

The fiber reinforced resin member 21 is fastened by the fastening portion 22 in a state of being disposed in the recess 3 formed in the tank main body 1 as a set of upper and lower. That is, the outside of the tank body 1 is held by the pair of fiber reinforced resin members 21. The fiber reinforced resin member 21 disposed on the lower side is continuously disposed across the third side wall 15, the lower wall 11 and the fourth side wall 16. Also, the fiber reinforced resin member 21 disposed on the upper side is continuously disposed across the third side wall 15, the upper wall 12 and the fourth side wall 16. The arrangement position of the fiber reinforced resin member 21 may be appropriately set in accordance with the shape and use of the tank body 1.

FIG. 5 is an enlarged sectional view of an essential part of a portion A of FIG. FIG. 5 schematically shows a cross section of the band portion 21 a of the fiber reinforced resin member 21.
The fiber reinforced resin member 21 is composed of, for example, three fiber reinforced layers 31 and four matrix resin layers 32, and the layers are alternately laminated. In addition, the thickness of the layer and the number of layers are schematically shown, and the present invention is not limited.

The fiber reinforcing layer 31 is a layer formed by impregnating a fiber sheet 41 (see FIG. 7) with a matrix resin (a matrix resin sheet 42 (see FIG. 7)) and curing.
The matrix resin layer 32 is a layer formed by curing of a matrix resin (matrix resin sheet 42). The matrix resin layer 32 is formed on both sides of the fiber reinforced layer 31 (that is, between the fiber reinforced layers 31 and the outermost layer (surface) of the fiber reinforced resin member 21).

FIG. 6 is an enlarged cross-sectional view of an essential part of a portion B of FIG. FIG. 6 schematically shows a cross section of the extending portion 21b of the fiber reinforced resin member 21. As shown in FIG.
The fiber reinforcing layer 31 does not reach the end of the extending portion 21b, and a plurality of matrix resins (matrix resin sheets 42 (see FIG. 7)) are integrally formed at the end of the extending portion 21b. A hardened non-reinforced portion 33 is formed. In addition, although illustration is abbreviate | omitted, the unreinforced part 33 is formed also in the both sides in the width direction of the fiber reinforcement layer 31. As shown in FIG. Therefore, the fiber reinforced resin member 21 in this embodiment is covered with the matrix resin so that the fiber reinforced layer 31 is not exposed to the outside. In addition, it is preferable that the attachment hole 21c (refer FIG. 3) is formed not in the area | region of the unreinforced part 33 but in the part which the fiber reinforcement layer 31 extends.

Next, a method of manufacturing a fuel tank will be described. In the method of manufacturing a fuel tank, a tank main body forming step, a fiber reinforced resin member forming step, and a fiber reinforced resin member attaching step are mainly performed.

The tank body molding step is a step of blow molding the tank body 1 (see FIG. 1) with the tank body molding die. In the main body molding process, a cylindrical or sheet-like parison is discharged from a die between one mold and the other mold. The parison is, for example, a thermoplastic resin composed of a plurality of layers including a barrier layer inside. The mold for the tank body is preheated to a predetermined temperature so that the parison is plastically deformed. The parison is transferred to the molding surface of the tank body molding mold by supplying air to the inside while clamping one mold and the other mold. The parison may be drawn onto the mold for the tank main body by suctioning the parison using vacuum suction means provided in one mold and the other mold. After a predetermined time has elapsed, the mold is removed from the mold, and the excess burrs are removed to complete the tank body 1.

Next, the fiber reinforced resin member forming step will be described. The fiber reinforced resin member forming step is a step of manufacturing the fiber reinforced resin member 21. The fiber-reinforced resin member forming step mainly includes a preparation step, an arranging step, and a main forming step.

The preparation step is a step of forming a laminate 40 by sequentially overlapping a plurality of fiber sheets 41 and a plurality of matrix resin sheets 42 as shown in FIG. 7. In the preparation step, the matrix resin sheets 42 are disposed on both sides of the fiber sheet 41. Thereby, the matrix resin sheet 42 is arrange | positioned between the fiber sheets 41 and the outermost layer (surface) of the laminated body 40. As shown in FIG.

