JP2004066546A - Method for molding resin coat - Google Patents
Method for molding resin coat Download PDFInfo
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- JP2004066546A JP2004066546A JP2002226535A JP2002226535A JP2004066546A JP 2004066546 A JP2004066546 A JP 2004066546A JP 2002226535 A JP2002226535 A JP 2002226535A JP 2002226535 A JP2002226535 A JP 2002226535A JP 2004066546 A JP2004066546 A JP 2004066546A
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- resin
- bag
- mold
- resin layer
- fiber reinforced
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- 229920005989 resin Polymers 0.000 title claims abstract description 144
- 239000011347 resin Substances 0.000 title claims abstract description 144
- 238000000034 method Methods 0.000 title claims abstract description 40
- 238000000465 moulding Methods 0.000 title claims abstract description 31
- 239000000835 fiber Substances 0.000 claims abstract description 60
- 238000010438 heat treatment Methods 0.000 claims abstract description 14
- 239000000463 material Substances 0.000 claims description 43
- 238000007789 sealing Methods 0.000 claims description 9
- 238000000576 coating method Methods 0.000 claims description 7
- 230000002093 peripheral effect Effects 0.000 claims description 3
- 239000007787 solid Substances 0.000 claims description 3
- 239000007921 spray Substances 0.000 claims description 3
- 230000007423 decrease Effects 0.000 claims description 2
- 230000003014 reinforcing effect Effects 0.000 abstract 2
- 239000011800 void material Substances 0.000 abstract 1
- 239000011162 core material Substances 0.000 description 8
- 239000012779 reinforcing material Substances 0.000 description 8
- 239000006260 foam Substances 0.000 description 7
- 230000002787 reinforcement Effects 0.000 description 7
- 229920000049 Carbon (fiber) Polymers 0.000 description 4
- 239000004917 carbon fiber Substances 0.000 description 4
- 239000003822 epoxy resin Substances 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- 239000012778 molding material Substances 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- 239000000565 sealant Substances 0.000 description 4
- 229920001187 thermosetting polymer Polymers 0.000 description 4
