JP2005305673A - Fiber-reinforced laminated material and its manufacturing method - Google Patents

Fiber-reinforced laminated material and its manufacturing method Download PDF

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JP2005305673A
JP2005305673A JP2004122127A JP2004122127A JP2005305673A JP 2005305673 A JP2005305673 A JP 2005305673A JP 2004122127 A JP2004122127 A JP 2004122127A JP 2004122127 A JP2004122127 A JP 2004122127A JP 2005305673 A JP2005305673 A JP 2005305673A
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fiber
laminated material
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reinforced laminated
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JP4146817B2 (en
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Shoichi Mitamura
庄一 三田村
Shigechika Aoki
繁周 青木
Takayuki Seki
隆之 関
Hidetake Suzuki
秀武 鈴木
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Sakai Ovex Co Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a fiber-reinforced laminated material capable of also certainly performing the display of a symbol mark or the like on its surface, and its manufacturing method. <P>SOLUTION: As shown by Fig. (a), the symbol mark 21a is formed on the surface of the fiber-reinforced laminated material 21 and satin-like unevenness 21b is further formed on the whole surface threreof. The fiber-reinforced laminated material 21 is a cabon fiber-reinforced plastic (CFRP) having a thickness of about 2 mm as a whole. As shown by Fig (b), the fiber-reinforced laminated material 21 is produced by thermally curing a prepreg laminated material 22. The prepreg laminated material 22 is held between release films 22 and 23 being perforated release films and both sides of the release films are further held between bleeder cloths 26 and 27 through a symbol-shaped transfer molds 25 with a thickness of about 1 mm to be further held between press plates 28 and 29. The whole held between the press plates 28 and 29 is housed in a vacuum bag to be heated and pressed in an autoclave. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

本発明は、ＦＲＰなどの繊維強化積層材およびその製造方法に関する。   The present invention relates to a fiber-reinforced laminated material such as FRP and a method for producing the same.

従来から、繊維材料で強化した合成樹脂は、繊維強化プラスチック（ＦＲＰ）と呼ばれ、広く使用されている。繊維強化プラスチックは、積層板として利用されることが多い。積層材は、繊維基材に熱硬化性樹脂を含浸して形成されるプリプレグのシートを複数枚重ねて加熱加圧して製造する。加熱加圧の方法は、プレス加工法とオートクレーブ加工法とに大別される。   Conventionally, a synthetic resin reinforced with a fiber material is called a fiber reinforced plastic (FRP) and is widely used. Fiber reinforced plastics are often used as laminates. The laminated material is manufactured by stacking a plurality of prepreg sheets formed by impregnating a fiber base material with a thermosetting resin and heating and pressing. Heating and pressing methods are roughly classified into a press working method and an autoclave working method.

図５は、プレス加工法の概要を示す。プレス加工法では、プリプレグ積層物１をプレスの熱板２，３で積層方向の両側から挟んで加熱しながら加圧する。加熱によってプリプレグ積層物１中の樹脂成分がいったん低粘度の液状となり、外部にしみ出す。プリプレグ積層物１の表裏両面は多孔性シートであるピールフライで覆われ、さらに離型フィルム６，７で覆われる。離型フィルム６，７の両側は、成形ジグ８，９で挟まれ、さらに緩衝材１０，１１を介して、プレスの熱板２，３からの加圧が行われる。   FIG. 5 shows an outline of the press working method. In the press working method, the prepreg laminate 1 is pressed while being sandwiched between the hot plates 2 and 3 of the press from both sides in the laminating direction. By heating, the resin component in the prepreg laminate 1 once becomes a low-viscosity liquid and exudes to the outside. Both front and back surfaces of the prepreg laminate 1 are covered with a peel fly which is a porous sheet, and further covered with release films 6 and 7. Both sides of the release films 6 and 7 are sandwiched between molding jigs 8 and 9, and pressurization from the hot plates 2 and 3 of the press is performed via the buffer materials 10 and 11.

図６は、オートクレーブ加工法の一例についての概要を示す。図６に示すオートクレーブ加工法では、プリプレグ積層物１の上方の表面を多孔性離型フィルム１２で覆い、さらに樹脂を吸収するブリーダクロス１３で覆い、さらに離型フィルム１４で覆った全体をブリーダクロス１５で包む。プリプレグ積層物１は、離型フィルム１６上に載置し、離型フィルム１６と離型フィルム１４とで、包込むようにする。下側の離型フィルム１６には、バキュームバッグ１７を被せ、周囲を真空用シール材１８で気密にシールする。バキュームバッグ１７の内部は、真空引口１７ａからの真空吸引で低圧にしておき、外圧でプリプレグ積層物１を加圧する。バキュームバッグ１７を被せたプリプレグ積層物１を含む組立体は、成形ジグ１９上に載置して、オートクレーブに装入し、加熱する。加熱温度は、熱電対２０で測定する。   FIG. 6 shows an outline of an example of the autoclave processing method. In the autoclave processing method shown in FIG. 6, the upper surface of the prepreg laminate 1 is covered with a porous release film 12, further covered with a bleeder cloth 13 that absorbs resin, and further covered with a release film 14 as a whole. Wrap with 15 The prepreg laminate 1 is placed on the release film 16 and wrapped with the release film 16 and the release film 14. The lower release film 16 is covered with a vacuum bag 17 and the periphery is hermetically sealed with a vacuum sealing material 18. The inside of the vacuum bag 17 is kept at a low pressure by vacuum suction from the vacuum suction port 17a, and the prepreg laminate 1 is pressurized with an external pressure. The assembly including the prepreg laminate 1 covered with the vacuum bag 17 is placed on the forming jig 19, charged in an autoclave, and heated. The heating temperature is measured with a thermocouple 20.

