JP2009012359A - Molding method of frp molded item with foam core - Google Patents
Molding method of frp molded item with foam core Download PDFInfo
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- JP2009012359A JP2009012359A JP2007177968A JP2007177968A JP2009012359A JP 2009012359 A JP2009012359 A JP 2009012359A JP 2007177968 A JP2007177968 A JP 2007177968A JP 2007177968 A JP2007177968 A JP 2007177968A JP 2009012359 A JP2009012359 A JP 2009012359A
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- 239000006260 foam Substances 0.000 title claims abstract description 67
- 238000000465 moulding Methods 0.000 title claims abstract description 67
- 238000000034 method Methods 0.000 title claims abstract description 54
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims abstract description 54
- 239000010936 titanium Substances 0.000 claims abstract description 54
- 229910052719 titanium Inorganic materials 0.000 claims abstract description 54
- 239000000835 fiber Substances 0.000 claims abstract description 36
- 239000000463 material Substances 0.000 claims abstract description 25
- 239000000758 substrate Substances 0.000 claims description 14
- 239000003365 glass fiber Substances 0.000 claims description 12
- 229920005989 resin Polymers 0.000 description 40
- 239000011347 resin Substances 0.000 description 40
- 239000011162 core material Substances 0.000 description 37
- 229920002430 Fibre-reinforced plastic Polymers 0.000 description 33
- 239000011151 fibre-reinforced plastic Substances 0.000 description 33
- 239000011159 matrix material Substances 0.000 description 7
- 238000010438 heat treatment Methods 0.000 description 6
- 230000002787 reinforcement Effects 0.000 description 6
- 229920001187 thermosetting polymer Polymers 0.000 description 6
- 239000002759 woven fabric Substances 0.000 description 6
- 238000007493 shaping process Methods 0.000 description 5
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 4
- 230000000694 effects Effects 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- 239000003822 epoxy resin Substances 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 229920005992 thermoplastic resin Polymers 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- PEEHTFAAVSWFBL-UHFFFAOYSA-N Maleimide Chemical compound O=C1NC(=O)C=C1 PEEHTFAAVSWFBL-UHFFFAOYSA-N 0.000 description 2
- 229920005830 Polyurethane Foam Polymers 0.000 description 2
- 229920006231 aramid fiber Polymers 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 239000011248 coating agent Substances 0.000 description 2
- 238000000576 coating method Methods 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 239000004643 cyanate ester Substances 0.000 description 2
- 239000004744 fabric Substances 0.000 description 2
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- -1 polyethylene Polymers 0.000 description 2
- 239000011496 polyurethane foam Substances 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 239000004408 titanium dioxide Substances 0.000 description 2
- 229920006337 unsaturated polyester resin Polymers 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- 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
- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004696 Poly ether ether ketone Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004734 Polyphenylene sulfide Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 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
- 239000003795 chemical substances by application Substances 0.000 description 1
- 238000001816 cooling Methods 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
- 238000001802 infusion Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 238000012966 insertion method Methods 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920002530 polyetherether ketone Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000009719 polyimide resin Substances 0.000 description 1
- 229920000069 polyphenylene sulfide Polymers 0.000 description 1
- 229920001155 polypropylene Polymers 0.000 description 1
- 229920006327 polystyrene foam Polymers 0.000 description 1
- 229920002635 polyurethane Polymers 0.000 description 1
- 239000004814 polyurethane Substances 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 229920002050 silicone resin Polymers 0.000 description 1
- 229910001220 stainless steel Inorganic materials 0.000 description 1
- 239000010935 stainless steel Substances 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 238000009966 trimming Methods 0.000 description 1
- 238000009941 weaving Methods 0.000 description 1
Abstract
Description
本発明は、繊維強化プラスチック（ＦＲＰ）製の製品あるいはその部品として使用される、発泡体コアを有するＦＲＰ成形品の成形方法に関する。 The present invention relates to a method for molding an FRP molded product having a foam core used as a product made of fiber reinforced plastic (FRP) or a part thereof.