- 229920006231 aramid fiber Polymers 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- PEEHTFAAVSWFBL-UHFFFAOYSA-N Maleimide Chemical compound O=C1NC(=O)C=C1 PEEHTFAAVSWFBL-UHFFFAOYSA-N 0.000 description 2
- 239000004677 Nylon Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 239000004643 cyanate ester Substances 0.000 description 2
- 239000003733 fiber-reinforced composite Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 229920001778 nylon Polymers 0.000 description 2
- 230000000379 polymerizing effect Effects 0.000 description 2
- 238000005507 spraying Methods 0.000 description 2
- 239000004593 Epoxy Substances 0.000 description 1
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 240000007182 Ochroma pyramidale Species 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000004918 carbon fiber reinforced polymer Substances 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 230000006837 decompression Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000002648 laminated material Substances 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 229920007790 polymethacrylimide foam Polymers 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000009974 thixotropic effect Effects 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
Images
Abstract
Description
【０００１】
【発明の属する技術分野】
本発明は、型の一面に樹脂を塗布して樹脂層を形成し、前記樹脂層の樹脂を繊維強化材に含浸させて加熱硬化させる樹脂コート成形法に関する。
【０００２】
【従来の技術】
従来、繊維強化複合材料の製造にはプリプレグが用いられている。プリプレグは、繊維強化材に熱硬化性樹脂を含浸し、手作業で容易に取扱うことができる程度に硬化反応を進めた成形材料である。主として、炭素繊維、ボロン繊維、アラミド繊維などの繊維強化材とエポキシ系の樹脂を用いて構成したプリプレグが用いられている。
【０００３】
プリプレグの成形は、型の内面に敷設した複数枚のプリプレグを加圧下で加熱硬化させることにより行う。プリプレグはその構造から表面にタックがあり、積層する際にプリプレグ間にエアーを噛み込む。このため、外部から十分加圧することなく大気圧で加圧成形を行う真空バッグ成形の場合には、得られる成形品中にはエアーの残存によるボイドが発生し、成形品の物性が低下してしまうという問題がある。
【０００４】
このようなボイドの発生を防止するものとして、国際公開ＷＯ００／２７６３２には、樹脂層の少なくとも一面に繊維強化材を積重した成形材料が開示されている。また、特開平５−２６９９０９号公報には、プリプレグに代えて繊維強化材と熱硬化性樹脂の樹脂フィルムを用いる方法も開示されている。この方法は、繊維強化材と樹脂フィルムを積重した後加熱して樹脂フィルムの樹脂を繊維強化材に含浸させるとともに硬化させ成形品とする。
【０００５】
これらの成形材料を用いる方法は、従来のプリプレグと比較してボイドの発生を抑制することができる。また、オートクレーブのような特別な装置を必要とせず、硬化炉を使用した真空バッグ成形で容易に成形品を得ることができ、低い製造コストで製品が得られる利点がある。しかし、成形材料として用いる樹脂はフィルム化する必要があり、使用できる樹脂が制限される。また、室温でフィルムの形状を保持するため低温で保存を行う必要があるほか、樹脂のライフが短い等その取扱いは困難である。
【０００６】
【発明が解決しようとする課題】
本発明の目的は、取扱いが困難な樹脂フィルムを必要とせず、エアーの残存によるボイドが発生しない成形法を提供することにある。
【０００７】
【課題を解決するための手段】
上記課題を解決する本発明は、以下に記載するものである。
【０００８】
〔１〕 型の一面上に樹脂層を形成し、前記樹脂層に繊維強化材シートを積重した後、積重した繊維強化材シート上にバッグを重ねると共に当該バッグ周縁を型に気密にシールしてバッグと型との間を排気し、加熱することにより樹脂層の樹脂を繊維強化材シートに含浸させ硬化させる樹脂コート成形法。