図７は、オートクレーブ加工法の他の例についての概要を示す。プリプレグ積層物１は、成形ジグ１９上に載置した離型フィルム１６上に載置する。プリプレグ積層物１の上面側には、離型フィルム１４ブリーダクロス１５およびバキュームバッグ１７で順次覆う。バキュームバッグ１７の周囲は真空用シール材１８で気密にシールする。   FIG. 7 shows an outline of another example of the autoclave processing method. The prepreg laminate 1 is placed on a release film 16 placed on a forming jig 19. The upper surface of the prepreg laminate 1 is sequentially covered with a release film 14 bleeder cloth 15 and a vacuum bag 17. The periphery of the vacuum bag 17 is hermetically sealed with a vacuum sealing material 18.

プレス加圧法での加熱の際に、微細凹凸形状と離型性とを有するフィルムを挟んで、微細凹凸を積層材の表面に転写させる技術が開示されている（たとえば、特許文献１参照。）。プリプレグを加熱加圧する金型の表面に凹凸を形成して、成型品の表面に凹凸を転写する技術も開示されている（たとえば、特許文献２、３、４参照。）。絵柄や模様が施されたプリプレグシートを、シート・モールディング・コンパウンド（ＳＭＣ）と一体的に成型して、繊維強化プラスチック成形品を製造する技術も開示されている（たとえば、特許文献５、６参照。）。   A technique for transferring fine irregularities onto the surface of a laminated material by sandwiching a film having fine irregularities and releasability during heating by a pressurizing method is disclosed (for example, see Patent Document 1). . A technique is also disclosed in which irregularities are formed on the surface of a mold for heating and pressurizing a prepreg and the irregularities are transferred to the surface of a molded product (see, for example, Patent Documents 2, 3, and 4). There is also disclosed a technique for manufacturing a fiber-reinforced plastic molded article by integrally molding a prepreg sheet having a pattern or a pattern with a sheet molding compound (SMC) (see, for example, Patent Documents 5 and 6). .)

プリプレグの各層は炭素繊維を一方向に引き揃え、複数層を繊維の方向が直交するように積層して、加熱加圧時にメッシュを挟んで、表面に網目模様を形成する技術も開示されている（たとえば、特許文献７参照。）。   Each layer of the prepreg is also disclosed a technique in which carbon fibers are aligned in one direction, a plurality of layers are laminated so that the directions of the fibers are orthogonal, and a mesh pattern is formed on the surface by sandwiching a mesh during heating and pressurization. (For example, see Patent Document 7).

特開平７−２１４７１３号公報JP-A-7-214713 特開平７−３１４４７４号公報JP-A-7-314474 特開２００１−２６９９５６号公報JP 2001-269956 A 特開２００１−２６９９５７号公報JP 2001-269957 A 特開平９−１０９１６７号公報JP-A-9-109167 特開平９−１０９１６７号公報JP-A-9-109167 特開平９−２５４２６５号公報JP-A-9-254265

繊維強化積層材は、軽量で高強度を有するので、自動車、列車、航空機などの移動体の内装材などに好適に使用される。しかしながら、これらの内装材では、乗客などに対する案内などのシンボルや、運行サービスの提供者などのロゴマークなどの表示が必要となることが多い。前述の各特許文献では、表面に凹凸を形成することは可能でも、各種マークやシンボルなどの表示を有効に行うことができない。そのため、シンボルなどの表示が必要であれば、シンボルなどを表示するラベルなどを別に用意し、貼り付けて使用している。ラベルなどを貼り付けるのは、手間がかかる。また、いったん貼り付けたラベルなどは、脱落するおそれもある。   Since the fiber reinforced laminated material is lightweight and has high strength, it is suitably used as an interior material for moving bodies such as automobiles, trains, and airplanes. However, in these interior materials, it is often necessary to display symbols such as guidance for passengers and logo marks such as operation service providers. In each of the aforementioned patent documents, it is possible to form irregularities on the surface, but it is not possible to effectively display various marks and symbols. For this reason, if it is necessary to display a symbol or the like, a label or the like for displaying the symbol or the like is separately prepared and pasted. It takes time and effort to apply labels. In addition, once affixed labels or the like may fall off.

本発明の目的は、表面でシンボルなどの表示も確実に行うことができる繊維強化積層材およびその製造方法を提供することである。   An object of the present invention is to provide a fiber-reinforced laminated material capable of reliably displaying symbols and the like on the surface and a method for producing the same.

本発明は、合成樹脂の母材を複数の繊維層で強化した繊維強化積層材であって、
表面が凹凸模様面であり、かつ予め定めるシンボル形状が該凹凸模様よりも大きな凹凸で形成されていることを特徴とする繊維強化積層材である。 The present invention is a fiber-reinforced laminated material obtained by reinforcing a base material of a synthetic resin with a plurality of fiber layers,
The fiber-reinforced laminate material is characterized in that the surface is a concavo-convex pattern surface and a predetermined symbol shape is formed with concavo-convex larger than the concavo-convex pattern.