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。 FRP is a thermosetting resin such as unsaturated polyester resin, epoxy resin, polyimide resin, matrix resin of thermoplastic resin such as polyethylene, polypropylene, polyamide, PPS, PEEK, carbon fiber, glass fiber, aramid fiber, etc. In recent years, it is used in a wide range of fields from the aerospace industry to the general industrial field because it is made of reinforcing fibers and is lightweight and excellent in strength properties.
内部に発泡体コアを有するＦＲＰ成形品は、ＦＲＰの表面部材で軽量の芯材を被覆して、樹脂で一体構造化した複合材である。かかる複合材は、軽量で大きな曲げ剛性が得られることから、特に軽量性が要求される航空機や船舶等の部材として利用される。そして、かかる部材の成形方法としては、樹脂トランスファー（ＲＴＭ）成形法や樹脂フィルムインフュージョン成形法などもあるが、繊維強化材（繊維基材）に樹脂を含浸させ、流動性や粘着性を除いて取り扱い性を良くした、シート状の成形中間体であるプリプレグを用いる方法も便利である。 An FRP molded product having a foam core inside is a composite material in which a lightweight core material is covered with a surface member of FRP and is integrally structured with a resin. Since such a composite material is lightweight and has a large bending rigidity, it is used as a member for aircrafts, ships, and the like that are particularly required to be lightweight. And there are resin transfer (RTM) molding method and resin film infusion molding method as the molding method of such members, but the fiber reinforcement (fiber substrate) is impregnated with resin to remove fluidity and adhesiveness. It is also convenient to use a prepreg which is a sheet-like molding intermediate with improved handling properties.
ＲＴＭ成形法では、プリプレグの代わりにドライの繊維基材を用いる。ドライの繊維基材は、シート状の成形中間体（ドライ基材という）であり樹脂を含浸していないため、容易に成形型に沿わすことが出来、取り扱い性が良いという特徴がある。プリプレグを用いて、成形する方法としては、オートクレーブ成形法、ホットプレス成形法、真空バッグ成形法等が知られている。 In the RTM molding method, a dry fiber substrate is used instead of the prepreg. A dry fiber base material is a sheet-like molding intermediate (referred to as a dry base material) and is not impregnated with resin, and therefore can be easily fitted along a molding die and has good characteristics in handling. As a method for molding using a prepreg, an autoclave molding method, a hot press molding method, a vacuum bag molding method, and the like are known.
しかし、いずれの成形方法を取るにしても、例えば、ウレタンフォーム等の発泡体コアは、軽量で柔軟であるが故に、その表面にうねりが生じ易く、引いてはそれがＦＲＰ成形品の表面状態を劣ったものにするという問題があった。本発明者はかかる問題点を解決することを検討している過程で、成形型の内表面と発泡体コアの間にチタン紙を挿入すれば、前記うねりの問題が解決できることを知見した。なお、チタン紙を繊維強化樹脂板や化粧板に使用することは知られているが（例えば、特許文献１と２参照）、発泡体コアを有するＦＲＰ成形品に応用したのは、本発明者の知る限り本発明が初めてである。
本発明は、ＦＲＰ製の製品あるいはその部品として使用される、発泡体コアを有する高品質のＦＲＰ成形品を成形する方法を提供するものである。 The present invention provides a method for molding a high-quality FRP molded article having a foam core, which is used as an FRP product or a part thereof.
