JP2006123475A - Molding method of hollow member made of frp profile in its cross section - Google Patents
Molding method of hollow member made of frp profile in its cross section Download PDFInfo
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- JP2006123475A JP2006123475A JP2004318444A JP2004318444A JP2006123475A JP 2006123475 A JP2006123475 A JP 2006123475A JP 2004318444 A JP2004318444 A JP 2004318444A JP 2004318444 A JP2004318444 A JP 2004318444A JP 2006123475 A JP2006123475 A JP 2006123475A
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- 238000000465 moulding Methods 0.000 title abstract description 26
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- 230000001788 irregular Effects 0.000 claims description 8
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- 238000004804 winding Methods 0.000 claims description 3
- 229920005989 resin Polymers 0.000 description 22
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- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 20
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- 229920000049 Carbon (fiber) Polymers 0.000 description 5
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- 239000002184 metal Substances 0.000 description 2
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- REEBJQTUIJTGAL-UHFFFAOYSA-N 3-pyridin-1-ium-1-ylpropane-1-sulfonate Chemical compound [O-]S(=O)(=O)CCC[N+]1=CC=CC=C1 REEBJQTUIJTGAL-UHFFFAOYSA-N 0.000 description 1
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
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- 239000004962 Polyamide-imide Substances 0.000 description 1
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- JUPQTSLXMOCDHR-UHFFFAOYSA-N benzene-1,4-diol;bis(4-fluorophenyl)methanone Chemical compound OC1=CC=C(O)C=C1.C1=CC(F)=CC=C1C(=O)C1=CC=C(F)C=C1 JUPQTSLXMOCDHR-UHFFFAOYSA-N 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- UHESRSKEBRADOO-UHFFFAOYSA-N ethyl carbamate;prop-2-enoic acid Chemical compound OC(=O)C=C.CCOC(N)=O UHESRSKEBRADOO-UHFFFAOYSA-N 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000013007 heat curing Methods 0.000 description 1
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- 238000007493 shaping process Methods 0.000 description 1
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- 238000003856 thermoforming Methods 0.000 description 1
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Images
Abstract
Description
本発明は、ＦＲＰ製中空部材の成形法、更に詳しくは、断面異形のＦＲＰ製中空部材を内圧成形法により成形する方法に関する。 The present invention relates to a method for forming a hollow member made of FRP, and more particularly, to a method for forming a hollow member made of FRP having a deformed cross section by an internal pressure forming method.
繊維強化プラスチック（ＦＲＰ）は、不飽和ポリエステル樹脂、エポキシ樹脂、ポリイミド樹脂等の熱硬化性樹脂や、ポリエチレン、ポリプロピレン、ポリアミド、ＰＰＳ、ＰＥＥＫ等の熱可塑性樹脂のマトリックス樹脂と、炭素繊維、ガラス繊維、アラミド繊維等の強化繊維からなるものであり、軽量で且つ強度特性に優れるため、近年、航空宇宙産業から一般産業分野に至るまで、幅広い分野において利用されている。 Fiber reinforced plastic (FRP) is a thermosetting resin such as unsaturated polyester resin, epoxy resin and polyimide resin, matrix resin of thermoplastic resin such as polyethylene, polypropylene, polyamide, PPS, PEEK, carbon fiber, glass fiber In recent years, it is used in a wide range of fields from the aerospace industry to the general industrial field.