【０００９】
〔２〕 型の一面上に樹脂層を形成し、前記樹脂層に繊維強化材シートを積重した後、積重した繊維強化材シート上にバッグを重ねると共に当該バッグ周縁を型の他面を被覆した他のバッグに気密にシールし、次いでバッグと型との間を排気し、加熱することにより樹脂層の樹脂を繊維強化材シートに含浸させ硬化させる樹脂コート成形法。
【００１０】
〔３〕 型の一面上に樹脂層を形成し、前記樹脂層に繊維強化材シートを積重した後、積重した繊維強化材シート上にバッグを重ねると共に当該バッグ周縁を型に気密にシールしてバッグと型との間を排気し、オートクレーブで加圧下加熱することにより樹脂層の樹脂を繊維強化材シートに含浸させ硬化させる樹脂コート成形法。
【００１１】
〔４〕 型の一面上に樹脂層を形成し、前記樹脂層に繊維強化材シートを積重した後、積重した繊維強化材シート上にバッグを重ねると共に当該バッグ周縁を型の他面を被覆した他のバッグに気密にシールし、次いでバッグと型との間を排気し、オートクレーブで加圧下加熱することにより樹脂層の樹脂を繊維強化材シートに含浸させ硬化させる樹脂コート成形法。
【００１２】
〔５〕 樹脂層の形成を刷毛塗り法又は噴霧法により行う〔１〕乃至〔４〕のいずれかに記載の樹脂コート成形法。
【００１３】
〔６〕 樹脂層を形成する樹脂の２５℃における粘度が１００Ｐａ・ｓ〜半固形であり、成形加熱時に粘度が０．１〜１０Ｐａ・ｓに減少する〔１〕乃至〔４〕のいずれかに記載の樹脂コート成形法。
【００１４】
【発明の実施の形態】
樹脂層を形成する樹脂としては、通常用いられる熱硬化性樹脂が使用できる。具体的には、エポキシ樹脂、不飽和ポリエステル樹脂、フェノール樹脂、メラミン樹脂、ポリウレタン樹脂、シリコン樹脂、マレイミド樹脂、ビニルエステル樹脂、シアン酸エステル樹脂、マレイミド樹脂とシアン酸エステル樹脂を予備重合した樹脂等が挙げられ、本発明においてはこれらの樹脂の混合物を使用することもできる。繊維強化複合材料を用途とする場合には、耐熱性、弾性率、耐薬品性に優れたエポキシ樹脂組成物が好ましい。これらの熱硬化性樹脂には、硬化剤、硬化促進剤等が含まれていてもよい。
【００１５】
樹脂の硬化温度は、６０〜１８０℃となるよう調製することが好ましく、７０〜１３０℃に調製することがより好ましい。
【００１６】
２５℃における樹脂粘度は、型に塗布した樹脂の液だれを防止するため１００Ｐａ・ｓ〜半固形であることが好ましい。
【００１７】
また、成形加熱時に樹脂粘度が０．１〜１０Ｐａ・ｓに粘度減少するものが好ましい。かかる粘度を有する樹脂は、型に塗布する際に好適に用いることができる。
【００１８】
繊維強化材シートとしては、炭素繊維、ガラス繊維、アラミド繊維、ボロン繊維、金属繊維等の強化繊維が使用できる。中でも、炭素繊維、ガラス繊維、アラミド繊維が好ましい。また、これらの繊維強化材シートの形態は、一方向に引き揃えたもの又は多方向に引き揃えたもの、織物、編物、不織布等の任意の加工品が利用できる。
【００１９】
繊維強化材シートの目付は２００〜３０００ｇ／ｍ２が好ましく、４００〜２０００ｇ／ｍ２がより好ましい。
【００２０】
以下、図１を参照して本発明の樹脂コート成形法について説明する。
【００２１】
まず、型２の一面に沿って所要の厚さまで型に樹脂を塗布して樹脂層４を形成し、樹脂層４上に繊維強化材シート６を積重する（図１（ａ））。型は特に制限がなく公知のものが使用できる。
【００２２】
型に樹脂層を形成する方法としては、刷毛塗り法、噴霧法等の任意の形成法を用いることができる。樹脂層の樹脂量は、積重する繊維強化材と樹脂層の樹脂量を加えた重量の３５〜５５％とすることが好ましい。
【００２３】
また、型上に形成する樹脂層は、室温で適度なタック性を有することが好ましい。適度なタック性を有する樹脂層は繊維強化材を積重する際に作業性を高めることができ好適である。
【００２４】
室温で適度なタック性を有する樹脂層を形成する方法としては、高粘度の樹脂を加熱して低粘度とし型に塗布後、常温に戻すことにより適度なタック性を有する樹脂層とする方法、低粘度樹脂を型に塗布し、加熱時に繊維強化材に含浸する程度に樹脂を部分的に重合させることにより適度なタック性を有する樹脂層とする方法、樹脂のチキソトロピー性を利用して適度のタック性を有する樹脂層とする方法等を挙げることができる。
【００２５】
繊維強化材シート６を積重した後、バッグ８を繊維強化材に重ねて配置してバッグ８の周縁を型２と気密にシールし、密封する（図１（ｂ））。バッグを用いて繊維強化材シートを密封した後、型２とバッグ８間の気体を排気して減圧にする（図１（ｃ））。型とバッグ間を減圧にすることによりバッグが変形し、繊維強化材は型上に形成された樹脂層に密着する。
【００２６】
バッグの材質は特に制限されず、通常用いられる公知のものを使用することができる。更に、バッグの形状としては特に制限されず、型や目的とする成形品の形状によりシート状、袋状等の形状を適宜選択して用いることができる。また、バッグのシールは減圧により繊維強化材が型上に形成した樹脂層に密着するように行うことができればよい。例えば、バッグをシーラントで型に直接シールする方法、繊維強化材を積重した型を袋状のバッグに挿入しバッグ周縁を型にシールする方法、繊維強化材上に重ねて配置した一のバッグと型の他面に配置した他のバッグをシーラントで気密にシールする方法等を例示できる。バッグ同士をシールして型全体をバッグで覆う方法は、型を貫通する治具取付け孔があって型に直接シールしても密封できない場合や、型が通気性材料で形成されている場合等に特に有効である。
