JP2006334805A - Manufacturing method of frp lining metal pipe - Google Patents
Manufacturing method of frp lining metal pipe Download PDFInfo
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- JP2006334805A JP2006334805A JP2005159008A JP2005159008A JP2006334805A JP 2006334805 A JP2006334805 A JP 2006334805A JP 2005159008 A JP2005159008 A JP 2005159008A JP 2005159008 A JP2005159008 A JP 2005159008A JP 2006334805 A JP2006334805 A JP 2006334805A
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- 229910052751 metal Inorganic materials 0.000 title claims abstract description 102
- 239000002184 metal Substances 0.000 title claims abstract description 102
- 238000004519 manufacturing process Methods 0.000 title claims description 20
- 229920005989 resin Polymers 0.000 claims abstract description 35
- 239000011347 resin Substances 0.000 claims abstract description 35
- 238000010438 heat treatment Methods 0.000 claims abstract description 29
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 23
- 230000002093 peripheral effect Effects 0.000 claims abstract description 18
- 229910000838 Al alloy Inorganic materials 0.000 claims abstract description 14
- 239000010935 stainless steel Substances 0.000 claims abstract description 9
- 229910001220 stainless steel Inorganic materials 0.000 claims abstract description 9
- 239000004088 foaming agent Substances 0.000 claims description 28
- 239000004744 fabric Substances 0.000 claims description 7
- 239000004831 Hot glue Substances 0.000 claims description 6
- 229920001684 low density polyethylene Polymers 0.000 claims description 5
- 239000004702 low-density polyethylene Substances 0.000 claims description 5
- 229920000103 Expandable microsphere Polymers 0.000 claims description 4
- 239000004743 Polypropylene Substances 0.000 claims description 3
- -1 polypropylene Polymers 0.000 claims description 3
- 229920001155 polypropylene Polymers 0.000 claims description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 3
- 238000005507 spraying Methods 0.000 claims description 2
- 102100040287 GTP cyclohydrolase 1 feedback regulatory protein Human genes 0.000 claims 1
- 101710185324 GTP cyclohydrolase 1 feedback regulatory protein Proteins 0.000 claims 1
- 239000004918 carbon fiber reinforced polymer Substances 0.000 claims 1
- 239000000463 material Substances 0.000 abstract description 15
- 238000004804 winding Methods 0.000 description 18
- 229920002379 silicone rubber Polymers 0.000 description 8
- 229920000049 Carbon (fiber) Polymers 0.000 description 7
- 239000004917 carbon fiber Substances 0.000 description 7
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 7
- 230000000694 effects Effects 0.000 description 6
- 239000012943 hotmelt Substances 0.000 description 6
- 238000000034 method Methods 0.000 description 6
- 239000004677 Nylon Substances 0.000 description 5
- 229920001778 nylon Polymers 0.000 description 5
- 238000001723 curing Methods 0.000 description 4
- 239000007789 gas Substances 0.000 description 4
- ZWEHNKRNPOVVGH-UHFFFAOYSA-N 2-Butanone Chemical compound CCC(C)=O ZWEHNKRNPOVVGH-UHFFFAOYSA-N 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 229920001971 elastomer Polymers 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 239000003365 glass fiber Substances 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000002313 adhesive film Substances 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 230000008602 contraction Effects 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 238000005187 foaming Methods 0.000 description 2
- 238000013035 low temperature curing Methods 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 239000004945 silicone rubber Substances 0.000 description 2
- 239000012798 spherical particle Substances 0.000 description 2
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 230000032798 delamination Effects 0.000 description 1
- 230000006355 external stress Effects 0.000 description 1
- 239000000284 extract Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 230000005484 gravity Effects 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000003475 lamination Methods 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920001225 polyester resin Polymers 0.000 description 1
- 239000004645 polyester resin Substances 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000012258 stirred mixture Substances 0.000 description 1
- 230000035882 stress Effects 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920005992 thermoplastic resin Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
Images
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- Moulding By Coating Moulds (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
Abstract
Description
本発明は印刷用ロールを初め、フィルムや紙などのシート類繰り出し・巻き取り用ロール、液晶パネルやフラットパネルディスプレーなどのパネル類搬送用ロール、その他の各種回転ロールに使って有効なＦＲＰ（繊維強化樹脂）ライニング金属管の製造法に関する。 The present invention is effective for use in printing rolls, rolls for taking out and winding sheets such as films and papers, rolls for transporting panels such as liquid crystal panels and flat panel displays, and other various rotating rolls. Reinforced resin) relates to a method of manufacturing a lining metal tube.
高剛性（耐摩耗性）と軽量さ（低慣性モーメント）が特に要求される各種高速回転（例えば約１０００〜２０００r.p.m)ロール用のＦＲＰライニング金属管を製造する方法として、特開２０００−１４１４８５号が提案されている。 As a method for producing FRP-lined metal tubes for various high-speed rotation (for example, about 1000 to 2000 rpm) rolls that particularly require high rigidity (wear resistance) and light weight (low moment of inertia), JP-A-2000-141485 is disclosed. No. has been proposed.
この製造法では、予じめエポキシ樹脂やフェノール樹脂などの熱硬化性樹脂が含浸された炭素繊維プリプレグを芯棒（マンドレル）へ巻き付けて、その芯棒を先ずアルミ合金やステンレス鋼などから成る金属管の内部へ挿入し、次いで上記プリプレグが軟化する温度まで加熱して、その芯棒を膨張させることにより、上記金属管への内張り状態に押し付け、更に加熱温度を上げて、上記プリプレグを完全に硬化させ、最後に常温まで冷却することにより、その芯棒を収縮復元させて抜き出すようになっている。 In this manufacturing method, a carbon fiber prepreg impregnated with a thermosetting resin such as an epoxy resin or a phenol resin is wound around a mandrel, and the mandrel is first made of a metal made of aluminum alloy or stainless steel. The tube is inserted into the tube, and then heated to a temperature at which the prepreg softens, and the core rod is expanded to press it into the lining state on the metal tube. By curing and finally cooling to room temperature, the core rod is restored to contraction and extracted.
つまり、炭素繊維プリプレグの加熱による軟化と、芯棒の膨張・収縮とを利用している点で、本発明に最も近似する公知技術であると考えられる。
ところが、上記公知発明の芯棒はゴム管又は熱膨張率の高いナイロン樹脂棒から成り、その明細書段落〔００１０〕に「ＳＵＳ管を１００℃まで昇温した状態で、シリコンゴム管の一方の端を封じ、もう片方の端から圧縮空気を吹き込む事で、シリコンゴムを膨張させた。シリコンゴムの膨張で樹脂が軟化したプリプレグを、薄肉ＳＵＳ管の内側に押し付けた状態で、樹脂の硬化温度である１２０℃まで上昇させて１２時間放置し、樹脂を硬化させた。常温まで冷却後、シリコンゴム管の空気を抜き収縮させた後、シリコンゴム管を抜いた。」と記載されているように、シリコンゴム管の開口一端部を封止して、残る開口他端部から圧縮空気を吹き込まなければ、そのシリコンゴム管を膨張させることができず、製造工程上甚だ煩雑であり、そのための特別な付帯装置も必要となる。 However, the core rod of the above-mentioned known invention is composed of a rubber tube or a nylon resin rod having a high coefficient of thermal expansion, and in the paragraph [0010] of the specification, “one of the silicon rubber tubes is heated in a state where the temperature of the SUS tube is raised to 100 ° C. Silicon rubber was expanded by sealing one end and blowing compressed air from the other end, while the prepreg, which had been softened by expansion of the silicon rubber, was pressed against the inside of the thin SUS tube, the curing temperature of the resin The temperature was raised to 120 ° C. and allowed to stand for 12 hours to cure the resin.After cooling to room temperature, the silicone rubber tube was deflated and contracted, and then the silicone rubber tube was removed. ” In addition, if one end of the opening of the silicon rubber tube is sealed and compressed air is not blown from the other end of the remaining opening, the silicon rubber tube cannot be expanded, which is very complicated in the manufacturing process. Also it requires special accessory devices for.