本発明に従えば、繊維強化積層材は、合成樹脂の母材を複数の繊維層で強化してあるので、軽量でも高強度を容易に得ることができる。繊維強化積層材の表面が凹凸模様面であり、かつ予め定めるシンボル形状が該凹凸模様よりも大きな凹凸で形成されているので、シンボル形状を凹凸模様よりも目立つようにして、シンボルについての確実な表示を行うことができる。   According to the present invention, since the fiber-reinforced laminated material is reinforced with a synthetic resin base material by a plurality of fiber layers, high strength can be easily obtained even with a light weight. Since the surface of the fiber reinforced laminated material is a concavo-convex pattern surface and the predetermined symbol shape is formed with a concavo-convex pattern larger than the concavo-convex pattern, the symbol shape is made more conspicuous than the concavo-convex pattern, and the symbol Display can be made.

また本発明で、前記繊維層は、全体に対する体積で２０〜７０％を占めることを特徴とする。   In the present invention, the fiber layer may occupy 20 to 70% of the total volume.

本発明に従えば、繊維層が全体に対する体積で２０〜７０％を占め、残りの合成樹脂で表面の凹凸形成やシンボル形状の表示などに対応する成形を行わせることができる。   According to the present invention, the fiber layer occupies 20 to 70% of the total volume, and the remaining synthetic resin can be molded corresponding to the formation of surface irregularities and the display of symbol shapes.

また本発明で、前記繊維層は、繊維束を開繊処理した開繊糸を使用する織物で形成されることを特徴とする。   In the present invention, the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle.

本発明に従えば、繊維層は、繊維束を開繊処理した開繊糸を使用する織物で形成されるので、厚さは薄くても、充分な強度となるように強化することができ、合成樹脂の占める割合を大きくして、成形性を高めることができる。   According to the present invention, the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle, so that even if the thickness is thin, the fiber layer can be reinforced to have sufficient strength, The moldability can be improved by increasing the proportion of the synthetic resin.

さらに本発明は、複数の繊維層を含む板状の合成樹脂材料の両側を多孔性の離型フィルムで挟み、
離型フィルムの少なくとも一方の一部に、シンボル形状転写型を配置し、
シンボル形状転写型を含む離型フィルムの両側を、樹脂吸収層で挟み、
樹脂吸収層の両側から硬質板で挟んで成形することを特徴とする繊維強化積層材の製造方法である。 Furthermore, the present invention sandwiches both sides of a plate-shaped synthetic resin material including a plurality of fiber layers with a porous release film,
Place a symbol shape transfer mold on a part of at least one of the release films,
Hold both sides of the release film including the symbol shape transfer mold with the resin absorption layer,
It is a manufacturing method of the fiber reinforced laminated material characterized by shape | molding by pinching with a hard board from the both sides of a resin absorption layer.

本発明に従えば、複数の繊維層を含む板状の合成樹脂材料の両側を多孔性の離型フィルムで挟むので、成形時に合成樹脂材料から樹脂成分がはみ出してきても、樹脂成分を透過させ、合成樹脂材料の硬化後には、容易に離型フィルムを剥がして、繊維強化積層材を得ることができる。離型フィルムの少なくとも一方の一部に、シンボル形状転写型を配置し、シンボル形状転写型を含む離型フィルムの両側を、樹脂吸収層で挟み、樹脂吸収層の両側から硬質板で挟んで成形する。成形された繊維強化積層材は、表面に樹脂吸収層の表面の凹凸が転写され、さらにシンボル形状転写型からシンボル形状が転写されるので、繊維強化積層材の表面でシンボル形状を表示することができる。繊維強化積層材の表面に直接シンボル形状などが形成されるので、ラベルのように剥がれるおそれをなくすることができる。   According to the present invention, since both sides of a plate-shaped synthetic resin material including a plurality of fiber layers are sandwiched between porous release films, the resin component is allowed to permeate even if the resin component protrudes from the synthetic resin material during molding. After the synthetic resin material is cured, the release film can be easily peeled off to obtain a fiber-reinforced laminated material. A symbol shape transfer mold is arranged on at least one part of the release film, and both sides of the release film including the symbol shape transfer mold are sandwiched between resin absorption layers and molded between both sides of the resin absorption layer with a hard plate. To do. Since the molded fiber reinforced laminate material has the surface irregularities of the resin absorption layer transferred to the surface, and the symbol shape is transferred from the symbol shape transfer mold, the symbol shape can be displayed on the surface of the fiber reinforced laminate material. it can. Since the symbol shape or the like is directly formed on the surface of the fiber reinforced laminate, it is possible to eliminate the possibility of peeling off like a label.

また本発明で、前記合成樹脂材料は、熱硬化性樹脂のプリプレグであることを特徴とする。   In the present invention, the synthetic resin material is a prepreg of a thermosetting resin.

本発明に従えば、熱硬化性樹脂のプリプレグを加熱して硬化させる際に、表面の凹凸形成と、シンボル形状の形成とを、容易に行うことができる。   According to the present invention, when the thermosetting resin prepreg is heated and cured, surface unevenness formation and symbol shape formation can be easily performed.

本発明によれば、繊維強化積層材の表面が凹凸模様面であり、かつ予め定めるシンボル形状が該凹凸模様よりも大きな凹凸で形成されているので、シンボル形状を凹凸模様よりも目立つようにして、シンボルについての確実な表示を行うことができる。   According to the present invention, the surface of the fiber reinforced laminate is an uneven pattern surface, and the predetermined symbol shape is formed with an unevenness larger than the uneven pattern, so that the symbol shape stands out from the uneven pattern. , A reliable display of symbols can be performed.