ＦＲＰを管状ないし中空状の中空部材に成形する方法としては、遠心成形法、プルトルージョン成形法、フィラメントワインディング成形法、内圧成形法等が知られている。遠心成形法は、回転する円筒体の内面に、この円筒体内に同心的に配備されたローラから繊維を巻き付け、この繊維にマトリックス用の樹脂を噴霧して含浸させた後、硬化させる方法であり、比較的径が大きく、単純な形状の製品を製造するのに適している。プルトルージョン成形法は、樹脂を強化繊維基材に含浸させた後、金型を利用して引き抜き、樹脂を固化或いは硬化させて成形品を得る方法であり、一様の断面の真直ぐなパイプの製造に用いられる。フィラメントワインディング成形法は、樹脂を含浸した繊維をマンドレルに巻き付け、樹脂が固化或いは硬化した後にマンドレルを引き抜く方法であり、長繊維の比率を高めることができるので比較的高強度で、軸対称の中空体を製造するのに用いられる。内圧成形法は、金型キャビティ内に筒状の成形素材を配置し、これを筒の内側から圧力を与えて金型に密着させた状態にて加熱硬化させる方法であり、マトリックス樹脂が熱硬化性であっても熱可塑性であっても適用可能であり、通常の中空管状のＦＲＰ製品を成形するのに適している。
内圧成形法で中空管状のＦＲＰ製品を成形するには、通常、プリプレグを用い、金型キャビティ内に中空管状に配置したプリプレグの内部に、膨張性を有するバッグやチューブ等を入れる。次いで、圧縮空気等を用いてバッグやチューブ等をふくらませ、型の内側から圧力をかけてプリプレグを型の内壁面に押しつけ、この状態でプリプレグを加熱硬化させ成形を行う加圧バッグ成形法が用いられている。しかしながら、上記のような従来の加圧バッグ成形法によって製造することができる中空管状成形品は、パイプ等の形状が簡単なものに限られ、複雑な形状、例えば、外側断面が異形の中空管状体を成形する場合には、成形体の肉厚が１ｍｍ程度以上になると、プリプレグの剛性のため金型の形状に沿いにくくなる、従って、所望の形状のものが得られないという問題がある。
本発明の課題は、複雑な形状、特に断面が異形のＦＲＰ製中空部材を、内圧成形法で容易に、且つ均質な成形体として得る方法を提供することにある。 An object of the present invention is to provide a method for easily obtaining a FRP hollow member having a complicated shape, particularly an irregular cross-section, by an internal pressure molding method as a homogeneous molded body.
即ち、本発明は、断面異形のＦＲＰ製中空部材を成形するに際し、（１）断面が円形のマンドレルにプリプレグを巻回し、その後マンドレルを引き抜いてプリプレグの中空部材を作成し、（２）該プリプレグの中空部材の中空部分に圧力バッグを挿入し、（３）該圧力バッグが挿入された中空部材を、中空部材の異形状に対応した形状を有する金型であって異形部に補充用のプリプレグを配置した金型内に設置し、（４）次いで、内圧成形法により成形することを特徴とする断面異形のＦＲＰ製中空部材の成形法である。 That is, in the present invention, when forming a FRP hollow member having an irregular cross section, (1) a prepreg is wound around a mandrel having a circular cross section, and then the mandrel is pulled out to form a hollow member of the prepreg. A pressure bag is inserted into a hollow portion of the hollow member, and (3) a prepreg for refilling the deformed portion of the hollow member into which the pressure bag is inserted is a mold having a shape corresponding to the deformed shape of the hollow member. (4) Next, the FRP hollow member having a deformed cross section is formed by an internal pressure forming method.
本発明によれば、基本的に従来公知の内圧成形法を用いて、均質な、断面異形のＦＲＰ製中空部材を容易に得ることができる。 According to the present invention, it is basically possible to easily obtain a FRP hollow member having a uniform cross-sectional shape by using a conventionally known internal pressure molding method.
本発明において、断面異形のＦＲＰ製中空部材とは、中空部材の部材部分の外側断面が異形、即ち、多角形状の中空部材を意味するが、多角形状としては角部を有する典型的な多角形状だけでなく、角部がＲ状になっているものも含む。例えば、外側断面が正方形なら、四角が直角のものだけでなく、四角が丸みを帯びたもの、即ち、Ｒ状になっているものでも良い。また、中空部の形状はどの様なものでもかまわない。断面が円形のマンドレルは、これにプリプレグを巻き付けて中空の部材を作るためのものであり、断面は、ほぼ円形のもの、例えば、楕円形のものでもかまわない。 In the present invention, the FRP hollow member having an irregular cross-section means an outer cross-section of the member portion of the hollow member that is irregular, that is, a polygonal hollow member, but a polygonal shape having a corner is a typical polygonal shape As well as those having corners that are rounded. For example, if the outer cross section is a square, not only a square having a right angle but also a square having a rounded shape, that is, an R shape may be used. Further, the hollow portion may have any shape. The mandrel having a circular cross section is for making a hollow member by winding a prepreg around the mandrel, and the cross section may be substantially circular, for example, an elliptical one.