又、シリコンゴム管から成る芯棒の場合、これを膨張させる前の状態では、その外周面からの加圧力に耐えることが困難であるため、これに炭素繊維プリプレグのＵＤテープ材を直交する数プライ層として、精密・確固に安定良く巻き付けることができず、仕上がり状態の品質にバラツキを生じることは必至である。 Further, in the case of a core rod made of a silicon rubber tube, it is difficult to withstand the applied pressure from the outer peripheral surface of the core rod before it is expanded. Therefore, the UD tape material of the carbon fiber prepreg is a number orthogonal to this. It is inevitable that the ply layer cannot be wound accurately and firmly and stably and the quality of the finished state varies.
更に、上記プリプレグをＳＵＳ管の内側へ押し付けた状態のもとに、その熱硬化性樹脂が完全に硬化するまでの加熱温度：１２０℃と、１２時間の放置時間を要するため、作業効率が非常に悪く、量産効果を発揮させることもできない。 Furthermore, under the condition that the prepreg is pressed to the inside of the SUS tube, a heating temperature of 120 ° C. until the thermosetting resin is completely cured requires a standing time of 12 hours. It is not good for mass production.
他方、芯棒の材質として上記ゴム管のほかに、熱膨張率の高いナイロン樹脂棒も挙げられているが、これは熱可塑性であるため、上記１２時間という長時間に亘って、高温に耐えることができず、その意味からも１２０℃の加熱温度で足りる所謂低温硬化タイプの炭素繊維プリプレグが採用されたものと考えられる。 On the other hand, as a material of the core rod, besides the rubber tube, a nylon resin rod having a high coefficient of thermal expansion is also mentioned, but since it is thermoplastic, it can withstand high temperatures for a long time of 12 hours. In view of this, it is considered that a so-called low-temperature curing type carbon fiber prepreg, which requires a heating temperature of 120 ° C., was adopted.
しかし、茲に低温硬化タイプの炭素繊維プリプレグは特殊・高価な材料であり、通常１３０〜１５０℃で硬化するタイプの安価な炭素繊維プリプレグのみならず、ガラス繊維クロスプリプレグも採用することができず、製造法としての汎用性に劣る。ガラス繊維クロスプリプレグでも、１３０〜１５０℃の加熱温度において硬化するタイプの熱硬化性樹脂が使用されている通例だからである。 However, carbon fiber prepregs of low temperature curing type are special and expensive materials, and not only low-cost carbon fiber prepregs that are normally cured at 130 to 150 ° C but also glass fiber cloth prepregs cannot be adopted. Inferior versatility as a manufacturing method. This is because, even in a glass fiber cloth prepreg, a thermosetting resin of a type that cures at a heating temperature of 130 to 150 ° C. is commonly used.
更に、上記ナイロン樹脂棒はその文字どおりのナイロン樹脂のみから成り、別個な金属によって軸支されていないため、上記加熱温度を長時間受けて、形崩れするおそれもあり、その炭素繊維強化樹脂を金属管の内周面へ均一な張り付け膜として、安定・強固にライニングすることができない。 Furthermore, since the nylon resin rod is made of only the literal nylon resin and is not supported by a separate metal, it may be deformed by receiving the heating temperature for a long time. As a uniform adhesive film on the inner peripheral surface of the tube, it cannot be lined stably and firmly.
本発明はこのような諸問題の改良を目的としており、その目的を達成するために、請求項１ではＦＲＰライニング金属管の製造法として、アルミ合金又はステンレス鋼を素材とする金属管と、その金属管の薄くとも約３倍に厚肉化されたアルミ合金のマンドレルとを用意して、
The present invention aims to improve such problems, and in order to achieve the object, in
上記マンドレルへＦＲＰプリプレグを、その外径が上記金属管の内径と０．１〜０．３mmの一定間隙を保つ積層状態に巻き付け一体化して、その金属管の内部へ差し込み貫通させた上、 The FRP prepreg was wound around the mandrel in a laminated state in which the outer diameter maintained a constant gap of 0.1 to 0.3 mm with the inner diameter of the metal tube, and inserted and penetrated into the metal tube.
上記ＦＲＰプリプレグをこれに含浸された熱硬化性樹脂が硬化するまでの加熱過程において、上記金属管よりも多大に熱膨張するマンドレルからの内圧により、上記内外相互間隙を埋め尽す如く金属管の内周面ヘ張り付け一体化させるように定めたことを特徴とする。 In the heating process until the thermosetting resin impregnated in the FRP prepreg is hardened, the internal pressure inside the metal tube is filled up by the internal pressure from the mandrel that thermally expands much more than the metal tube. It is characterized in that it is determined to be attached to the peripheral surface and integrated.
請求項２の構成では、マンドレルに巻き付け一体化したＦＲＰプリプレグの最外層へ、霧吹きや湿した拭き布などによって水分を付与した後、低密度ポリエチレンのフィルムから成る熱溶融性テープを巻き付けて、
In the configuration of
ＦＲＰプリプレグの加熱過程において溶融した上記テープが、その下地の水分から蒸発した気体を封じ込めた発泡剤又はホットメルト接着剤と化して、上記ＦＲＰプリプレグの最外層を金属管の内周面へ能動的に張り付け一体化させるように定めたことを特徴とする。 The above-mentioned tape melted in the heating process of the FRP prepreg is converted into a foaming agent or a hot-melt adhesive containing the gas evaporated from the underlying moisture, and the outermost layer of the FRP prepreg is actively applied to the inner peripheral surface of the metal tube. It is characterized in that it is determined to be attached to and integrated with.
又、請求項３の構成ではマンドレルに巻き付け一体化するＦＲＰプリプレグの最外層へ、熱膨張性マイクロスフェアーから成る発泡剤が混練された熱硬化性樹脂を塗り付けて、 Further, in the configuration of claim 3, a thermosetting resin kneaded with a foaming agent composed of thermally expandable microspheres is applied to the outermost layer of the FRP prepreg that is wound around and integrated with the mandrel,
ＦＲＰプリプレグの加熱過程において膨張する上記発泡剤により、そのＦＲＰプリプレグの最外層を金属管の内周面ヘ積極的に張り付け一体化させるように定めたことを特徴とする。 The foaming agent that expands during the heating process of the FRP prepreg is defined such that the outermost layer of the FRP prepreg is positively attached to and integrated with the inner peripheral surface of the metal tube.
請求項４の構成では、最外層の熱硬化性樹脂に熱膨張性の発泡剤が混練されたシート状のＦＲＰプリプレグを、マンドレルに巻き付け一体化して、 In the configuration of claim 4, the sheet-like FRP prepreg in which the thermally expandable foaming agent is kneaded with the thermosetting resin of the outermost layer is wound around and integrated with a mandrel,
ＦＲＰプリプレグの加熱過程において膨張する上記発泡剤により、そのＦＲＰプリプレグの最外層を金属管の内周面ヘ積極的に張り付け一体化させるように定めたことを特徴とする。 The foaming agent that expands during the heating process of the FRP prepreg is defined such that the outermost layer of the FRP prepreg is positively attached to and integrated with the inner peripheral surface of the metal tube.
更に、請求項５の構成ではＦＲＰプリプレグをＣＦＲＰプリプレグ又はＧＦＲＰプリプレグとして、マンドレルへ金属管の長さよりも長く巻き付け一体化することにより、その最外層の両端部を金属管の両端部から一定量づつ張り出し露呈する状態に保ち、 Furthermore, in the configuration of claim 5, the FRP prepreg is made into a CFRP prepreg or a GFRP prepreg, and is wound around the mandrel longer than the length of the metal tube so that both end portions of the outermost layer are fixed from the both end portions of the metal tube. Keep it overhanging,
その張り出し露呈する最外層の両端部を残して、上記ＦＲＰプリプレグの両端木口面とマンドレルの表面との境界段差部へ、引き続き延伸ポリプロピレンのブリーダーテープを肉盛り状態に巻き付けた上、 The stretched polypropylene bleeder tape was continuously wound on the border step between the both ends of the FRP prepreg and the surface of the mandrel, leaving both ends of the outermost layer exposed to the overhang,
上記ＦＲＰプリプレグを約１３０℃〜１５０℃の温度により加熱し、その熱硬化性樹脂の硬化後に上記一定量づつの張り出し両端部を切り捨てることを特徴とする。 The FRP prepreg is heated at a temperature of about 130 ° C. to 150 ° C., and after the thermosetting resin is cured, both ends of the projecting portion are cut off.