また本発明によれば、繊維層が全体に対する体積で２０〜７０％を占め、残りの合成樹脂で表面の凹凸形成やシンボル形状の表示などに対応する成形を行わせることができる。   Moreover, according to this invention, a fiber layer occupies 20 to 70% by the volume with respect to the whole, and shaping | molding corresponding to surface unevenness formation, a symbol shape display, etc. can be performed with the remaining synthetic resin.

また本発明によれば、繊維層は、開繊糸を使用する織物で形成されるので、厚さは薄くても、充分な強度となるように強化することができる。   Further, according to the present invention, the fiber layer is formed of a woven fabric using a spread yarn, so that the fiber layer can be reinforced to have sufficient strength even if the thickness is thin.

さらに本発明によれば、成形された繊維強化積層材は、表面に樹脂吸収層の表面の凹凸が転写され、さらにシンボル形状転写型からシンボル形状が転写されるので、繊維強化積層材の表面でシンボル形状を表示することができる。繊維強化積層材の表面に直接シンボル形状などが形成されるので、ラベルのように剥がれるおそれをなくすることができる。   Furthermore, according to the present invention, the molded fiber reinforced laminate material has the surface irregularities of the resin absorbent layer transferred to the surface, and the symbol shape is transferred from the symbol shape transfer mold. The symbol shape can be displayed. Since the symbol shape or the like is directly formed on the surface of the fiber reinforced laminate, it is possible to eliminate the possibility of peeling off like a label.

また本発明によれば、熱硬化性樹脂のプリプレグを加熱して硬化させる際に、表面の凹凸形成と、シンボル形状の形成とを、容易に行うことができる。   Further, according to the present invention, when the thermosetting resin prepreg is heated and cured, surface unevenness and symbol shape can be easily formed.

図１は、本発明の実施の一形態である繊維強化積層材２１とその製造方法を示す。図１（ａ）は繊維強化積層材２１として製造された状態を示し、図１（ｂ）はオートクレーブ加工法で成形する工程での加熱加圧状態を示す。   FIG. 1 shows a fiber-reinforced laminated material 21 and a method for manufacturing the same according to an embodiment of the present invention. FIG. 1A shows a state manufactured as a fiber reinforced laminate 21, and FIG. 1B shows a heating and pressurizing state in a step of molding by an autoclave processing method.

図１（ａ）に示すように、繊維強化積層材２１は、表面にたとえば「Ａ」のようなシンボルマーク２１ａが凹所として形成され、さらに表面全体に梨地状の凹凸２１ｂが形成されている。繊維強化積層材２１は、全体としては厚さが約２ｍｍ程度の炭素繊維強化プラスチック（ＣＦＲＰ）である。すなわち繊維強化積層材２１は、合成樹脂の母材を複数の繊維層で強化した繊維強化積層材であって、表面に梨地状の凹凸２１ｂが形成される凹凸模様面であり、かつ予め定めるシンボルマーク２１ａによるシンボル形状が凹凸模様よりも大きな凹凸で形成されている。   As shown in FIG. 1A, the fiber reinforced laminated material 21 has, for example, a symbol mark 21a such as “A” formed as a recess on the surface, and further a satin-like unevenness 21b formed on the entire surface. . The fiber reinforced laminated material 21 is a carbon fiber reinforced plastic (CFRP) having a thickness of about 2 mm as a whole. That is, the fiber reinforced laminated material 21 is a fiber reinforced laminated material obtained by reinforcing a base material of a synthetic resin with a plurality of fiber layers, and is a concavo-convex pattern surface on which a satin-like concavo-convex 21b is formed, and a predetermined symbol. The symbol shape by the mark 21a is formed with a larger unevenness than the uneven pattern.

繊維強化積層材２１は、合成樹脂の母材を複数の繊維層で強化してあるので、軽量でも高強度を容易に得ることができる。繊維強化積層材２１の表面が凹凸模様面であり、かつ予め定めるシンボル形状が凹凸模様よりも大きな凹凸で形成されているので、シンボル形状を凹凸模様よりも目立つようにして、シンボルについての確実な表示を行うことができる。なお、シンボルマーク２１ａは、機械的な切削加工などによって形成されていないので、強化繊維が切断されるようなことはなく、強度を維持することができる。   Since the fiber-reinforced laminated material 21 is made of a synthetic resin base material reinforced with a plurality of fiber layers, high strength can be easily obtained even if it is lightweight. Since the surface of the fiber reinforced laminated material 21 is a concavo-convex pattern surface, and the predetermined symbol shape is formed with a concavo-convex pattern larger than the concavo-convex pattern, the symbol shape is more conspicuous than the concavo-convex pattern, so Display can be made. Since the symbol mark 21a is not formed by mechanical cutting or the like, the reinforcing fiber is not cut and the strength can be maintained.