本発明の請求項１に記載された発明は、発泡体コアを有するＦＲＰ成形品を成形するに際し、該ＦＲＰ成形品の成形型の内表面に沿って、（Ａ）先ずプリプレグを敷設した後、該プリプレグ上にチタン紙を重ねて配置し、又は、（Ｂ）先ずチタン紙を敷設した後、該チタン紙上にプリプレグを重ねて配置し、次いで、前記発泡体コアを、前記成形型の内部に、前記プリプレグとチタン紙を介して配置し、その後、前記成形型を型締めしてプレス成形法で成形することを特徴とする発泡体コアを有するＦＲＰ成形品の成形方法である。なお、本発明においてプレス成形法というときには、オートクレーブ成形法、ホットプレス成形法、真空バッグ成形法等の、プリプレグを用いて成形型で加熱・加圧することによって成形する方法を全て含むものとする。 In the invention described in claim 1 of the present invention, when molding an FRP molded article having a foam core, (A) first laying a prepreg along the inner surface of the mold of the FRP molded article, Place titanium paper on top of the prepreg, or (B) first lay titanium paper, then place prepreg on the titanium paper, and then place the foam core inside the mold. The method for forming an FRP molded product having a foam core, characterized in that it is disposed through the prepreg and titanium paper, and then the mold is clamped and molded by a press molding method. In the present invention, the press molding method includes all methods of molding by heating and pressing with a molding die using a prepreg, such as an autoclave molding method, a hot press molding method, and a vacuum bag molding method.
請求項２に記載された発明は、プリプレグが、ガラス繊維のプリプレグであることを特徴とする請求項１記載の発泡体コアを有するＦＲＰ成形品の成形方法である。 The invention described in claim 2 is the method for molding an FRP molded article having a foam core according to claim 1, wherein the prepreg is a glass fiber prepreg.
請求項３に記載された発明は、発泡体コアが、硬質発泡体であることを特徴とする請求項１又は２項記載の発泡体コアを有するＦＲＰ成形品の成形方法である。 Invention of Claim 3 is a shaping | molding method of the FRP molded product which has a foam core of Claim 1 or 2 characterized by the above-mentioned.
請求項４に記載された発明は、チタン紙が、着色したチタン紙であることを特徴とする請求項１〜３のいずれか１項記載の発泡体コアを有するＦＲＰ成形品の成形方法である。 Invention of Claim 4 is a shaping | molding method of the FRP molded product which has a foam core of any one of Claims 1-3, wherein titanium paper is colored titanium paper .
請求項５に記載された発明は、発泡体コアを有するＦＲＰ成形品を成形するに際し、該ＦＲＰ成形品の成形型の内表面に沿って、（Ａ）先ず繊維基材を敷設した後、該繊維基材上にチタン紙を重ねて配置し、又は、（Ｂ）先ずチタン紙を敷設した後、該チタン紙上に繊維基材を重ねて配置し、次いで、前記発泡体コアを、前記成形型の内部に、前記繊維基材とチタン紙を介して配置し、その後、前記成形型を型締めしてＲＴＭ成形法で成形することを特徴とする発泡体コアを有するＦＲＰ成形品の成形方法である。ここでいう繊維基材とは、樹脂を含まないドライ基材を意味する。 In the invention described in claim 5, when molding an FRP molded article having a foam core, (A) after first laying a fiber base material along the inner surface of the molding die of the FRP molded article, Titanium paper is placed on the fiber base material, or (B) the titanium paper is first laid, then the fiber base material is placed on the titanium paper, and then the foam core is placed on the mold. In the molding method of the FRP molded product having a foam core, which is disposed inside the fiber base material and the titanium paper, and then the mold is clamped and molded by the RTM molding method. is there. The fiber substrate here means a dry substrate containing no resin.
請求項６に記載された発明は、繊維基材が、ガラス繊維の基材であることを特徴とする請求項５記載の発泡体コアを有するＦＲＰ成形品の成形方法である。 The invention described in claim 6 is the method for forming an FRP molded article having a foam core according to claim 5, wherein the fiber base material is a glass fiber base material.