請求項１の上記構成によれば、ＦＲＰプリプレグをその熱硬化性樹脂が硬化するまでの加熱進行中、金属管とマンドレルは何れも内外方向（求心方向と放射方向）へ熱膨張することになるが、その際金属管とＦＲＰプリプレグとの内外相互間隙は予じめ０．１〜０．３mmに設定されているため、併せてマンドレルの厚みは金属管における厚みの約３倍以上として厚肉化されているため、その金属管よりも多量に熱膨張するマンドレルの大きな内圧が、一旦熱硬化性樹脂の溶融したＦＲＰプリプレグに作用して、そのＦＲＰプリプレグを金属管の内周面へ、上記間隙を完全に埋め尽す如く張り付け一体化させることができ、その最終的に硬化した張り付け状態での優れたＦＲＰライニング金属管を得られるのである。
According to the above configuration of
他方、上記ＦＲＰプリプレグの完全な硬化後に、常温まで冷却すれば、金属管とマンドレルは当初の太さまで収縮復元することになるが、そのマンドレルの復元収縮量は金属管のそれよりも多く、その結果上記内外相互間隙の設定数値範囲とも相俟って、金属管への内張りライニング状態に硬化したＦＲＰプリプレグの内部から、上記マンドレルを支障なく円滑に抜き出すこともでき、冒頭の公知発明に比し、ＦＲＰライニング金属管を短時間での効率良く製造し得るのであり、量産効果の向上に役立つ。 On the other hand, if the FRP prepreg is completely cured and then cooled to room temperature, the metal tube and mandrel will shrink and restore to their original thickness, but the amount of restoration shrinkage of the mandrel is greater than that of the metal tube, As a result, together with the set numerical range of the inner and outer mutual gaps, it is possible to smoothly extract the mandrel from the inside of the FRP prepreg cured in a lining state on the metal pipe without any trouble, compared with the first known invention. The FRP-lined metal tube can be efficiently manufactured in a short time, which is useful for improving the mass production effect.
又、ＦＲＰプリプレグの巻き付け芯となるマンドレルは、冒頭に述べた公知発明のゴム管やナイロン樹脂棒と異なり、剛性なアルミ合金から成るものとして、その素材に固有の線膨張係数と上記厚肉化に基き熱膨張するため、形崩れするおそれがないことは勿論、その表面へＦＲＰプリプレグのＵＤテープ材やクロス材を精密・確固に安定良く巻き付け一体化することができ、製品−ＦＲＰライニング金属管の品質にバラツキを生じるおそれもなく、量産効果がますます向上する。 Also, the mandrel that becomes the winding core of the FRP prepreg is made of a rigid aluminum alloy, unlike the rubber tube and nylon resin rod of the known invention described at the beginning. As a result of thermal expansion based on the FRP lining metal tube, there is no risk of losing its shape, and the UD tape material and cloth material of the FRP prepreg can be wound accurately and firmly on the surface in a stable and integrated manner. There is no risk of variations in quality, and the mass production effect is further improved.
特に、請求項２の構成を採用するならば、安全な水分の付与と、その後ありふれた熱溶融性テープの巻き付けにより、上記ＦＲＰプリプレグの加熱を活用し、独立気泡の発泡剤又はホットメルト接着剤を生成することができ、従って特別の発泡剤を使用する必要がなく、量産効果がますます向上する。
In particular, if the configuration of
そして、このような発泡剤又はホットメルト接着剤と化した熱溶融性テープは、一旦溶融した熱硬化性樹脂との一体膜になり、上記マンドレルの熱膨張による多大な内圧とも相俟って、そのＦＲＰプリプレグの最外層を金属管の内周面へ能動的に張り付け一体化させることができ、耐久強度と安定性に優れた製品−ＦＲＰライニング金属管を得られる効果がある。 And, the heat-meltable tape that has been converted into such a foaming agent or hot-melt adhesive becomes an integral film with the once-melted thermosetting resin, coupled with a great internal pressure due to the thermal expansion of the mandrel, The outermost layer of the FRP prepreg can be actively attached to and integrated with the inner peripheral surface of the metal tube, and there is an effect that a product-FRP lining metal tube excellent in durability strength and stability can be obtained.
請求項３や請求項４に記載の特別な発泡剤を使用することも可能であり、これらの構成によれば、発泡剤の積極的な熱膨張作用と、上記マンドレルからの多大な熱膨張力（内圧）とが相乗的に働くため、やはりＦＲＰプリプレグの最外層を金属管の内周面へ、安定良く強固に張り付け一体化させることができ、優れた製品を得られることになる。 It is also possible to use the special foaming agent according to claim 3 or claim 4, and according to these configurations, the thermal expansion action of the foaming agent and the great thermal expansion force from the mandrel Since (internal pressure) works synergistically, the outermost layer of the FRP prepreg can also be firmly and firmly attached to the inner peripheral surface of the metal tube and integrated, and an excellent product can be obtained.
更に、請求項５の構成を採用するならば、ＦＲＰプリプレグにおける最外層の両端部を一定量づつ張り出し露呈する状態に残して、肉盛り状態に巻き付けられたブリーダーテープにより、そのＦＲＰプリプレグの熱硬化性樹脂が両端木口面から溶け出すことを封止できる一方、空気はその張り出し露呈する最外層の両端部から押し出すことができ、高品質な製品を得られる効果がある。 Further, if the configuration of claim 5 is adopted, the FRP prepreg is thermally cured by a bleeder tape wound in a built-up state, leaving both ends of the outermost layer of the FRP prepreg overhanging and exposing a certain amount. It is possible to seal the melting resin from melting the both ends, while air can be pushed out from both ends of the outermost layer exposed to the overhang, so that a high quality product can be obtained.
又、そのＦＲＰプリプレグの加熱温度が約１３０℃〜１５０℃に設定されているため、冒頭に述べた公知発明と異なり、ありふれた安価な１３０℃〜１５０℃硬化タイプのＣＦＲＰプリプレグやＧＦＲＰクロスプリプレグを制約なく採用することができ、汎用性と量産効果の向上に役立つ。 In addition, since the heating temperature of the FRP prepreg is set to about 130 ° C. to 150 ° C., unlike the known invention described at the beginning, a common low cost 130 ° C. to 150 ° C. curing type CFRP prepreg or GFRP cross prepreg is used. It can be used without restrictions, and helps to improve versatility and mass production effects.
以下、図面に基いて本発明の詳細を説明すると、その本発明の第１実施形態を示した図１〜１４において、（１０）はアルミ合金又はステンレス鋼を素材とする薄肉な金属管であり、その外径が６０mm以下の場合には約１〜２mmの厚み（ｔ１）として、同じく外径が６０mmを越える場合には約１．５〜３．０mmの厚み（ｔ１）として準備されるが、図示の一例では外径が６０．５mm、内径（ｄ１）が５７．５mm、厚み（ｔ１）が１．５mmのステンレス鋼から成る金属管（１０）を採用している。 Hereinafter, the details of the present invention will be described with reference to the drawings. In FIGS. 1 to 14 showing the first embodiment of the present invention, (10) is a thin metal tube made of aluminum alloy or stainless steel. When the outer diameter is 60 mm or less, the thickness (t1) is about 1-2 mm, and when the outer diameter is more than 60 mm, the thickness (t1) is about 1.5-3.0 mm. In the illustrated example, a metal tube (10) made of stainless steel having an outer diameter of 60.5 mm, an inner diameter (d1) of 57.5 mm, and a thickness (t1) of 1.5 mm is employed.