図１（ｂ）に示すように、繊維強化積層材２１は、プリプレグ積層材２２を熱硬化させて製造する。プリプレグ積層材２２は、多孔性の離型フィルムであるリリースフィルム２３，２４で挟み、さらに厚さ１ｍｍ程度のシンボル形状転写型２５を挟んで、両側をブリーダクロス２６，２７で挟み、さらに押え板２８，２９で挟む。ブリーダクロス２６と押え板２８との間には、樹脂が押え板２８に付着してしまうことを防ぐため、無孔の離型フィルム４０が介在される。押え板２８，２９は板厚が数ｍｍ〜１０数ｍｍ程度のアルミニウム板である。前記シンボル形状転写型２５および各押え板２８，２９の表面は、樹脂の付着を防ぐため、ポリテトラフルオロエチレン（商品名テフロン）から成る薄膜によって被覆されている。   As shown in FIG.1 (b), the fiber reinforced laminated material 21 is manufactured by thermosetting the prepreg laminated material 22. As shown in FIG. The prepreg laminate 22 is sandwiched between release films 23 and 24, which are porous release films, further sandwiched between symbol shape transfer molds 25 having a thickness of about 1 mm, both sides are sandwiched between bleeder cloths 26 and 27, and a press plate 28, 29. A non-porous release film 40 is interposed between the bleeder cloth 26 and the presser plate 28 in order to prevent the resin from adhering to the presser plate 28. The holding plates 28 and 29 are aluminum plates having a thickness of about several mm to several tens mm. The surfaces of the symbol shape transfer mold 25 and the pressing plates 28 and 29 are covered with a thin film made of polytetrafluoroethylene (trade name Teflon) in order to prevent adhesion of resin.

押え板２８，２９で挟まれた全体は、図６および図７に示すようなオートクレーブ加工法と同様に、バキュームバッグに収納し、たとえば０．４ＭＰａ程度に加圧したオートクレーブ中で、たとえば１２０℃、２時間の加熱を行う。   Similar to the autoclave processing method as shown in FIGS. 6 and 7, the whole sandwiched between the presser plates 28 and 29 is housed in a vacuum bag and is pressurized to, for example, about 0.4 MPa, for example, 120 ° C. Heat for 2 hours.

プリプレグ積層材２２は、たとえば炭素繊維の束を開繊処理した開繊糸を平織状に製織した基材を、８枚積層し、エポキシ樹脂を含浸させ、硬化の反応を途中まで進めておく。樹脂に対する繊維材の体積割合は、４０％としておく。一般の繊維強化複合材料では、樹脂の割合が比較的少ないけれども、開繊糸を使用した薄い基材を積層することによって、樹脂の割合を多くすることができる。   The prepreg laminated material 22 is formed by, for example, laminating eight base materials obtained by weaving open fibers obtained by opening a bundle of carbon fibers into a plain weave shape, impregnating with an epoxy resin, and proceeding the curing reaction halfway. The volume ratio of the fiber material to the resin is set to 40%. In a general fiber reinforced composite material, the proportion of resin can be increased by laminating thin substrates using spread yarns, although the proportion of resin is relatively small.

ブリーダクロス２６，２７は、リリースフィルム２３，２４に設ける孔からしみ出す液状樹脂を吸収するために用いられる。ブリーダクロス２６，２７としては、不織布を好適に用いることができる。不織布の表面は平滑ではないけれども、この凹凸がリリースフィルム２３，２４を介して繊維強化積層材２１の表面に転写され、梨地状の凹凸２１ｂとなる。さらに、シンボル形状転写型２５の形状が繊維強化積層材２１の表面に転写され、シンボルマーク２１ａが形成される。   The bleeder cloths 26 and 27 are used to absorb liquid resin that oozes out from holes provided in the release films 23 and 24. As the bleeder cloths 26 and 27, a nonwoven fabric can be suitably used. Although the surface of the nonwoven fabric is not smooth, the unevenness is transferred to the surface of the fiber-reinforced laminated material 21 via the release films 23 and 24 to form a textured unevenness 21b. Further, the shape of the symbol shape transfer mold 25 is transferred to the surface of the fiber reinforced laminated material 21 to form a symbol mark 21a.

前述のように、プリプレグ積層材２２中の繊維層は、全体に対する体積の割合で４０％程度であるけれども、２０〜７０％の範囲であれば、良好なシンボルマーク２１ａの転写が可能である。繊維層の割合が大きくなると、樹脂の割合が少なくなり、凹凸がある成形が困難となる。また、繊維層の割合が小さくなると、シンボル形状転写型２５がオートクレーブでの加熱加圧処理中にプリプレグ積層材２２中に沈み込んでしまい、表面に良好なシンボルマーク２１ａを残せなくなってしまう。特に、３０〜５０％で樹脂の割合が大きければ、充分凹凸でシンボルマーク２１ａ，３１ａを形成することができる。   As described above, the fiber layer in the prepreg laminated material 22 is about 40% in terms of the volume ratio with respect to the whole, but if it is in the range of 20 to 70%, a good symbol mark 21a can be transferred. When the ratio of the fiber layer is increased, the ratio of the resin is decreased, and molding with unevenness becomes difficult. Further, when the ratio of the fiber layer is reduced, the symbol shape transfer mold 25 sinks into the prepreg laminated material 22 during the heating and pressurizing process in the autoclave, and a good symbol mark 21a cannot be left on the surface. In particular, if the proportion of the resin is large at 30 to 50%, the symbol marks 21a and 31a can be formed with sufficient unevenness.