The fiber sheet 41 is a thin sheet formed of carbon fiber, glass fiber, resin fiber or the like. The type of the fiber sheet 41 is not particularly limited, and may be, for example, a cloth woven from fibers or a felt from which chopped short fibers are formed. Further, the shape and size of the fiber sheet 41 are not particularly limited, but it is preferable that the shape and size of the fiber sheet 41 be previously formed in accordance with the shape of the finished product. The fiber sheet 41 here has a strip-like shape in accordance with the fiber reinforced resin member 21 (see FIG. 3).

The matrix resin sheet 42 is a thin film formed of a thermoplastic resin (high density polyethylene, polyethylene, polyamide (nylon), etc.) or a thermosetting resin (phenol resin, epoxy resin, etc.). The matrix resin sheet 42 preferably has a shape and a size capable of covering the fiber sheet 41, and is, for example, similar in shape to the fiber sheet 41 and larger in size than the fiber sheet 41. The matrix resin sheet 42 here has a strip shape similar to the fiber sheet 41, and the size is larger than the fiber sheet 41. Note that only the size of the matrix resin sheet 42 disposed in the outermost layer (surface) of the laminate 40 may be set to a size that can cover the fiber sheet 41.

The disposing step is a step of disposing the laminate 40 in the mold K, as shown in FIG. The mold K uses a first mold K1 disposed on the lower side and a second mold K2 disposed on the upper side. Both the first type K1 and the second type K2 are provided with a temperature control means M inside. In the disposing step, the laminate 40 is disposed between the first type K1 and the second type K2.

This molding step is a step of molding the fiber reinforced resin member 21 (see FIG. 3) by the molding die K as shown in FIG. 8, and the first mold K1 and the second mold K2 are clamped and press molded . In the main forming step, the temperature of the forming die K may be appropriately set to a temperature at which the laminate 40 can be formed. Then, after the mold is removed, unnecessary portions are cut by laser processing, water jet processing or the like, and the fiber reinforced resin member 21 (see FIG. 3) is completed. Here, it is the area of the unreinforced portion 33 (see FIG. 6) to cut unnecessary portions, so that the fiber reinforced layer 31 is not cut (that is, the outside of the fiber reinforced layer 31 is cut). In addition, a position outside the end of the fiber sheet 41, that is, a region of the non-reinforced portion 33 may be pinched (sandwiched) by the molding die K to cut an unnecessary portion.

In addition, a pre-forming step may be performed before the main forming step. In the pre-forming step and the main forming step, for example, the temperature of the mold K is different, and after performing the pre-forming step, unnecessary portions may be cut and then the main forming step may be performed. In that case, after cutting after the pre-forming step, a new matrix resin sheet 42 may be disposed on the outermost layer (surface) and the main forming step may be performed.
In addition, by adjusting the size of the matrix resin sheet 42 so that unnecessary portions do not occur after the main forming step, it is possible to omit the work of cutting the unnecessary portions.

Next, the fiber reinforced resin member attaching process will be described. The fiber reinforced resin member attaching step is a step of attaching the fiber reinforced resin member 21 (see FIG. 3) to the tank main body 1 (see FIG. 1). In the fiber reinforced resin member attaching process, the fiber reinforced resin member 21 is disposed in the recess 3 formed in the lower wall 11 and the upper wall 12 of the tank body 1. Then, the fiber reinforced resin members 21 disposed one on top of the other are fastened using the fastening portion 22 as one set. Thus, the fuel tank T shown in FIG. 1 is completed. A cushion member (not shown) may be disposed between the tank main body 1 and the fiber reinforced resin member 21.

According to the manufacturing method of the fiber reinforced resin member according to the first embodiment described above, as shown in FIG. 6, the fiber reinforced layer 31 does not reach the end of the fiber reinforced resin member 21, and the fiber reinforced resin member An unreinforced portion 33 is formed at the end of the portion 21. Thereby, since the fiber reinforcement layer 31 is not exposed to the exterior of the fiber reinforced resin member 21, generation | occurrence | production of the fuzz of a fiber can be suppressed. Therefore, while the handling of the fiber reinforced resin member 21 becomes easy, in the fiber reinforced resin member attaching process, the fiber reinforced resin member 21 can be assembled easily. In addition, it is possible to prevent the fibers of the fiber reinforcing layer 31 from fraying and the substance from entering between the fibers and the resin and deteriorating.

Further, in the example of the present embodiment, since the outer side of the fiber sheet 41 is pinched by the molding die K, the work of separately cutting the end can be omitted, so that the number of working steps can be reduced.