本発明においては、断面が円形（ほぼ円形のものも含む）のマンドレルにプリプレグを巻き付け、その後マンドレルを引き抜いてプリプレグの中空部材を作成するが、巻き付けるプリプレグは一枚であっても、複数積層してもかまわない。巻き付けたものの直径は、金型の内周より若干小さくするのが良い。 In the present invention, a prepreg is wound around a mandrel having a circular cross section (including a substantially circular one), and then the mandrel is pulled out to create a hollow member of the prepreg. It doesn't matter. The diameter of the wound object should be slightly smaller than the inner periphery of the mold.
次いで、得られたプリプレグの中空部材の中空部分に圧力バッグを挿入し、この圧力バッグが挿入された中空部材を、金型内に設置し、内圧成形することによりＦＲＰ製中空部材が得られる。本発明においては、この際、目的とする断面異形の中空部材の外表面の異形状に対応した形状を有する金型を用いるのは当然であるが、金型の異形部、即ち、多角形状の角部（角部がＲ状になっているものも含む）に、補充用のプリプレグを配置しておくことを特徴とするものである。 Next, a pressure bag is inserted into the hollow portion of the hollow member of the obtained prepreg, and the hollow member into which the pressure bag is inserted is placed in a mold and subjected to internal pressure molding to obtain a FRP hollow member. In the present invention, in this case, it is natural to use a mold having a shape corresponding to the shape of the outer surface of the hollow member having a deformed cross section, but the shape of the mold, that is, a polygonal shape. A prepreg for replenishment is arranged at a corner (including a corner having an R shape).
本発明において、プリプレグとしては後述のものを用いることができるが、補充用のプリプレグとしては、一方向配列繊維強化材からなるプリプレグ、あるいは、それと他のプリプレグとを組合わせたものが好ましい。また、かかる一方向配列繊維強化材からなるプリプレグを、その繊維軸方向が中空部材の軸方向と一致させるようにして金型の異形部に配置するのが好ましい。補充用のプリプレグは一枚であっても、複数積層して配置しても良い。 In the present invention, the following prepregs can be used, but the prepreg for replenishment is preferably a prepreg made of a unidirectionally arranged fiber reinforcing material, or a combination of this and other prepregs. Moreover, it is preferable to arrange | position the prepreg which consists of this unidirectional arrangement | sequence fiber reinforcement material in the deformed part of a metal mold | die so that the fiber axial direction may correspond with the axial direction of a hollow member. The replenishment prepreg may be a single sheet or a plurality of layers may be stacked.
本発明における内圧成形法とは、公知の成形方法であり、金型キャビティ内に筒状のプリプレグ等の成形素材を配置し、これを筒の内側から圧力を与えて金型に密着させた状態にて加熱硬化させる方法を意味する。例えば、ナイロンやシリコンゴムのような、可撓性があり且つ耐熱性に優れた材料で形成した圧力バッグに、プリプレグ等の成形素材を筒状に巻き付け、あるいは、芯金（マンドレル）を用いて予備成形した成形素材の中心にこの圧力バッグを挿入・配置したものを、金型キャビティ内に設置し、圧力バッグ内に加圧媒体を送り込んで圧力バッグを膨張させ、成形素材を金型内面に押し付けて加熱成形する方法である。本発明においては、後者の方法でプリプレグの中空部材が作成される。 The internal pressure molding method in the present invention is a known molding method, in which a molding material such as a cylindrical prepreg is placed in a mold cavity, and this is in close contact with the mold by applying pressure from the inside of the cylinder It means a method of heat curing at For example, a pressure bag formed of a flexible and heat-resistant material such as nylon or silicon rubber is wrapped with a molding material such as a prepreg in a cylindrical shape, or a mandrel is used. The pressure bag inserted and placed at the center of the preformed molding material is placed in the mold cavity, the pressure medium is sent into the pressure bag to expand the pressure bag, and the molding material is placed on the inner surface of the mold. It is a method of pressing and thermoforming. In the present invention, the prepreg hollow member is formed by the latter method.