プリプレグとしての熱硬化性樹脂材料としては、エポキシ樹脂ばかりではなく、ポリエステルやフェノールなども同様に使用することができる。また、樹脂中には、充填材などを混入させることもできる。エポキシ樹脂などを透明に近い状態で母材として使用すると、繊維層の意匠が表面から見えるようになる。炭素繊維の開繊糸を使用すると、黒色で細い繊維が同一方向に向いて帯状になっている状態で、平織などの組織を形成しているので、独特の質感が得られる。また、繊維としては、ガラス繊維やアラミド繊維などを使用することもでき、ガラス繊維では白色、アラミド繊維では黄色など、その繊維特有の着色で繊維強化積層材２１を形成することができる。異種の繊維を混在させれば、色彩模様を組合わせることができる。   As the thermosetting resin material as the prepreg, not only the epoxy resin but also polyester, phenol, and the like can be used. Moreover, a filler etc. can also be mixed in resin. When an epoxy resin or the like is used as a base material in a nearly transparent state, the design of the fiber layer can be seen from the surface. When the carbon fiber spread yarn is used, a texture such as a plain weave is formed in a state where the black and thin fibers are in a band shape in the same direction, so that a unique texture can be obtained. Moreover, as a fiber, a glass fiber, an aramid fiber, etc. can also be used, and the fiber reinforced laminated material 21 can be formed by coloring peculiar to the fiber, such as white in a glass fiber and yellow in an aramid fiber. If different types of fibers are mixed, color patterns can be combined.

なお、炭素繊維ばかりではなく、ガラス繊維やアラミド繊維なども、単繊維を集束させ、繊維束を開繊処理した開繊糸を使用する織物で強化繊維として使用することができる。繊維層は、繊維束を開繊処理した開繊糸を使用する織物で形成されるので、厚さは薄くても、充分な強度となるように強化することができ、合成樹脂の占める割合を大きくして、成形性を高めることができる。   Note that not only carbon fibers but also glass fibers and aramid fibers can be used as reinforcing fibers in fabrics that use single yarns bundled to open fiber bundles that have been subjected to fiber opening treatment. Since the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle, the fiber layer can be reinforced to have sufficient strength even if the thickness is thin. The moldability can be increased by increasing the size.

図２は、本発明の実施の他の形態である繊維強化積層材３１とその製造のためのシンボル形状転写型３５とを示す。図２（ａ）に示すように、繊維強化積層材３１の表面には、浮立つシンボルマーク３１ａと梨地状の凹凸３１ｂとが形成される。このような浮立つシンボルマーク３１ａは、図２（ｂ）に示すようなシンボル形状転写型３５を図１（ｂ）のシンボル形状転写型２５に代えて用いることによって形成することができる。すなわち、シンボル形状転写型３５では、凹所としてシンボルマーク３１ａに対応する形状が形成されており、周囲は大略的にフラットである。梨地状などの凹凸が形成されていれば、その凹凸も転写される。このシンボル形状転写型３５もまた、前述の実施の形態のシンボル形状転写型２５と同様に、樹脂の付着を防ぐため、ポリテトラフルオロエチレン（商品名テフロン）によって被覆されている。   FIG. 2 shows a fiber reinforced laminate 31 and a symbol shape transfer mold 35 for manufacturing the same, which are another embodiment of the present invention. As shown in FIG. 2A, on the surface of the fiber reinforced laminated material 31, a floating symbol mark 31 a and a satin-like unevenness 31 b are formed. Such a floating symbol mark 31a can be formed by using a symbol shape transfer mold 35 as shown in FIG. 2B instead of the symbol shape transfer mold 25 of FIG. 1B. That is, in the symbol shape transfer mold 35, a shape corresponding to the symbol mark 31a is formed as a recess, and the periphery is substantially flat. If irregularities such as a satin finish are formed, the irregularities are also transferred. The symbol shape transfer mold 35 is also covered with polytetrafluoroethylene (trade name Teflon) in order to prevent adhesion of the resin, similarly to the symbol shape transfer mold 25 of the above-described embodiment.

図３は、本発明の実施のさらに他の形態である繊維強化積層材製造のための押え板３８の形状を示す。押え板３８の表面にシンボル形状に対応する凹凸を形成しておき、図１（ｂ）のシンボル形状転写型２５を使用しないで、押え板２８に代えて押え板３８を使用すれば、図１と同様な繊維強化積層材２１を形成することができる。   FIG. 3 shows the shape of a presser plate 38 for manufacturing a fiber-reinforced laminate material according to still another embodiment of the present invention. If unevenness corresponding to the symbol shape is formed on the surface of the presser plate 38 and the presser plate 38 is used instead of the presser plate 28 without using the symbol shape transfer mold 25 of FIG. The same fiber-reinforced laminated material 21 can be formed.

図４は、図１〜図３に示すような実施形態で繊維強化積層材２１，３１を製造するための大略的な製造工程を示す。ステップｓ０でシンボル形状転写型２５，３５または押え板３８など、シンボルマークの転写可能な資材の用意を含めて、成形に必要な準備を行う。ステップｓ１では、プリプレグを積層する工程を行う。ステップｓ２では、図１（ｂ）に示すように、プリプレグ積層材２２を押え板２８，２９などで挟む工程を行う。この工程で、シンボル形状転写型２５やブリーダクロス２６，２７などがプリプレグ積層材２２と押え板２８，２９との間に挟み込まれる。ステップｓ３では、図６，７と同様に、バキュームバッグ中に封入する工程を行う。ステップｓ４では、オートクレーブ中で加熱加圧する工程を行う。ステップｓ５では、バキュームバッグ中から繊維強化積層材２１などを取出す工程を行い、ステップｓ６で製造工程を終了する。   FIG. 4 shows a schematic manufacturing process for manufacturing the fiber-reinforced laminated materials 21 and 31 in the embodiment shown in FIGS. In step s0, preparations necessary for molding are performed, including preparation of a symbol mark transfer mold 25, 35 or a pressing plate 38, which can transfer a symbol mark. In step s1, a step of laminating a prepreg is performed. In step s2, as shown in FIG. 1B, a step of sandwiching the prepreg laminated material 22 between the pressing plates 28 and 29 is performed. In this step, the symbol shape transfer mold 25 and the bleeder cloths 26 and 27 are sandwiched between the prepreg laminated material 22 and the pressing plates 28 and 29. In step s3, the process of enclosing in a vacuum bag is performed like FIG. In step s4, a process of heating and pressing in an autoclave is performed. In step s5, a process of taking out the fiber reinforced laminated material 21 and the like from the vacuum bag is performed, and the manufacturing process is ended in step s6.