（Ｆ）はこのような金属管（１０）へ追って内張り状態にライニングされるＦＲＰ（繊維強化樹脂）プリプレグとして、ＣＦＲＰ（炭素繊維強化樹脂）のＵＤテープ材又はＧＦＲＰ（ガラス繊維強化樹脂）のクロス材に、予じめエポキシ樹脂やフェノール樹脂、ポリエステル樹脂などの熱硬化性樹脂が含浸され、その半硬化状態（プリプレグ）に形成されたものであり、その厚み（ｔ２）が薄くとも上記金属管（１０）の約２．５倍に関係設定されている。この点、図示の一例では外径（ｄ２）が５７mm、内径が４５mm、厚み（ｔ２）が６mmのＣＦＲＰプリプレグを採用している。 (F) is a RP tape material of CFRP (carbon fiber reinforced resin) or a GFRP (glass fiber reinforced resin) cloth as an FRP (fiber reinforced resin) prepreg lined in a lining state following such a metal tube (10). The metal tube is impregnated with a thermosetting resin such as an epoxy resin, a phenol resin, or a polyester resin in advance and formed into a semi-cured state (prepreg). The setting is about 2.5 times that of (10). In this regard, in the illustrated example, a CFRP prepreg having an outer diameter (d2) of 57 mm, an inner diameter of 45 mm, and a thickness (t2) of 6 mm is employed.
又、（Ｍ）は上記ＦＲＰプリプレグ（Ｆ）の巻き付け芯となるマンドレル（金型）であって、その厚み（ｔ３）が薄くとも上記金属管（１０）の約３倍に厚肉化されたアルミ合金管から成り、その金属管（１０）よりも大きく熱膨張できるようになっている。その場合、図示の一例では外径（ｄ３）が４５mm、内径が３５mm、厚み（ｔ３）が５mmのマンドレル（Ｍ）を採用している。 In addition, (M) is a mandrel (mold) that becomes a winding core of the FRP prepreg (F), and the thickness is increased to about 3 times that of the metal tube (10) even if the thickness (t3) is thin. It consists of an aluminum alloy tube, and can expand more thermally than the metal tube (10). In this case, in the illustrated example, a mandrel (M) having an outer diameter (d3) of 45 mm, an inner diameter of 35 mm, and a thickness (t3) of 5 mm is employed.
そこで、本発明のＦＲＰライニング金属管（Ａ）を製造する当っては、上記厚肉なマンドレル（Ｍ）の表面へ予じめ耐熱用の離型剤（図示省略）を塗布しておき、これを回転させることによって、その表面へ上記ＦＲＰプリプレグ（Ｆ）を図３のように巻き付け一体化する。 Therefore, in manufacturing the FRP-lined metal tube (A) of the present invention, a heat-resistant release agent (not shown) is applied in advance to the surface of the thick mandrel (M). , The FRP prepreg (F) is wound around and integrated with the surface as shown in FIG.
即ち、そのＦＲＰプリプレグ（ＣＦＲＰプリプレグ）（Ｆ）のＵＤテープ材（繊維を一方向に引き揃えたプリプレグ）（Ｆ１）（Ｆ２）（Ｆ３）（Ｆ４）をマンドレル（Ｍ）との関係上、順次９０度の方向性に２プライ、０度の方向性に５〜７プライ、再び９０度の方向性に同じく２プライ、再び０度の方向性に同じく５〜７プライとして、図４のような交互の縦横積層状態に巻き付けるのである。 That is, the UD tape material of the FRP prepreg (CFRP prepreg) (F) (prepreg in which fibers are aligned in one direction) (F1) (F2) (F3) (F4) in order with the mandrel (M) As shown in FIG. 4, 2 plies for 90 degree direction, 5 to 7 ply for 0 degree direction, 2 ply for 90 degree direction again, and 5 to 7 ply for 0 degree direction again. It is wound in an alternating vertical and horizontal lamination state.
茲に、巻き付けプライ数は製品の使用目的や用途などに応じて選定できるが、ＦＲＰプリプレグ（Ｆ）と上記金属管（１０）との内外相互間隙（Ｓ１）が０．１〜０．３mmの数値範囲となるように保つ。その０．３mmよりも広いと、金属管（１０）並びにマンドレル（Ｍ）における熱膨張率との関係上、後述する張り付けライニング状態の耐久強度や安定性が低下するおそれがあり、他方０．１mmよりも狭いと、そのＦＲＰプリプレグ（Ｆ）の巻き付けられたマンドレル（Ｍ）を、金属管（１０）の内部へ円滑に差し込み貫通させることができないからである。 Furthermore, the number of winding plies can be selected according to the purpose and application of the product, but the internal / external gap (S1) between the FRP prepreg (F) and the metal tube (10) is 0.1 to 0.3 mm. Keep in the numerical range. If the width is larger than 0.3 mm, the durability and stability of the lining state to be described later may be lowered due to the relationship between the thermal expansion coefficients of the metal tube (10) and the mandrel (M), and the other is 0.1 mm. If it is narrower, the mandrel (M) around which the FRP prepreg (F) is wound cannot be smoothly inserted and penetrated into the metal tube (10).
その場合、図５、６に抽出した部分拡大図では、最内層（１１）を形作る１プライ目の巻き付け始端部（ａ）と、同じく２プライ目の巻き付け終端部（ｂ）とのオーバーラップ状態を示しているにとどまるが、その９０度の方向性にある最内層（１１）のみならず、これと同じ方向性にある第３中間層（１３）や、０度の方向性にある第２中間層（１２）と最外層（１４）についても、そのＵＤテープ材（Ｆ１）〜（Ｆ４）の巻き付け始端部（ａ）と巻き付け終端部（ｂ）とは、例えば約２〜５mmの一定量（Ｘ）だけオーバーラップする状態に保っておくことにより、追って加熱軟化したＦＲＰプリプレグ（Ｆ）が、マンドレル（Ｍ）からの熱膨張力（内圧）を受けて径大化することに備える。 In that case, in the partially enlarged views extracted in FIGS. 5 and 6, the overlap state between the winding start end portion (a) of the first ply forming the innermost layer (11) and the winding end portion (b) of the second ply is also the same. However, not only the innermost layer (11) in the direction of 90 degrees, but also the third intermediate layer (13) in the same direction as this, and the second layer in the direction of 0 degrees. For the intermediate layer (12) and the outermost layer (14), the winding start end (a) and winding end (b) of the UD tape materials (F1) to (F4) are, for example, a certain amount of about 2 to 5 mm. By keeping the state overlapped by (X), the FRP prepreg (F) that has been softened by heating is prepared for receiving a thermal expansion force (internal pressure) from the mandrel (M) and increasing its diameter.
上記マンドレル（Ｍ）に巻き付けられたＦＲＰプリプレグ（Ｆ）の最外層（１４）へ、次に図７のような霧吹きや湿した拭き布などによって水分（１５ａ）を付与した上、低密度ポリエチレン（ＬＤＰＥ）のフィルムから成る熱溶融性テープ（１５ｂ）を巻き付ける。この点、図示の一例では幅が２５mm、厚みが３０μｍの熱溶融性テープ（１５ｂ）を５プライだけ巻き付けることにより、０．１５mmの厚みに積層させている。 Next, water (15a) was applied to the outermost layer (14) of the FRP prepreg (F) wound around the mandrel (M) with a spray or wet cloth as shown in FIG. A hot melt tape (15b) made of a film of LDPE) is wound. In this respect, in the example shown in the drawing, a heat-meltable tape (15b) having a width of 25 mm and a thickness of 30 μm is wound by 5 plies to be laminated to a thickness of 0.15 mm.