ＦＲＰは、繊維強化材に、熱硬化性樹脂や熱可塑性樹脂などのマトリックス樹脂を含浸・硬化させて得られるものであるが、本発明においては、用いられる繊維強化材やマトリックス樹脂に関しては特に制限はい。繊維強化材としては、炭素繊維、ガラス繊維、アラミド繊維、ボロン繊維、金属繊維等が挙げられる。 FRP is obtained by impregnating and curing a fiber reinforcement with a matrix resin such as a thermosetting resin or a thermoplastic resin. However, in the present invention, the fiber reinforcement and the matrix resin to be used are not particularly limited. Yes. Examples of the fiber reinforcing material include carbon fiber, glass fiber, aramid fiber, boron fiber, and metal fiber.
熱硬化性樹脂としては、例えば、エポキシ樹脂、不飽和ポリエステル樹脂、フェノール樹脂、ビニルエステル樹脂、シアン酸エステル樹脂、ウレタンアクリレート樹脂、フェノキシ樹脂、アルキド樹脂、ウレタン樹脂、マレイミド樹脂とシアン酸エステル樹脂の予備重合樹脂から選ばれる樹脂がある。これらは１種又は２種以上の混合物として用いることもできる。熱可塑性樹脂としては、ポリプロピレン、ポリスルホン、ポリエーテルスルホン、ポリエーテルケトン、ポリエーテルエーテルケトン、芳香族ポリアミド、芳香族ポリエステル、芳香族ポリカーボネート、ポリエーテルイミド、ポリアリーレンオキシド、熱可塑性ポリイミド、ポリアミドイミドがある。これらの樹脂は、２種以上併用しても良い。 Examples of the thermosetting resin include epoxy resins, unsaturated polyester resins, phenol resins, vinyl ester resins, cyanate ester resins, urethane acrylate resins, phenoxy resins, alkyd resins, urethane resins, maleimide resins and cyanate ester resins. There are resins selected from prepolymerized resins. These can also be used as one type or a mixture of two or more types. Examples of thermoplastic resins include polypropylene, polysulfone, polyethersulfone, polyetherketone, polyetheretherketone, aromatic polyamide, aromatic polyester, aromatic polycarbonate, polyetherimide, polyarylene oxide, thermoplastic polyimide, and polyamideimide. is there. Two or more of these resins may be used in combination.
繊維強化材は、通常、例えば、平織、綾織、朱子織等の経糸と緯糸から構成されるものの他、繊維束を一方向に引き揃えシート状とし、これを直角方向にステッチ糸で縫合した一軸織物、一方向に引き揃えたシート状物を角度を変えて複数積層し、これを直角方向にステッチ糸で縫合した多軸織物等の形で用いられる。 The fiber reinforcement is usually composed of warp and weft such as plain weave, twill weave, satin weave, etc., and the fiber bundle is aligned in one direction into a sheet shape, and this is uniaxially stitched with stitch threads in the perpendicular direction It is used in the form of a woven fabric, a multi-axis woven fabric in which a plurality of sheet-like materials arranged in one direction are stacked at different angles and stitched with a stitch thread in a perpendicular direction.
プリプレグとは、繊維強化材に、熱硬化性樹脂や熱可塑性樹脂などのマトリックス樹脂を含浸させ、流動性や粘着性を除いて取り扱い性を良くした成形中間材である。本発明の中空部材を形成するプリプレグの繊維強化材の形態については特に制限はないが、補充用のプリプレグとしては、一軸織物や多軸織物等の一方向配列繊維強化材からなるプリプレグ、あるいは、それらと他のプリプレグとの組合せが好ましい。 A prepreg is a molded intermediate material in which a fiber reinforcing material is impregnated with a matrix resin such as a thermosetting resin or a thermoplastic resin to improve handling properties except for fluidity and adhesiveness. The form of the fiber reinforced material of the prepreg that forms the hollow member of the present invention is not particularly limited. Combinations of these with other prepregs are preferred.