ステップｓ２の押え板で挟む工程では、複数の繊維層を含む板状の合成樹脂材料であるプリプレグ積層材２２の両側を、前述のように多孔性の離型フィルムであるリリースフィルム２３，２４で挟む。さらに、離型フィルムの少なくとも一方の一部に、シンボル形状転写型２５，３５を配置し、シンボル形状転写型２５，３５を含む離型フィルムの両側を、樹脂吸収層であるブリーダクロス２６，２７で挟む。さらに樹脂吸収層の両側から硬質板である押え板２８，２９で挟む。まず、プリプレグ積層材２２の両側を多孔性の離型フィルムであるリリースフィルム２３，２４で挟むので、成形時にプリプレグ積層材２２から樹脂成分がはみ出してきても、樹脂成分を透過させ、合成樹脂材料の硬化後には、容易にリリースフィルム２３，２４を剥がして、繊維強化積層材２１を得ることができる。リリースフィルム２３，２４の少なくとも一方の一部に、シンボル形状転写型２５，３５を配置し、シンボル形状転写型２５，３５を含むリリースフィルム２３，２５の両側を、フリーダクロス２６，２７で挟み、ブリーダクロス２６，２７の両側から押え板２８，２９で挟んで成形する。成形された繊維強化積層材２１は、表面にブリーダクロス２６，２７の表面の凹凸が転写され、さらにシンボル形状転写型２５，３５からシンボル形状が転写されるので、繊維強化積層材２１，３１の表面でシンボルマーク２１ａ，３１ａを表示することができる。繊維強化積層材２１，３１の表面に直接シンボル形状などが形成されるので、ラベルのように剥がれるおそれをなくすることができる。   In the step of sandwiching with the holding plate in step s2, both sides of the prepreg laminated material 22 which is a plate-like synthetic resin material including a plurality of fiber layers are released with the release films 23 and 24 which are porous release films as described above. Pinch. Further, the symbol shape transfer molds 25 and 35 are arranged on at least one part of the release film, and both sides of the release film including the symbol shape transfer molds 25 and 35 are placed on the bleeder cloths 26 and 27 which are resin absorption layers. Put it in. Further, the resin absorbing layer is sandwiched between the pressing plates 28 and 29 which are hard plates from both sides. First, since both sides of the prepreg laminate 22 are sandwiched between release films 23 and 24 that are porous release films, even if the resin component protrudes from the prepreg laminate 22 during molding, the resin component is permeated and the synthetic resin material After curing, the release films 23 and 24 can be easily peeled off to obtain the fiber reinforced laminate 21. Symbol shape transfer molds 25 and 35 are arranged on at least one part of the release films 23 and 24, and both sides of the release films 23 and 25 including the symbol shape transfer molds 25 and 35 are sandwiched between freeder cloths 26 and 27. The bleeder cloths 26 and 27 are formed by being sandwiched by pressing plates 28 and 29 from both sides. The molded fiber reinforced laminated material 21 has the surface irregularities of the bleeder cloths 26 and 27 transferred to the surface, and the symbol shape is transferred from the symbol shape transfer molds 25 and 35. The symbol marks 21a and 31a can be displayed on the surface. Since the symbol shape or the like is directly formed on the surface of the fiber reinforced laminated material 21, 31, it is possible to eliminate the possibility of peeling off like a label.

なお、シンボル形状転写型２５，３５に代えて、押え板３８によってシンボル形状を転写させることもできる。また、加熱および加圧は、オートクレーブを利用するばかりではなく、プレスを利用して行うこともできる。   Note that the symbol shape can be transferred by the presser plate 38 instead of the symbol shape transfer molds 25 and 35. The heating and pressurization can be performed not only using an autoclave but also using a press.

さらに、合成樹脂材料は、熱硬化性樹脂のプリプレグを用いているので、加熱して硬化させる際に、表面の凹凸形成と、シンボル形状の形成とを、容易に行うことができる。しかしながら、ナイロン、オレフィン、エステルなどの熱可塑性樹脂を繊維で強化した積層材を用いても、加熱時には少なくとも軟化し、加圧によって形状の転写が可能になるので、同様にシンボルマークや凹凸を形成することができる。   Further, since the synthetic resin material uses a prepreg of a thermosetting resin, it is possible to easily perform surface irregularity formation and symbol shape formation when heated and cured. However, even if a laminated material reinforced with fibers of a thermoplastic resin such as nylon, olefin, or ester is used, it is at least softened when heated, and the shape can be transferred by pressurization. can do.