【００２７】
その後、バッグ８で密封された樹脂層４及び繊維強化材シート６をオーブン又はオートクレーブで加熱することにより繊維強化樹脂層１３からなる成形品１２を得る（図１（ｄ））。加熱を行うことにより樹脂層の樹脂を繊維強化材シートに十分含浸させ、硬化させて成形品とすることができる。加熱温度は６０〜２００℃が好ましい。また、オートクレーブを用いる場合には、加圧圧力は０．１〜０．５ＭＰａとすることが好ましい。オーブン又はオートクレーブで処理を行う際には、型とバッグ間の気体を排気した後又は排気しながら処理を行うことが好ましい。
【００２８】
更に、本発明の成形法においては発泡コア材を内部に挿入してもよい。発泡コア材を使用した成形法の一例を図２に示す。
【００２９】
型２８上に樹脂を塗布して樹脂層１４ａを形成し、繊維強化材シート１６ａ、発泡コア材２４を敷設する。更に発泡コア材２４上に樹脂を塗布して樹脂層１４ｂを形成し、この樹脂層上に繊維強化材シート１６ｂを敷設する（図２（ａ））。その後、バッグ１８で密封した後、図１に示す場合と同様にバッグ内を減圧し、加熱成形を行い、繊維強化樹脂層２６ａ、２６ｂ、発泡コア材２４からなる成形品２２を得る（図２（ｂ））。発泡コア材としては、ウレタンフォーム、塩化ビニルフォーム、ポリメタアクリルイミドフォーム、アクリルフォーム、フェノールフォーム、ポリスチレンフォーム等が例示できる。また、バルサ材等も使用できる。
【００３０】
なお、本発明の樹脂コート成形法においては、成形品の用途に応じてゲルコートを使用してもよい。ゲルコートを使用する場合には、離型処理を行った型上にゲルコートを塗布してゲルコート層を形成し、ゲルコート層上に樹脂層を形成する。ゲルコート層は室温で又は加熱により重合させゲル化し、繊維強化材には含浸せず成形品の表面に残るため、成形品の表面を滑らかにすることができる。ゲルコートを塗布する場合には通常噴霧法、刷毛塗り法が用いられる。上記樹脂層の形成においても噴霧法又は刷毛塗り法を用いればゲルコート層と樹脂層の形成は同じ設備で行うことができ生産性の点で好ましい。
【００３１】
【実施例】
以下、実施例により本発明を更に詳細に説明する。
【００３２】
実施例１
８０℃に加熱したエピコート８３４（ジャパンエポキシレジン社製）を８０質量部、エピコート１００１（ジャパンエポキシレジン社製）を２０質量部、アンカー１０４０（エアープロダクツジャパン社製）を５質量部計量、混錬し、離型処理した平らなアルミ板の上に、１５００ｇ／ｍ２になるように刷毛で塗布した。その後、塗布した樹脂が室温に戻り、適度なタックを生じた後、寸法５００ｍｍ×５００ｍｍにカットした炭素繊維織物Ｗ−３１０１（東邦テナックス社製）を１０枚積層し、その上にピールクロスを積層した。その後、積層した材料全体をナイロンバッグ（ＷＲＩＧＨＴＬＯＮ ＃７４００、ＡＩＲＴＥＣＨ社製）で覆い、型とナイロンバッグをシーラントテープでシールし、バッグ内を真空ポンプで減圧した。
【００３３】
その後、硬化炉で１３０℃、２時間、真空ポンプで減圧しながら加熱硬化し、板厚２．２ｍｍのＣＦＲＰ板を得た。
【００３４】
【発明の効果】
本発明の成形法は、型上に樹脂層を形成しその上に繊維強化材を積重した後加熱することにより樹脂層の樹脂を繊維強化材シートに含浸させるので、樹脂をフィルム化する必要がない。このため、従来のように半硬化状態の樹脂フィルムの状態を使用時期まで保つため低温保存する必要がなく、調合した樹脂をすぐに使用できるため取扱いが容易で、樹脂ライフの点で有利である。真空バッグ成形を行っても従来のプリプレグのようなボイドを生じることがなく、高品位の成形品が得られる。
【図面の簡単な説明】
【図１】本発明の成形法の一例を示すフロー図で、（ａ）は樹脂層を形成し繊維強化材を積重した状態を示す断面図、（ｂ）は繊維強化材をバッグと型との間にシールした状態を示す断面図、（ｃ）はバッグと型との間を排気した状態を示す断面図、（ｄ）は樹脂を含浸させ成形品とした状態を示す断面図である。
【図２】本発明の成形法の他の例を示すフロー図で、発泡コア材を用いた成形法を示す図である。
【符号の説明】
２、２８ 型
４、１４ａ、１４ｂ 樹脂層
６、１６ａ、１６ｂ 繊維強化材シート
８、１８ バッグ
１０、２０ シーラント
１２、２２ 成形品
１３、２６ａ、２６ｂ 繊維強化樹脂層
２４ 発泡コア材[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a resin coating molding method in which a resin is applied to one surface of a mold to form a resin layer, and the resin of the resin layer is impregnated with a fiber reinforcement and cured by heating.