本発明による成形法の例を、ＦＲＰ製の断面が四角形（角部がＲ状になっている）の中空管状体を成形する場合の例で説明する。図１の（イ）は金型等の断面を示し、１は上型と下型が合わさった金型を、２は金型の内部に設置されたプリプレグの中空部材を示す。プリプレグの中空部材２は、断面が円形のマンドレルにプリプレグを巻回し、その後マンドレルを引き抜いて形成されたものである。３は金型の異形部で、４は異形部に配置された補充用のプリプレグを示している。図１の（イ）の状態で、プリプレグの中空部材の中空部分５に圧力バッグが挿入される。
An example of the molding method according to the present invention will be described using an example of molding a hollow tubular body made of FRP having a quadrangular cross section (corner portions are rounded). FIG. 1 (a) shows a cross section of a mold and the like, 1 is a mold in which an upper mold and a lower mold are combined, and 2 is a hollow member of a prepreg installed inside the mold. The prepreg
その状態は、図２で示されている。図２において、１は金型、２はプリプレグ、７は、例えば、ナイロンバッグの様な圧力バッグを示している。中空部材の中空部分５に圧力バッグ７を挿入した後は、公知の内圧成形法によって成形を行うことができる。具体的には、例えば、圧力バッグに圧縮空気を導入し、プリプレグの中空部材２を金型１の内面に圧着させる。この際、プリプレグの剛性のために、金型の異形部３の形状に沿わせることは困難であるが、図１の（イ）では、その異形部３に補充用のプリプレグ４が配置され、プリプレグの中空部材２が沿い易い様に調整されている。その後、金型１を硬化炉等（図示せず）に入れて加熱し、図１の（ロ）の形状の、断面異形のＦＲＰ製中空部材６が得られる。
This state is shown in FIG. In FIG. 2, 1 is a mold, 2 is a prepreg, and 7 is a pressure bag such as a nylon bag. After the pressure bag 7 is inserted into the hollow portion 5 of the hollow member, it can be molded by a known internal pressure molding method. Specifically, for example, compressed air is introduced into the pressure bag, and the prepreg
以下、実施例により本発明を説明する。 Hereinafter, the present invention will be described by way of examples.
図１の（ロ）に示した断面が四角形（正方形）状のＦＲＰ製中空部材を成形するため、先ず炭素繊維のプリプレグの中空部材を作成した。断面が円形のマンドレルに、プリプレグを巻き付け、その後マンドレルを引き抜いてプリプレグの中空部材を作成した。このプリプレグの中空部材の中空部分にナイロン製の圧力バッグを挿入し、圧力バッグが挿入された中空部材を、図１の（イ）に示した断面形状の金型の中に設置し型締めを行った。 In order to form a FRP hollow member having a quadrangular (square) cross section shown in FIG. 1B, first, a hollow member of a carbon fiber prepreg was prepared. A prepreg was wound around a mandrel having a circular cross section, and then the mandrel was pulled out to create a hollow member of the prepreg. A nylon pressure bag is inserted into the hollow portion of the hollow member of the prepreg, and the hollow member into which the pressure bag is inserted is placed in a mold having a cross-sectional shape shown in FIG. went.
金型の四角の異形部には、補充用のプリプレグとして、一方向配列炭素繊維強化材及び炭素繊維クロス材からなるプリプレグを配置した。この際、一方向配列繊維強化材からなるプリプレグの、繊維軸方向が中空部材の軸方向と一致するように配置した。次いで、金型を硬化炉に入れ、内圧成形法により成形した。即ち、圧力バッグ内に圧縮空気（４ｋｇ／ｃｍ２）を導入し、硬化炉の温度を１３０℃で２時間維持して加熱硬化せしめ、その後冷却、脱形して断面が図１の（ロ）に示した形状を有するＦＲＰ製中空部材を得た。 A prepreg made of a unidirectionally-arranged carbon fiber reinforcing material and a carbon fiber cloth material was disposed as a prepreg for replenishment in the square deformed portion of the mold. At this time, the prepreg composed of the unidirectionally arranged fiber reinforcement was arranged so that the fiber axis direction coincided with the axial direction of the hollow member. Next, the mold was placed in a curing furnace and molded by an internal pressure molding method. That is, compressed air (4 kg / cm 2 ) is introduced into the pressure bag, the temperature of the curing furnace is maintained at 130 ° C. for 2 hours to heat and cure, and then cooled and deshaped, and the cross section is shown in FIG. An FRP hollow member having the shape shown in 1 was obtained.