請求項７に記載された発明は、発泡体コアが、硬質発泡体であることを特徴とする請求項５又は６項記載の発泡体コアを有するＦＲＰ成形品の成形方法である。 The invention described in claim 7 is the method for molding an FRP molded article having a foam core according to claim 5 or 6, wherein the foam core is a hard foam.
そして、請求項８に記載された発明は、チタン紙が、着色したチタン紙であることを特徴とする請求項５〜７のいずれか１項記載の発泡体コアを有するＦＲＰ成形品の成形方法である。 The invention described in claim 8 is a method for forming an FRP molded article having a foam core according to any one of claims 5 to 7, wherein the titanium paper is a colored titanium paper. It is.
本発明によれば、ＦＲＰ製の製品あるいはその部品として使用される、発泡体コアを有する高品質のＦＲＰ成形品を、簡単に成形することができる。チタン紙として着色したチタン紙を用いると、成形後塗装処理等を行わなくても、直接、着色したＦＲＰ成形品が得られる。 ADVANTAGE OF THE INVENTION According to this invention, the high quality FRP molded product which has a foam core used as a product made from FRP or its component can be shape | molded easily. When colored titanium paper is used as the titanium paper, a colored FRP molded product can be obtained directly without performing post-molding coating or the like.
本発明においては、発泡体コアを有するＦＲＰ成形品を成形するに際し、成形型の内表面と発泡体コアの間にチタン紙を挿入することを特徴とする。そして、その挿入のさせ方として、ＦＲＰ成形品の成形型の内表面に沿って、（Ａ）先ずプリプレグあるいは繊維基材を敷設した後、該プリプレグあるいは繊維基材上にチタン紙を重ねて配置し、次いで、前記発泡体コアを、前記成形型の内部に、前記プリプレグとチタン紙を介して配置する方法と、（Ｂ）先ずチタン紙を敷設した後、該チタン紙上にプリプレグあるいは繊維基材を重ねて配置し、次いで、前記発泡体コアを、前記成形型の内部に、前記プリプレグあるいは繊維基材とチタン紙を介して配置する方法の２つの方法がある。前記（Ａ）と（Ｂ）のいずれの方法でも本発明の効果が達成される。 In the present invention, when an FRP molded product having a foam core is molded, titanium paper is inserted between the inner surface of the mold and the foam core. Then, as the method of insertion, along the inner surface of the mold of the FRP molded product, (A) first laying a prepreg or fiber base material, and then placing titanium paper over the prepreg or fiber base material Next, the foam core is disposed inside the mold via the prepreg and titanium paper, and (B) first laying the titanium paper and then prepreg or fiber base material on the titanium paper. And then placing the foam core inside the mold through the prepreg or fiber substrate and titanium paper. The effects of the present invention can be achieved by any of the methods (A) and (B).
そして、また、本発明においては、成形方法として２つの方法が採用されている。即ち、上記においてプリプレグを用いる場合は、プレス成形法が採用され、ドライの繊維基材を用いる場合は、ＲＴＭ成形法が採用される。プレス成形法では、成形型を型締めして後、公知の適当な方法で加圧、加熱することによって成形品が得られる。ＲＴＭ成形法では、成形型を型締めした後、上型と下型との間のキャビティ内を、排気口を通じて排気した後あるいは排気しながら、キャビティ内に樹脂を注入することによって成形品が得られる。 And in this invention, two methods are employ | adopted as a shaping | molding method. That is, when using a prepreg in the above, a press molding method is adopted, and when using a dry fiber substrate, an RTM molding method is adopted. In the press molding method, after a mold is clamped, a molded product is obtained by pressurizing and heating by a known appropriate method. In the RTM molding method, after a mold is clamped, a molded product is obtained by injecting resin into the cavity after exhausting or exhausting the cavity between the upper mold and the lower mold through the exhaust port. It is done.