そして、このようなＦＲＰプリプレグ（Ｆ）に加え、熱溶融性テープ（１５ｂ）も巻き付けられた上記マンドレル（Ｍ）を、予じめ用意された上記金属管（１０）の内部へ、図８のように差し込み貫通させるのである。図示の一例ではステンレス鋼から成る金属管（１０）の内径（ｄ１）が５７．５mm、ＦＲＰプリプレグ（ＣＦＲＰプリプレグ）（Ｆ）の外径（ｄ２）が上記５プライのテープ（１５）も含むそれとして５７．１５mmであるため、これらの巻き付けられたマンドレル（Ｍ）を、上記金属管（１０）の内部へ支障なく差し込み貫通させることができる。 Then, in addition to the FRP prepreg (F), the mandrel (M) on which the heat-meltable tape (15b) is wound is placed inside the metal tube (10) prepared in advance as shown in FIG. It is inserted and penetrated like this. In the illustrated example, the metal tube (10) made of stainless steel has an inner diameter (d1) of 57.5 mm, and the FRP prepreg (CFRP prepreg) (F) has an outer diameter (d2) including the 5-ply tape (15). Therefore, these wound mandrels (M) can be inserted and penetrated into the metal pipe (10) without any trouble.
その場合、金属管（１０）の長さ（Ｌ１）とＦＲＰプリプレグ（Ｆ）の長さ（Ｌ２）との関係については図８に併せて示す如く、ＦＲＰプリプレグ（Ｆ）の両端部が金属管（１０）の両端部から、例えば約５〜１０mmの一定量（Ｗ）づつ張り出すように予じめ設定されている。 In that case, as shown in FIG. 8 for the relationship between the length (L1) of the metal tube (10) and the length (L2) of the FRP prepreg (F), both ends of the FRP prepreg (F) are connected to the metal tube. For example, a predetermined amount (W) of about 5 to 10 mm is projected from both ends of (10).
茲に、ＦＲＰプリプレグ（Ｆ）の最外層（１４）を一定量（Ｗ）づつ張り出し露呈させた状態に残して、次にそのＦＲＰプリプレグ（Ｆ）の両端木口面と、上記マンドレル（Ｍ）の表面との境界段差部へ、耐熱性や離型性がある延伸ポリプロピレン（ＯＰＰ）のブリーダーテープ（１６）を、図９、１０のような肉盛り状態に巻き付けて、後述の加熱時にＦＲＰプリプレグ（Ｆ）の熱硬化性樹脂が、その両端木口面から余分に溶け出さないように封止すると共に、上記ＦＲＰプリプレグ（Ｆ）の一定量（Ｗ）づつ露呈した最外層（１４）から空気が円滑に押し出される状態に保つ。 The outermost layer (14) of the FRP prepreg (F) is left overhanging and exposed in a certain amount (W), and then both ends of the FRP prepreg (F) and the mandrel (M) A stretched polypropylene (OPP) bleeder tape (16) having heat resistance and releasability is wound around the surface stepped portion of the surface in a piled state as shown in FIGS. 9 and 10, and an FRP prepreg ( F) The thermosetting resin is sealed so as not to be excessively melted from the end surfaces of both ends, and air is smooth from the outermost layer (14) exposed by a certain amount (W) of the FRP prepreg (F). Keep it pushed out.
そして、図１０のような状態から約１３０℃〜１５０℃の温度を保つ加熱炉（図示省略）へ挿入し、所要時間（例えば約３〜４時間）だけ加熱することにより、上記ＦＲＰプリプレグ（Ｆ）を完全に硬化させるのである。 And it inserts into the heating furnace (illustration omitted) which maintains the temperature of about 130 to 150 degreeC from the state like FIG. 10, and heats only for the required time (for example, about 3 to 4 hours), The said FRP prepreg (F ) Is completely cured.
そうすれば、その加熱の進行過程において、上記マンドレル（Ｍ）に巻き付けられているＦＲＰプリプレグ（Ｆ）の熱硬化性樹脂が、一旦溶融軟化して流動性状となるため、当初曲げ応力を加えられていたＵＤテープ材（Ｆ１）〜（Ｆ４）が自由になり、そのＵＤテープ材（Ｆ１）〜（Ｆ４）にはフラットな状態へ復元しようとする力が発生する。 Then, in the process of heating, the thermosetting resin of the FRP prepreg (F) wound around the mandrel (M) is once melted and softened to become fluid, so that an initial bending stress is applied. The UD tape materials (F1) to (F4) that have been used become free, and a force to restore the UD tape materials (F1) to (F4) to a flat state is generated.
又、上記マンドレル（Ｍ）と金属管（１０）も加熱を受けて、各々図２の矢印で示す内外方向（求心方向と放射方向）へ膨張するが、そのマンドレル（Ｍ）の厚み（ｔ３）は金属管（１０）のそれに比して、薄くとも約３倍に関係設定されているため、その金属管（１０）よりも多量に熱膨張するマンドレル（Ｍ）の大きな勢力（内圧）を受けたＦＲＰプリプレグ（Ｆ）のＵＤテープ材（Ｆ１）〜（Ｆ４）が図６のように、その巻き付け始端部（ａ）と巻き付け終端部（ｂ）との押し広げられる拡張状態に径大化し、そのＦＲＰプリプレグ（Ｆ）の最外層（１４）はやがて金属管（１０）の内周面へ張り付き溶着一体化する結果となり、図１、２と図１１、１２との対比から明白なように、当初存在していたＦＲＰプリプレグ（Ｆ）と金属管（１０）との内外相互間隙（Ｓ１）が、完全に埋め尽されるのである。 Further, the mandrel (M) and the metal tube (10) are also heated and expanded in the inner and outer directions (centripetal direction and radial direction) indicated by arrows in FIG. 2, respectively. The thickness (t3) of the mandrel (M) Is set to about three times as thin as that of the metal tube (10), so that it receives a large force (internal pressure) of the mandrel (M) that thermally expands more than the metal tube (10). The UD tape materials (F1) to (F4) of the FRP prepreg (F) are increased in diameter in an expanded state in which the winding start end (a) and the winding end (b) are spread as shown in FIG. As a result, the outermost layer (14) of the FRP prepreg (F) was eventually attached to the inner peripheral surface of the metal tube (10) by welding and integrated, and as is clear from the comparison between FIGS. FRP prepreg (F) and metal tube that existed initially Out mutual gap between the 10) (S1) is in the completely filled exhausted.
しかも、上記ＦＲＰプリプレグ（Ｆ）の最外層（１４）に巻き付けられていた熱溶融性テープ（１５ｂ）は、低密度ポリエチレンのフィルムから成り、約７０℃を越えると溶融する一方、その下地の水分（１５ａ）も加熱されて蒸発するため、図１３に拡大して示す如く、その溶融したテープ（１５ｂ）に無数の気体が独立気泡として封じ込められ、その状態のもとで上記マンドレル（Ｍ）からの多大な熱膨張力（内圧）を受けることになる。 Moreover, the heat-meltable tape (15b) wound around the outermost layer (14) of the FRP prepreg (F) is made of a low-density polyethylene film and melts when the temperature exceeds about 70 ° C. Since (15a) is also heated and evaporates, as shown in an enlarged view in FIG. 13, innumerable gases are contained as closed cells in the melted tape (15b), and from that state, the mandrel (M) Will receive a large thermal expansion force (internal pressure).
つまり、水分（１５ａ）から蒸発した気体を封入した溶融状態の上記テープ（１５ｂ）が、言わば発泡剤（１７）又はホットメルト接着剤と化して、ＦＲＰプリプレグ（Ｆ）の溶けた熱硬化性樹脂と一体の膜になり、その能動的な働きによってＦＲＰプリプレグ（Ｆ）の最外層（１４）を金属管（１０）への内張り状態にライニングする結果となる。その発泡剤（１７）として能動的に働く上記テープ（１５ｂ）は、ＦＲＰプリプレグ（Ｆ）と金属管（１０）との内外相互間隙（Ｓ１）から空気を自づと押し出すことになるため、その両者の層間剥離を生ずるおそれもなく、耐久強度に富む安定な焼きバメ状態を得られるのである。 That is, the above-mentioned tape (15b) in a molten state in which gas evaporated from moisture (15a) is sealed becomes a foaming agent (17) or a hot-melt adhesive, and the thermosetting resin in which the FRP prepreg (F) is dissolved. As a result, the outermost layer (14) of the FRP prepreg (F) is lined in a lining state on the metal tube (10) by the active action. The tape (15b) that works actively as the foaming agent (17) pushes air out of the internal / external gap (S1) between the FRP prepreg (F) and the metal tube (10). There is no fear of delamination of the two, and a stable shrinking state having a high durability strength can be obtained.