[0002]
[Prior art]
Conventionally, prepregs have been used for producing fiber-reinforced composite materials. A prepreg is a molding material obtained by impregnating a fiber reinforced material with a thermosetting resin and proceeding a curing reaction to such an extent that it can be easily handled manually. A prepreg mainly composed of a fiber reinforcing material such as carbon fiber, boron fiber, and aramid fiber and an epoxy-based resin is used.
[0003]
The prepreg is formed by heating and curing a plurality of prepregs laid on the inner surface of the mold under pressure. The prepreg has a tack on the surface due to its structure, and air is bitten between the prepregs when laminating. For this reason, in the case of vacuum bag molding in which pressure molding is performed at atmospheric pressure without sufficient external pressure, voids are generated in the resulting molded product due to residual air, and the physical properties of the molded product are reduced. Problem.
[0004]
As a device for preventing the generation of such voids, WO 00/27632 discloses a molding material in which a fiber reinforcing material is stacked on at least one surface of a resin layer. Also, Japanese Patent Application Laid-Open No. 5-269909 discloses a method using a resin film of a fiber reinforced material and a thermosetting resin instead of a prepreg. In this method, a fiber reinforced material and a resin film are stacked and then heated to impregnate the resin of the resin film into the fiber reinforced material and harden to obtain a molded product.
[0005]
The method using these molding materials can suppress the generation of voids as compared with the conventional prepreg. Also, there is an advantage that a molded product can be easily obtained by vacuum bag molding using a curing furnace without requiring a special device such as an autoclave, and the product can be obtained at a low manufacturing cost. However, the resin used as the molding material needs to be formed into a film, and the usable resin is limited. In addition, it is necessary to store the film at a low temperature in order to maintain the shape of the film at room temperature, and it is difficult to handle the resin because the life of the resin is short.
[0006]
[Problems to be solved by the invention]
An object of the present invention is to provide a molding method that does not require a resin film that is difficult to handle and does not generate voids due to remaining air.
[0007]
[Means for Solving the Problems]
The present invention that solves the above-mentioned problems is described below.
[0008]
[1] A resin layer is formed on one surface of a mold, and a fiber reinforced material sheet is stacked on the resin layer. Then, a bag is stacked on the stacked fiber reinforced material sheets, and the periphery of the bag is hermetically sealed to the mold. A resin coat molding method in which the space between the bag and the mold is evacuated and heated to impregnate the resin of the resin layer into the fiber reinforced material sheet and harden.
[0009]
[2] After forming a resin layer on one surface of a mold, stacking a fiber reinforced material sheet on the resin layer, stacking a bag on the stacked fiber reinforced material sheet, and attaching the periphery of the bag to the other surface of the mold. A resin coat molding method in which the bag is airtightly sealed to another coated bag, and then the space between the bag and the mold is evacuated and heated to impregnate the resin of the resin layer into the fiber reinforced material sheet and cure the resin.
[0010]
[3] Forming a resin layer on one surface of a mold, stacking a fiber reinforced material sheet on the resin layer, stacking a bag on the stacked fiber reinforced material sheet, and hermetically sealing the periphery of the bag with the mold. A resin coat molding method in which the space between the bag and the mold is evacuated, and the resin in the resin layer is impregnated into the fiber reinforced material sheet and cured by heating under pressure in an autoclave.
[0011]
[4] A resin layer is formed on one surface of a mold, and a fiber reinforced material sheet is stacked on the resin layer. Then, a bag is stacked on the stacked fiber reinforced material sheets, and the periphery of the bag is attached to the other surface of the mold. A resin coat molding method in which the bag is airtightly sealed with another coated bag, and then the space between the bag and the mold is evacuated and heated under pressure in an autoclave to impregnate the resin of the resin layer into the fiber reinforced material sheet and cure the resin.
[0012]
[5] The resin coat molding method according to any one of [1] to [4], wherein the resin layer is formed by a brush coating method or a spray method.
[0013]
[6] The resin according to any one of [1] to [4], wherein the viscosity of the resin forming the resin layer at 25 ° C. is 100 Pa · s to semi-solid, and the viscosity decreases to 0.1 to 10 Pa · s during molding and heating. The resin coating molding method according to the above.