Further, in an example of the present embodiment, the laminate 40 is configured of a plurality of fiber sheets 41 and a plurality of matrix resin sheets 42 disposed between the fiber sheets 41 and in the outermost layer. Then, in the preparation step, only the size of the matrix resin sheet 42 disposed in the outermost layer is made larger than the fiber sheet 41. Therefore, the material cost can be reduced.

Second Embodiment
In the second embodiment, the case where a thin plate-like fiber reinforced resin member is attached to the outer surface (for example, the upper surface) of a rectangular tank body (not shown) will be described.
The fiber reinforced resin member forming process according to the second embodiment mainly performs a preparing process, an arranging process, and a main forming process, as in the first embodiment.

The preparation step is a step of forming a laminate 140 by sequentially overlapping a plurality of fiber sheets 141 and a plurality of matrix resin sheets 142, as shown in FIG. In the preparation step, the matrix resin sheets 142 are disposed on both sides of the fiber sheet 141. Thereby, the matrix resin sheet 42 is arrange | positioned between the fiber sheets 41 and the outermost layer (surface) of the laminated body 140. FIG.

The fiber sheet 141 has a rectangular shape, and a notch 141a is formed in the central portion. The notch 141a corresponds to, for example, a pump module (not shown) of a rectangular tank body (not shown). The matrix resin sheet 142 has a shape and a size capable of covering the fiber sheet 141, and has a rectangular shape here.

The disposing step and the main forming step are the same as in the first embodiment, and thus the description thereof is omitted. The outline of the fiber reinforced resin member 121 completed by the manufacturing method of the fiber reinforced resin member of 2nd embodiment is shown in FIG. FIG. 10 schematically shows a plane of the fiber reinforced resin member 121. As shown in FIG.

The fiber reinforced resin member 121 is composed of a fiber reinforced layer 131 and a matrix resin layer 132 formed on both sides of the fiber reinforced layer 131, and the layers are alternately laminated. The notches 132a formed in the matrix resin layer 132 are formed, for example, by pinching (sandwiching) by the forming die K in the main forming process. In the preparation step, the matrix resin sheet 142 in which the notches are formed may be prepared in advance and may be stacked.

The fiber reinforcing layer 131 does not reach the outer edge of the fiber reinforced resin member 121, and a plurality of matrix resins (matrix resin sheet 142 (see FIG. 9)) are integrated with the outer edge of the fiber reinforced resin member 121. A hardened non-reinforcing portion 133 is formed. The unreinforced portion 133 is formed all around the outer edge of the fiber reinforcing layer 131. That is, the fiber reinforced layer 131 is not exposed to the outside by the unreinforced portion 133.

According to the manufacturing method of the fiber reinforced resin member concerning a second embodiment explained above, the same effect as the manufacturing method of the fiber reinforced resin member concerning a first embodiment is produced.

Although the embodiments of the present invention have been described above, design changes can be made as appropriate without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 1 Tank main body 3 recessed

part

21, 121 fiber reinforced

resin member

31, 131 fiber reinforced

layer

32, 132

matrix resin layer

33, 133

unreinforced part

40, 140

laminated body

41, 141

fiber sheet

42, 142 matrix resin sheet (resin sheet)
T fuel tank K mold

Claims

Preparing a laminated body in which a fiber sheet is laminated so as to be sandwiched by a resin sheet having a size larger than that of the fiber sheet;
And a main forming step of pressure forming the laminate so that the fiber sheet is not exposed.
The method according to claim 1, wherein in the main forming step, the resin sheet is pinched by a forming die at a position outside the end of the fiber sheet.
The laminate is constituted of a plurality of the fiber sheets and a plurality of the resin sheets disposed between the plurality of the fiber sheets and in the outermost layer,
The method for producing a fiber reinforced resin member according to claim 1 or 2, wherein in the preparing step, the size of only the resin sheet disposed in the outermost layer is made larger than the fiber sheet.
With the tank body,
A pair of fiber reinforced resin members sandwiching the outside of the tank body;
And a fastening portion for fastening both ends of the pair of fiber reinforced resin members,
The fiber reinforced resin member is configured by laminating a fiber reinforced layer and a matrix resin layer, and a fuel is characterized in that an unreinforced portion in which the fiber reinforced layer is not interposed is formed at an end portion. tank.
A fiber reinforced resin member characterized in that a fiber reinforced layer and a matrix resin layer are laminated and configured, and an unreinforced portion not having the fiber reinforced layer interposed is formed at an end portion.