何れにしても、上記ＦＲＰプリプレグ（Ｆ）の完全な硬化後には、加熱炉から取り出して、常温まで冷却する。そうすれば、金属管（１０）のみならず、マンドレル（Ｍ）も当初の太さまで収縮復元することになるが、既に述べた通り、マンドレル（Ｍ）の厚み（ｔ３）は金属管（１０）のそれに比し、薄くとも約３倍に設定されているため、その冷却時の復元収縮量も多く、これに対してＦＲＰプリプレグ（Ｆ）の線膨張係数は極めて小さく、実質的に膨張・収縮しない関係上、その硬化したＦＲＰプリプレグ（Ｆ）の内部からマンドレル（Ｍ）を支障なく円滑に抜き出すことができる。 In any case, after the FRP prepreg (F) is completely cured, the FRP prepreg (F) is taken out from the heating furnace and cooled to room temperature. Then, not only the metal tube (10) but also the mandrel (M) is restored to its original thickness, but as already stated, the thickness (t3) of the mandrel (M) is the metal tube (10). Since it is set to about three times as thin as that of, the amount of restoration shrinkage at the time of cooling is large. On the other hand, the linear expansion coefficient of FRP prepreg (F) is extremely small and substantially expands and contracts. Therefore, the mandrel (M) can be smoothly extracted from the inside of the cured FRP prepreg (F) without hindrance.
つまり、図示の一例として挙げた数値において、当初金属管（ステンレス鋼管）（１０）とＦＲＰプリプレグ（ＣＦＲＰプリプレグ）（Ｆ）との内外相互間に存在していた０．２５mmの間隙（Ｓ１）が、その熱膨張により埋め尽くされる一方、その当初マンドレル（アルミ合金管）（Ｍ）への巻き付け状態に密着していた上記ＦＲＰプリプレグ（Ｆ）が、マンドレル（Ｍ）の収縮復元によって、そのマンドレル（Ｍ）との内外相互間に間隙（Ｓ２）を発生することになるため、金属管（１０）への内張りライニング状態に硬化したＦＲＰプリプレグ（Ｆ）の内部から、マンドレル（Ｍ）を抜き出せるわけである。 In other words, in the numerical values given as an example in the figure, there is a 0.25 mm gap (S1) that existed between the inside and outside of the metal pipe (stainless steel pipe) (10) and the FRP prepreg (CFRP prepreg) (F). The FRP prepreg (F), which was initially filled with the thermal expansion of the mandrel (aluminum alloy tube) (M), was brought into close contact with the mandrel (M) due to the shrinkage and restoration of the mandrel (M). Since a gap (S2) is generated between the inside and outside of M), the mandrel (M) can be extracted from the inside of the FRP prepreg (F) cured to the lining state on the metal tube (10). It is.
上記硬化したＦＲＰプリプレグ（Ｆ）からマンドレル（Ｍ）を抜芯した最後には、未だ上記ブリーダーテープ（１６）が付属している半成状態の金属管（１０）とＦＲＰプリプレグ（Ｆ）の両端部を、図１４のように切り捨てることにより、一定な有効長さ（Ｌ）の製品：ＦＲＰライニング金属管（Ａ）として完成させれば良い。 Finally, the mandrel (M) is removed from the hardened FRP prepreg (F), and the ends of the semi-finished metal tube (10) to which the bleeder tape (16) is still attached and the FRP prepreg (F) are still attached. The part may be cut off as shown in FIG. 14 to complete the product with a fixed effective length (L): FRP-lined metal tube (A).
尚、ＦＲＰプリプレグ（Ｆ）に含浸されている熱硬化性樹脂の溶融し得る加熱温度を受けたマンドレル（Ｍ）と金属管（１０）は、何れも内外方向（放射方向と求心方向）へ膨張するが、その際ＦＲＰプリプレグ（Ｆ）と金属管（１０）との内外相互間隙（Ｓ１）が予じめ０．１〜０．３mmに設定されている関係上、又マンドレル（Ｍ）の厚み（ｔ３）は金属管（１０）における厚み（ｔ１）の約３倍以上として厚肉化されている関係上、その金属管（１０）よりも多いマンドレル（Ｍ）の熱膨張量により、最終的に硬化したＦＲＰプリプレグ（Ｆ）を金属管（１０）の内周面へ、完全な張り付け状態にライニング一体化することができ、その限りでは上記熱溶融性テープ（１５ｂ）の巻き付けと、その下地となる水分（１５ａ）の付与を省略してもさしつかえない。 Note that the mandrel (M) and the metal tube (10) that have been subjected to a melting temperature of the thermosetting resin impregnated in the FRP prepreg (F) both expand inward and outward (radial direction and centripetal direction). However, in this case, the inner / outer mutual gap (S1) between the FRP prepreg (F) and the metal tube (10) is set to 0.1 to 0.3 mm in advance, and the thickness of the mandrel (M) (T3) is thickened to be about three times or more the thickness (t1) of the metal tube (10), so that the final amount of thermal expansion of the mandrel (M) is larger than that of the metal tube (10). The FRP prepreg (F) cured to the inner circumference of the metal tube (10) can be lined and integrated in a completely attached state, as long as the hot melt tape (15b) is wound and the base Omit moisture (15a) No problem even if the.
因みに、アルミ合金（Ａ５０５２）の線膨張係数は約２３．６×１０-6／℃、ステンレス鋼（ＳＵＳ３０４）の線膨張係数は約１７．５×１０-6／℃、ＣＦＲＰ（ＰＡＮ系繊維Ｔ３００〜Ｔ８００、Ｖｆ：６０）の線膨張係数は約０．２〜０．４×１０-6／℃、ＧＦＲＰ（Ｖｆ：６０）の線膨張係数は約７×１０-6／℃である。 Incidentally, the linear expansion coefficient of aluminum alloy (A5052) is about 23.6 × 10 −6 / ° C., the linear expansion coefficient of stainless steel (SUS304) is about 17.5 × 10 −6 / ° C., CFRP (PAN-based fiber T300). ˜T800, Vf: 60) has a linear expansion coefficient of about 0.2 to 0.4 × 10 −6 / ° C., and GFRP (Vf: 60) has a linear expansion coefficient of about 7 × 10 −6 / ° C.
次に、図１５〜１９は本発明の第２実施形態に係り、その図示の一例では金属管（１０）として外径が５５mm、内径（ｄ１）が５１mm、厚み（ｔ１）が２mmのアルミ合金管を、マンドレル（Ｍ）として外径（ｄ３）が４５mm、内径が３３mm、厚み（ｔ３）が６mmの同じアルミ合金管を、又ＦＲＰプリプレグ（Ｆ）として外径（ｄ２）が５０．５mm、内径が４５mm、厚み（ｔ２）が２．７５mmのＧＦＲＰクロスプリプレグを採用している。 Next, FIGS. 15 to 19 relate to a second embodiment of the present invention. In the illustrated example, an aluminum alloy having an outer diameter of 55 mm, an inner diameter (d1) of 51 mm, and a thickness (t1) of 2 mm as a metal tube (10). The same aluminum alloy tube having an outer diameter (d3) of 45 mm, an inner diameter of 33 mm, and a thickness (t3) of 6 mm as a mandrel (M), and an outer diameter (d2) of 50.5 mm as an FRP prepreg (F), A GFRP cross prepreg having an inner diameter of 45 mm and a thickness (t2) of 2.75 mm is employed.