[0014]
BEST MODE FOR CARRYING OUT THE INVENTION
As the resin forming the resin layer, a thermosetting resin that is usually used can be used. Specifically, epoxy resin, unsaturated polyester resin, phenol resin, melamine resin, polyurethane resin, silicone resin, maleimide resin, vinyl ester resin, cyanate ester resin, resin obtained by pre-polymerizing maleimide resin and cyanate ester resin, etc. In the present invention, a mixture of these resins can also be used. When a fiber-reinforced composite material is used, an epoxy resin composition having excellent heat resistance, elastic modulus, and chemical resistance is preferable. These thermosetting resins may contain a curing agent, a curing accelerator, and the like.
[0015]
The curing temperature of the resin is preferably adjusted to 60 to 180 ° C, more preferably 70 to 130 ° C.
[0016]
The resin viscosity at 25 ° C. is preferably 100 Pa · s to semi-solid in order to prevent dripping of the resin applied to the mold.
[0017]
Further, it is preferable that the viscosity of the resin is reduced to 0.1 to 10 Pa · s during molding and heating. A resin having such a viscosity can be suitably used when applied to a mold.
[0018]
As the fiber reinforcing material sheet, reinforcing fibers such as carbon fiber, glass fiber, aramid fiber, boron fiber, and metal fiber can be used. Among them, carbon fiber, glass fiber and aramid fiber are preferred. Further, as the form of these fiber reinforced material sheets, any processed product such as one aligned in one direction or one aligned in multiple directions, a woven fabric, a knitted fabric, and a nonwoven fabric can be used.
[0019]
Basis weight of the fibrous reinforcement sheet is preferably 200~3000g / m 2, 400~2000g / m 2 is more preferable.
[0020]
Hereinafter, the resin coat molding method of the present invention will be described with reference to FIG.
[0021]
First, a resin is applied to a mold to a required thickness along one surface of the
[0022]
As a method of forming the resin layer on the mold, an arbitrary forming method such as a brush coating method and a spraying method can be used. It is preferable that the resin amount of the resin layer is 35 to 55% of the total weight of the fiber reinforcing material to be stacked and the resin amount of the resin layer.
[0023]
Further, the resin layer formed on the mold preferably has an appropriate tackiness at room temperature. A resin layer having an appropriate tackiness is preferable because workability can be improved when stacking fiber reinforcing materials.
[0024]
As a method of forming a resin layer having an appropriate tackiness at room temperature, a method of heating a high-viscosity resin to a low-viscosity mold and applying it to a mold, and then returning to room temperature to form a resin layer having an appropriate tackiness, A method of applying a low-viscosity resin to a mold and forming a resin layer having an appropriate tackiness by partially polymerizing the resin to an extent that the resin is impregnated into the fiber reinforcement at the time of heating, an appropriate method using the thixotropic property of the resin. A method of forming a resin layer having tackiness can be given.
[0025]
After stacking the fiber reinforced
[0026]
The material of the bag is not particularly limited, and a commonly used known material can be used. Furthermore, the shape of the bag is not particularly limited, and a shape such as a sheet shape or a bag shape can be appropriately selected and used depending on the shape of a mold and a target molded product. Further, the bag may be sealed as long as the fiber reinforcing material can be adhered to the resin layer formed on the mold by decompression. For example, a method of directly sealing a bag with a mold with a sealant, a method of inserting a mold stacked with a fiber reinforced material into a bag-shaped bag and sealing the periphery of the bag with the mold, a bag laid over the fiber reinforced material And a method of airtightly sealing another bag arranged on the other surface of the mold with a sealant. The method of sealing the bags and covering the whole mold with the bag is when there is a jig mounting hole that penetrates the mold and it cannot be sealed even if it is directly sealed to the mold, or when the mold is formed of a breathable material, etc. It is especially effective for
[0027]
Thereafter, the
[0028]
Further, in the molding method of the present invention, a foam core material may be inserted inside. FIG. 2 shows an example of a molding method using a foamed core material.