得られたＦＲＰ製中空部材の機械的性能は非常に優れたものであった。 The mechanical performance of the obtained FRP hollow member was very excellent.
１ 金型
２ 金型の内部に設置されたプリプレグの中空部材
３ 金型の異形部
４ 補充用のプリプレグ
５ プリプレグの中空部材の中空部分
６ 断面異形のＦＲＰ製中空部材
７ 圧力バッグ
DESCRIPTION OF
Claims (3)
The method for forming a hollow member made of FRP having a deformed cross section according to claim 2, wherein the prepreg made of a unidirectionally arranged fiber reinforcing material is arranged such that its fiber axis direction coincides with the axial direction of the hollow member.
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| JP2004318444A JP2006123475A (en) | 2004-11-01 | 2004-11-01 | Molding method of hollow member made of frp profile in its cross section |
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| WO2009078419A1 (en) | 2007-12-17 | 2009-06-25 | Toyota Jidosha Kabushiki Kaisha | Method of molding fiber-reinforced-resin hollow part |
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| US8408972B2 (en) | 2010-01-25 | 2013-04-02 | Apple Inc. | Apparatus and method for intricate cuts |
| US8511498B2 (en) | 2010-01-25 | 2013-08-20 | Apple Inc. | Method for manufacturing an electronic device enclosure |
| US8857128B2 (en) | 2009-05-18 | 2014-10-14 | Apple Inc. | Reinforced device housing |
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| US9120272B2 (en) | 2010-07-22 | 2015-09-01 | Apple Inc. | Smooth composite structure |
| US10407955B2 (en) | 2013-03-13 | 2019-09-10 | Apple Inc. | Stiff fabric |
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| US11518138B2 (en) | 2013-12-20 | 2022-12-06 | Apple Inc. | Using woven fibers to increase tensile strength and for securing attachment mechanisms |
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| US8808480B2 (en) | 2007-08-01 | 2014-08-19 | Toyota Jidosha Kabushiki Kaisha | Flanged fiber-reinforced resin hollow part and method of molding the same |
| WO2009017217A1 (en) | 2007-08-01 | 2009-02-05 | Toyota Jidosha Kabushiki Kaisha | Fiber-reinforced resin hollow part with flange and method of forming the same |
| WO2009078419A1 (en) | 2007-12-17 | 2009-06-25 | Toyota Jidosha Kabushiki Kaisha | Method of molding fiber-reinforced-resin hollow part |
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| US8857128B2 (en) | 2009-05-18 | 2014-10-14 | Apple Inc. | Reinforced device housing |
| US8408972B2 (en) | 2010-01-25 | 2013-04-02 | Apple Inc. | Apparatus and method for intricate cuts |
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| US10398042B2 (en) | 2010-05-26 | 2019-08-27 | Apple Inc. | Electronic device with an increased flexural rigidity |
| US9120272B2 (en) | 2010-07-22 | 2015-09-01 | Apple Inc. | Smooth composite structure |
| US9011623B2 (en) | 2011-03-03 | 2015-04-21 | Apple Inc. | Composite enclosure |
| US10407955B2 (en) | 2013-03-13 | 2019-09-10 | Apple Inc. | Stiff fabric |
| US11518138B2 (en) | 2013-12-20 | 2022-12-06 | Apple Inc. | Using woven fibers to increase tensile strength and for securing attachment mechanisms |
| US10864686B2 (en) | 2017-09-25 | 2020-12-15 | Apple Inc. | Continuous carbon fiber winding for thin structural ribs |
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