本発明の実施の一形態である繊維強化積層材２１とその製造方法を示す斜視図および分解側面図である。It is the perspective view and decomposition | disassembly side view which show the fiber reinforced laminated material 21 which is one Embodiment of this invention, and its manufacturing method. 本発明の実施の他の形態である繊維強化積層材３１とその製造のためのシンボル形状転写型３５とを示す斜視図である。It is a perspective view which shows the fiber shape laminated material 31 which is the other form of implementation of this invention, and the symbol shape transcription | transfer type | mold 35 for the manufacture. 本発明の実施のさらに他の形態である繊維強化積層材製造のための押え板３８の形状を示す斜視図である。It is a perspective view which shows the shape of the pressing board 38 for the fiber reinforcement laminated material manufacture which is further another form of implementation of this invention. 図１〜図３に示すような実施形態で繊維強化積層材２１，３１を製造するための大略的な製造工程図である。It is a rough manufacturing-process figure for manufacturing the fiber reinforced laminated material 21 and 31 by embodiment as shown in FIGS. 1-3. 従来からのプレス加工による繊維強化積層材の製造方法を示す分解側面図である。It is a decomposition | disassembly side view which shows the manufacturing method of the fiber reinforced laminated material by the conventional press work. 従来からのオートクレーブ処理による繊維強化積層材の製造方法の一例を示す側面断面図である。It is side surface sectional drawing which shows an example of the manufacturing method of the fiber reinforced laminated material by the conventional autoclave process. 従来からのオートクレーブ処理による繊維強化積層材の製造方法の他の例を示す側面断面図である。It is side surface sectional drawing which shows the other example of the manufacturing method of the fiber reinforced laminated material by the conventional autoclave process.

符号の説明Explanation of symbols

２１，３１ 繊維強化積層材
２２ プリプレグ積層材
２５，３５ シンボル形状転写型
２６，２７ ブリーダクロス
２８，２９，３８ 押え板
21, 31 Fiber reinforced laminated material 22 Prepreg laminated material 25, 35 Symbol shape transfer mold 26, 27 Bleeder cloth 28, 29, 38 Presser plate

Claims (5)

合成樹脂の母材を複数の繊維層で強化した繊維強化積層材であって、
表面が凹凸模様面であり、かつ予め定めるシンボル形状が該凹凸模様よりも大きな凹凸で形成されていることを特徴とする繊維強化積層材。 A fiber reinforced laminate in which a synthetic resin matrix is reinforced with a plurality of fiber layers,
A fiber-reinforced laminated material, wherein the surface is a concavo-convex pattern surface, and a predetermined symbol shape is formed with concavo-convex larger than the concavo-convex pattern. 前記繊維層は、全体に対する体積で２０〜７０％を占めることを特徴とする請求項１記載の繊維強化積層材。   The fiber-reinforced laminated material according to claim 1, wherein the fiber layer occupies 20 to 70% by volume with respect to the whole. 前記繊維層は、繊維束を開繊処理した開繊糸を使用する織物で形成されることを特徴とする請求項１または２記載の繊維強化積層材。   The fiber-reinforced laminated material according to claim 1 or 2, wherein the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle. 複数の繊維層を含む板状の合成樹脂材料の両側を多孔性の離型フィルムで挟み、
離型フィルムの少なくとも一方の一部に、シンボル形状転写型を配置し、
シンボル形状転写型を含む離型フィルムの両側を、樹脂吸収層で挟み、
樹脂吸収層の両側から硬質板で挟んで成形することを特徴とする繊維強化積層材の製造方法。 Sandwiching both sides of a plate-shaped synthetic resin material containing a plurality of fiber layers with a porous release film,
Place a symbol shape transfer mold on a part of at least one of the release films,
Hold both sides of the release film including the symbol shape transfer mold with the resin absorption layer,
A method for producing a fiber-reinforced laminated material, comprising molding between both sides of a resin absorption layer with a hard plate. 前記合成樹脂材料は、熱硬化性樹脂のプリプレグであることを特徴とする請求項４記載の繊維強化積層材の製造方法。   The said synthetic resin material is a prepreg of a thermosetting resin, The manufacturing method of the fiber reinforced laminated material of Claim 4 characterized by the above-mentioned.
JP2004122127A 2004-04-16 2004-04-16 Manufacturing method of fiber reinforced laminate Expired - Fee Related JP4146817B2 (en)

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Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009078388A1 (en) * 2007-12-14 2009-06-25 Zeon Corporation Prepreg, method for producing the same, and fiber-reinforced composite material
WO2010125996A1 (en) * 2009-04-30 2010-11-04 日本バルカー工業株式会社 Fluororesin molded body and method for producing same
JP2012111169A (en) * 2010-11-26 2012-06-14 Mitsubishi Electric Corp Fiber-reinforced plastic, method and device of manufacturing the same
JP2015522443A (en) * 2012-05-14 2015-08-06 サン−ゴバン グラス フランス Method for texturing a substrate having a large area

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2009078388A1 (en) * 2007-12-14 2009-06-25 Zeon Corporation Prepreg, method for producing the same, and fiber-reinforced composite material
WO2010125996A1 (en) * 2009-04-30 2010-11-04 日本バルカー工業株式会社 Fluororesin molded body and method for producing same
JP2012111169A (en) * 2010-11-26 2012-06-14 Mitsubishi Electric Corp Fiber-reinforced plastic, method and device of manufacturing the same
JP2015522443A (en) * 2012-05-14 2015-08-06 サン−ゴバン グラス フランス Method for texturing a substrate having a large area

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