図１〜１４に示した上記第１実施形態の場合、低密度ポリエチレンのフィルムから成る熱溶融性テープ（１５ｂ）とその下地の水分（１５ａ）を、加熱により膨張する発泡剤（１７）又はホットメルト接着剤として機能させている構成のため、特別な発泡剤を必要とせず、製造コストダウンに役立つ利点があるが、上記熱溶融性テープ（１５ｂ）と水分（１５ａ）に代る特別の発泡剤（１８）を採用しても勿論良い。 In the case of the first embodiment shown in FIGS. 1 to 14, a heat-meltable tape (15b) made of a low-density polyethylene film and its underlying moisture (15a) are expanded by heating with a foaming agent (17) or hot. The structure functioning as a melt adhesive does not require a special foaming agent and has the advantage of helping to reduce the manufacturing cost. However, a special foaming alternative to the hot-melt tape (15b) and moisture (15a) is used. Of course, the agent (18) may be employed.
この点、本発明の第２実施形態ではその発泡剤（１８）として、「EXPANCEL/ エクスパンセル」（商品名）と称する熱膨張性マイクロスフェアーを採用している。これはガスバリアー性の熱可塑性樹脂製外殻に、少量の液状炭化水素を内包した平均粒径：約１０〜１７μｍ、真比重：１０００〜１３００kg/m2 の球状粒子であり、約１００〜２００℃に加熱されると、その体積が４０倍以上に膨張する。 In this regard, in the second embodiment of the present invention, as the foaming agent (18), a thermally expandable microsphere called “EXPANCEL” (trade name) is adopted. This is a spherical particle having an average particle diameter of about 10 to 17 μm and a true specific gravity of 1000 to 1300 kg / m 2 in which a small amount of liquid hydrocarbon is encapsulated in an outer shell made of a gas barrier thermoplastic resin. When heated to ° C., the volume expands over 40 times.
そこで、このような発泡剤（１８）の未膨張状態にある粒子を、上記ＦＲＰプリプレグ（Ｆ）と同じ熱硬化性樹脂に約１０重量パーセントだけ混合・攪拌して、その攪拌した混合液を極性の強い溶剤（好ましくはメチルエチルケトン）で適度に稀釈した上、これをＦＲＰプリプレグ（Ｆ）の最外層（１４）へ塗り付けておく。但し、その塗り付けはＦＲＰプリプレグ（Ｆ）をマンドレル（Ｍ）へ巻き付けた後に行なっても良く、その巻き付け前の最外層（１４）となるＵＤテープ材（Ｆ４）やクロス材へ、予じめ練り込んでおいてもさしつかえない。 Therefore, the unexpanded particles of the foaming agent (18) are mixed and stirred in the same thermosetting resin as the FRP prepreg (F) by about 10 weight percent, and the stirred mixture is polarized. The solution is appropriately diluted with a strong solvent (preferably methyl ethyl ketone) and applied to the outermost layer (14) of the FRP prepreg (F). However, the coating may be performed after the FRP prepreg (F) is wound around the mandrel (M), and it is preliminarily applied to the UD tape material (F4) or cloth material that becomes the outermost layer (14) before the winding. There is no problem even if it is kneaded.
何れにしても、このようなＦＲＰプリプレグ（Ｆ）が巻き付けられたマンドレル（Ｍ）を、その後第１実施形態の上記製造工程に準じて、予じめ用意された金属管（１０）の内部へ差し込み貫通させ、約１３０℃〜１５０℃の温度を保つ加熱炉（図示省略）により、所要時間（例えば約３〜４時間）だけ加熱して、上記ＦＲＰプリプレグ（Ｆ）を完全に硬化させるのである。 In any case, the mandrel (M) around which such FRP prepreg (F) is wound is then introduced into the preliminarily prepared metal tube (10) according to the manufacturing process of the first embodiment. The FRP prepreg (F) is completely cured by heating for a required time (for example, about 3 to 4 hours) in a heating furnace (not shown) that is inserted and penetrated and maintains a temperature of about 130 ° C. to 150 ° C. .
そうすれば、その加熱が進むに連れて、上記マンドレル（Ｍ）と金属管（１０）はやはり図１６の矢印で示す内外方向へ膨張するが、上記ＦＲＰプリプレグ（Ｆ）の最外層（１４）へ熱硬化性樹脂との混練状態に塗布されている球状粒子の発泡剤（１８）も、その外殻の軟化により体積が劇的に膨張し、図１９のような中空の粒子を含む膜となって、上記金属管（１０）の内周面へ張り付き、当初存在していたＦＲＰプリプレグ（Ｆ）と金属管（１０）との内外相互間隙（Ｓ１）が、積極的に埋め尽くされるのであり、最終的に硬化したＦＲＰプリプレグ（Ｆ）が図１７、１８のような金属管（１０）への内張り状態にライニングされた製品−ＦＲＰライニング金属管（Ａ）を得ることができる。しかも、その製品−ＦＲＰライニング管（Ａ）に外部応力が加えられた際の耐衝撃性を、上記発泡剤（１７）の張り付き膜により発揮させ得る効果もある。 Then, as the heating proceeds, the mandrel (M) and the metal tube (10) also expand inward and outward as indicated by arrows in FIG. 16, but the outermost layer (14) of the FRP prepreg (F). The spherical particle foaming agent (18) applied in a kneaded state with a thermosetting resin also has a volume that dramatically expands due to the softening of its outer shell, and a film containing hollow particles as shown in FIG. As a result, it sticks to the inner peripheral surface of the metal pipe (10), and the internal / external gap (S1) between the FRP prepreg (F) and the metal pipe (10), which originally existed, is actively filled. The product-FRP lining metal tube (A) in which the finally cured FRP prepreg (F) is lined in the state of lining the metal tube (10) as shown in FIGS. 17 and 18 can be obtained. Moreover, the product-FRP lining pipe (A) has an effect that the impact resistance when an external stress is applied can be exhibited by the adhesive film of the foaming agent (17).
尚、図１５〜１９の第２実施形態におけるその他の構成は上記第１実施形態と実質的に同一であるため、その図１５〜１９に図１〜１４との対応符号を記入するにとどめて、その詳細な説明を省略するが、上記の特別な発泡剤（１８）としては熱膨張性のマイクロスフェアーのみに限らず、ＦＲＰプリプレグ（Ｆ）が硬化する過程での加熱温度により膨張し得る適当な発泡剤（１８）を採用し、これをそのＦＲＰプリプレグ（Ｆ）の熱硬化性樹脂に予じめ混練したシート材として、そのＦＲＰプリプレグ（Ｆ）の最外層（１４）へ適当なプライ数だけ巻き付け積層させても良く、これによれば上記最内層（１１）や第２、３中間層（１２）（１３）と同じ巻き付け作業に統一できる利点があり、作業上の簡素化に役立つ。 In addition, since the other structure in 2nd Embodiment of FIGS. 15-19 is substantially the same as the said 1st Embodiment, only the corresponding code | symbol with FIGS. 1-14 is entered in the FIGS. 15-19. The detailed description is omitted, but the above-mentioned special foaming agent (18) is not limited to the thermally expandable microspheres, but can be expanded by the heating temperature in the process of curing the FRP prepreg (F). A suitable foaming agent (18) is employed, and this is preliminarily kneaded with the thermosetting resin of the FRP prepreg (F), and an appropriate ply is applied to the outermost layer (14) of the FRP prepreg (F). As many as the number of windings may be laminated. According to this, there is an advantage that the same winding work as that of the innermost layer (11) and the second and third intermediate layers (12) and (13) can be unified, which helps to simplify the work. .