[0029]
The resin is applied on the
[0030]
In the resin coat molding method of the present invention, a gel coat may be used depending on the use of the molded article. When a gel coat is used, a gel coat is applied on a mold that has been subjected to a release treatment to form a gel coat layer, and a resin layer is formed on the gel coat layer. The gel coat layer is polymerized and gelled at room temperature or by heating and remains on the surface of the molded article without impregnating the fiber reinforcing material, so that the surface of the molded article can be smoothened. When applying a gel coat, a spraying method or a brush coating method is usually used. Also in the formation of the resin layer, if the spray method or the brush coating method is used, the formation of the gel coat layer and the resin layer can be performed by the same equipment, which is preferable in terms of productivity.
[0031]
【Example】
Hereinafter, the present invention will be described in more detail with reference to examples.
[0032]
Example 1
80 parts by mass of Epicoat 834 (manufactured by Japan Epoxy Resin) heated to 80 ° C., 20 parts by mass of Epicoat 1001 (manufactured by Japan Epoxy Resin), and 5 parts by mass of anchor 1040 (manufactured by Air Products Japan) are kneaded and kneaded. Then, it was applied on a release-treated flat aluminum plate with a brush so as to be 1500 g / m 2 . Then, after the applied resin returns to room temperature and a moderate tack is generated, ten carbon fiber fabrics W-3101 (manufactured by Toho Tenax Co., Ltd.) cut to a size of 500 mm × 500 mm are laminated, and a peel cloth is laminated thereon. did. Thereafter, the entire laminated material was covered with a nylon bag (WRIGTLON # 7400, manufactured by AIRTECH), the mold and the nylon bag were sealed with a sealant tape, and the inside of the bag was evacuated with a vacuum pump.
[0033]
Thereafter, the mixture was cured by heating in a curing furnace at 130 ° C. for 2 hours while reducing the pressure with a vacuum pump to obtain a 2.2 mm thick CFRP plate.
[0034]
【The invention's effect】
In the molding method of the present invention, a resin layer is formed on a mold, a fiber reinforcement is stacked thereon, and then heated to impregnate the resin of the resin layer into the fiber reinforcement sheet. There is no. Therefore, it is not necessary to store the resin film in a semi-cured state until the time of use as in the prior art, and it is not necessary to store the resin film at a low temperature. . Even when vacuum bag molding is performed, voids unlike conventional prepregs are not generated, and a high-quality molded product can be obtained.
[Brief description of the drawings]
FIG. 1 is a flow chart showing an example of a molding method according to the present invention. FIG. 1 (a) is a cross-sectional view showing a state in which a resin layer is formed and fiber reinforcing materials are stacked, and FIG. (C) is a cross-sectional view showing a state where the space between the bag and the mold is evacuated, and (d) is a cross-sectional view showing a state where a resin is impregnated to form a molded product. .
FIG. 2 is a flowchart showing another example of the molding method of the present invention, and is a diagram showing a molding method using a foamed core material.
[Explanation of symbols]
2, 28
Claims (6)
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002226535A JP4052381B2 (en) | 2002-08-02 | 2002-08-02 | Resin coat molding method |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2002226535A JP4052381B2 (en) | 2002-08-02 | 2002-08-02 | Resin coat molding method |
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| JP2004066546A true JP2004066546A (en) | 2004-03-04 |
| JP4052381B2 JP4052381B2 (en) | 2008-02-27 |
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Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2007098819A (en) * | 2005-10-06 | 2007-04-19 | Mitsubishi Rayon Co Ltd | Manufacturing method of sandwich panel |
| JP2007098818A (en) * | 2005-10-06 | 2007-04-19 | Mitsubishi Rayon Co Ltd | Manufacturing method of fiber reinforced plastic panel |
| US7282990B2 (en) | 2005-04-22 | 2007-10-16 | Samsung Electronics Co., Ltd. | Operational amplifier for output buffer and signal processing circuit using the same |
-
2002
- 2002-08-02 JP JP2002226535A patent/JP4052381B2/en not_active Expired - Fee Related
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7282990B2 (en) | 2005-04-22 | 2007-10-16 | Samsung Electronics Co., Ltd. | Operational amplifier for output buffer and signal processing circuit using the same |
| JP2007098819A (en) * | 2005-10-06 | 2007-04-19 | Mitsubishi Rayon Co Ltd | Manufacturing method of sandwich panel |
| JP2007098818A (en) * | 2005-10-06 | 2007-04-19 | Mitsubishi Rayon Co Ltd | Manufacturing method of fiber reinforced plastic panel |
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| JP4052381B2 (en) | 2008-02-27 |
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