（１０）・金属管
（１１）・最内層
（１２）・第２中間層
（１３）・第３中間層
（１４）・最外層
（１５ａ）・水分
（１５ｂ）・熱溶融性テープ
（１６）・ブリーダーテープ
（１７）・発泡剤（ホットメルト接着剤）
（１８）・発泡剤
（Ａ）・ＦＲＰライニング金属管
（Ｆ）・ＦＲＰプリプレグ
（Ｆ１）（Ｆ２）（Ｆ３）（Ｆ４）・ＵＤテープ材
（Ｍ）・マンドレル
（ｔ１）（ｔ２）（ｔ３）・厚み
（Ｓ１）（Ｓ２）・間隙
（Ｘ）・オーバーラップ量
（Ｗ）・張り出し量
(10) Metal pipe (11) Innermost layer (12) Second intermediate layer (13) Third intermediate layer (14) Outermost layer (15a) Moisture (15b) Hot melt tape (16)・ Bleeder tape (17) ・ Foaming agent (hot melt adhesive)
(18)-Foaming agent (A)-FRP lining metal pipe (F)-FRP prepreg (F1) (F2) (F3) (F4)-UD tape material (M)-Mandrel (t1) (t2) (t3)・ Thickness (S1) (S2) ・ Gap (X) ・ Overlap amount (W) ・ Overhang amount
Claims (5)
上記マンドレル（Ｍ）へＦＲＰプリプレグ（Ｆ）を、その外径（ｄ２）が上記金属管（１０）の内径（ｄ１）と０．１〜０．３mmの一定間隙（Ｓ１）を保つ積層状態に巻き付け一体化して、その金属管（１０）の内部へ差し込み貫通させた上、
上記ＦＲＰプリプレグ（Ｆ）をこれに含浸された熱硬化性樹脂が硬化するまでの加熱過程において、上記金属管（１０）よりも多大に熱膨張するマンドレル（Ｍ）からの内圧により、上記内外相互間隙（Ｓ１）を埋め尽す如く金属管（１０）の内周面ヘ張り付け一体化させるように定めたことを特徴とするＦＲＰライニング金属管の製造法。 Prepare a metal tube (10) made of aluminum alloy or stainless steel, and an aluminum alloy mandrel (M) that is about three times thicker than the metal tube (10).
The FRP prepreg (F) is laminated on the mandrel (M) so that the outer diameter (d2) maintains a constant gap (S1) of 0.1 to 0.3 mm with the inner diameter (d1) of the metal tube (10). Wound and integrated, inserted into the inside of the metal tube (10) and penetrated,
In the heating process until the thermosetting resin impregnated with the FRP prepreg (F) is cured, the internal and external mutuals are caused by the internal pressure from the mandrel (M) that thermally expands much more than the metal pipe (10). A method of manufacturing an FRP-lined metal tube, characterized in that the gap is defined so as to be integrated with the inner peripheral surface of the metal tube (10) so as to fill the gap (S1).
ＦＲＰプリプレグ（Ｆ）の加熱過程において溶融した上記テープ（１５ｂ）が、その下地の水分（１５ａ）から蒸発した気体を封じ込めた発泡剤（１７）又はホットメルト接着剤と化して、上記ＦＲＰプリプレグ（Ｆ）の最外層（１４）を金属管（１０）の内周面へ能動的に張り付け一体化させるように定めたことを特徴とする請求項１記載のＦＲＰライニング金属管の製造法。 A heat-meltable tape comprising a low-density polyethylene film after water (15a) is applied to the outermost layer (14) of the FRP prepreg (F) wound and integrated around the mandrel (M) by spraying or dampening cloth. Wrap (15b)
The tape (15b) melted in the heating process of the FRP prepreg (F) is converted into a foaming agent (17) or a hot melt adhesive containing a gas evaporated from the moisture (15a) of the base, and the FRP prepreg ( 2. The method of manufacturing an FRP-lined metal tube according to claim 1, wherein the outermost layer (14) of F) is actively attached to and integrated with the inner peripheral surface of the metal tube (10).
ＦＲＰプリプレグ（Ｆ）の加熱過程において膨張する上記発泡剤（１８）により、そのＦＲＰプリプレグ（Ｆ）の最外層（１４）を金属管（１０）の内周面ヘ積極的に張り付け一体化させるように定めたことを特徴とする請求項１記載のＦＲＰライニング金属管の製造法。 The outermost layer (14) of the FRP prepreg (F) wound around and integrated with the mandrel (M) is coated with a thermosetting resin kneaded with the foaming agent (18) composed of thermally expandable microspheres,
The outermost layer (14) of the FRP prepreg (F) is positively attached to and integrated with the inner peripheral surface of the metal pipe (10) by the foaming agent (18) that expands in the heating process of the FRP prepreg (F). 2. The method for producing an FRP-lined metal tube according to claim 1, wherein
ＦＲＰプリプレグ（Ｆ）の加熱過程において膨張する上記発泡剤（１８）により、そのＦＲＰプリプレグ（Ｆ）の最外層（１４）を金属管（１０）の内周面ヘ積極的に張り付け一体化させるように定めたことを特徴とする請求項１記載のＦＲＰライニング金属管の製造法。 A sheet-like FRP prepreg (F), in which a thermally expandable foaming agent (18) is kneaded with the thermosetting resin of the outermost layer (14), is wound around the mandrel (M) and integrated,
The outermost layer (14) of the FRP prepreg (F) is positively attached to and integrated with the inner peripheral surface of the metal pipe (10) by the foaming agent (18) that expands in the heating process of the FRP prepreg (F). 2. The method for producing an FRP-lined metal tube according to claim 1, wherein
その張り出し露呈する最外層（１４）の両端部を残して、上記ＦＲＰプリプレグ（Ｆ）の両端木口面とマンドレル（Ｍ）の表面との境界段差部へ、引き続き延伸ポリプロピレンのブリーダーテープ（１６）を肉盛り状態に巻き付けた上、
上記ＦＲＰプリプレグ（Ｆ）を約１３０℃〜１５０℃の温度により加熱し、その熱硬化性樹脂の硬化後に上記一定量（Ｗ）づつの張り出し両端部を切り捨てることを特徴とする請求項１、２、３又は４記載のＦＲＰライニング金属管の製造法。 FRP prepreg (F) as CFRP prepreg or GFRP prepreg is wound around the mandrel (M) longer than the length (L1) of the metal tube (L1), so that both ends of the outermost layer (14) are made of metal. Keep the tube (10) overhanging by a certain amount (W) from both ends,
The stretched polypropylene bleeder tape (16) is subsequently applied to the boundary step between the both ends of the FRP prepreg (F) and the surface of the mandrel (M), leaving both ends of the outermost layer (14) exposed. After wrapping up in a thick state,
The FRP prepreg (F) is heated at a temperature of about 130 ° C to 150 ° C, and after the thermosetting resin is cured, the protruding both ends of the fixed amount (W) are cut off. 3. A method for producing an FRP-lined metal tube according to 3 or 4.
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Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2011167951A (en) * | 2010-02-19 | 2011-09-01 | Himecs:Kk | Method of manufacturing metal/frp pipe, metal/frp pipe and method of removing heat residual stress of metal/frp pipe |
| CN110789129A (en) * | 2019-06-28 | 2020-02-14 | 东莞科威医疗器械有限公司 | Enhanced medical cannula and manufacturing method thereof |
| CN111674123A (en) * | 2020-06-08 | 2020-09-18 | 首钢集团有限公司 | Fiber metal laminated plate, preparation method and resistance welding method |
| JP7195310B2 (en) | 2017-10-25 | 2022-12-23 | エボニック オペレーションズ ゲーエムベーハー | Method for manufacturing inliner lined pipe |
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2005
- 2005-05-31 JP JP2005159008A patent/JP4054342B2/en active Active
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP2011167951A (en) * | 2010-02-19 | 2011-09-01 | Himecs:Kk | Method of manufacturing metal/frp pipe, metal/frp pipe and method of removing heat residual stress of metal/frp pipe |
| JP7195310B2 (en) | 2017-10-25 | 2022-12-23 | エボニック オペレーションズ ゲーエムベーハー | Method for manufacturing inliner lined pipe |
| CN110789129A (en) * | 2019-06-28 | 2020-02-14 | 东莞科威医疗器械有限公司 | Enhanced medical cannula and manufacturing method thereof |
| CN111674123A (en) * | 2020-06-08 | 2020-09-18 | 首钢集团有限公司 | Fiber metal laminated plate, preparation method and resistance welding method |
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