本発明においては、チタン紙の挿入方法と成形方法を、請求項１と５の発明のように組み合わせることによって最良の効果が得られるが、繊維強化材としてガラス繊維を用いた場合に、特に本発明の効果が効果的に発揮される。 In the present invention, the best effect can be obtained by combining the insertion method and the forming method of titanium paper as in the inventions of claims 1 and 5, but this is particularly true when glass fiber is used as the fiber reinforcement. The effect of the invention is effectively exhibited.
本発明において、発泡体コアとは、例えば、加熱によって発泡する樹脂からなるものである。発泡体コアの材質は、後の工程での成形条件によって適宜選択することができ、特に制限されないが、取り扱いの点で好ましいのは、硬質の発泡体コアである。発泡体としては、例えば、硬質ポリウレタンフォーム、軟質ポリウレタンフォーム、ポリスチレンフォーム、フェノール樹脂フォーム、硬質ＰＶＣフォーム、ポリメタクリルイミド硬質発泡体が挙げられる。 In this invention, a foam core consists of resin which foams by heating, for example. The material of the foam core can be appropriately selected depending on the molding conditions in the subsequent steps, and is not particularly limited. However, a hard foam core is preferable in terms of handling. Examples of the foam include a rigid polyurethane foam, a flexible polyurethane foam, a polystyrene foam, a phenol resin foam, a rigid PVC foam, and a polymethacrylimide rigid foam.
発泡体コアの作成法は、特に制限はない。例えば、前記の様な発泡体（既に発泡しているもの）のシートあるいはブロックで、発泡体コア用の成形型よりも若干大きめのものを準備し、これを成形型の上型と下型の間で加圧・圧縮する。その後、型からはみ出した部分を切除あるいはトリミングすることによって発泡体コアを作成する。加圧・圧縮の条件は、特に限定されるものではなく、発泡体コアが十分に安定した形状を保つ程度の加圧・圧縮条件であれば良い。例えば、ポリメタクリルイミド硬質発泡体の場合には、１０〜１５ｋｇｆ／ｃｍ２、１〜２分程度で十分である。また、必要に応じて加熱しても良い。以上のようにして製作された発泡体コアは、通常、表面にうねりを有する場合が多いが、本発明においてはそのまま用いる。 There is no restriction | limiting in particular in the preparation methods of a foam core. For example, prepare a sheet or block of the foam (already foamed) as described above, which is slightly larger than the mold for the foam core. Press and compress between. Thereafter, the foam core is formed by cutting or trimming the portion protruding from the mold. The conditions for pressurization / compression are not particularly limited, and any pressurization / compression conditions may be used as long as the foam core maintains a sufficiently stable shape. For example, in the case of a polymethacrylimide hard foam, about 10 to 15 kgf / cm 2 and about 1 to 2 minutes are sufficient. Moreover, you may heat as needed. The foam core produced as described above usually has waviness on the surface in many cases, but is used as it is in the present invention.
本発明で用いられるチタン紙は、抄紙時に二酸化チタン粉末を配合することによって隠蔽性を持たせた紙を意味し、化粧紙とも呼ばれる。二酸化チタンと共に有色顔料を配合すると着色チタン紙が得られるが、本発明において着色チタン紙を用いると、成形後塗装処理等を行わなくても、直接、着色したＦＲＰ成形品が得られるという効果もある。なお、チタン紙は、成形に際し、樹脂が流動することによってＦＲＰ成形品と一体化するので、得られたＦＲＰ成形品の機械的物性には、何ら悪影響を及ぼすことはない。 Titanium paper used in the present invention means paper that has been concealed by blending titanium dioxide powder during paper making, and is also called decorative paper. Colored titanium paper is obtained when a colored pigment is blended with titanium dioxide. However, when colored titanium paper is used in the present invention, there is also an effect that a colored FRP molded product can be obtained directly without performing post-molding coating treatment or the like. is there. In addition, since titanium paper is integrated with the FRP molded product by the flow of the resin during molding, the mechanical properties of the obtained FRP molded product are not adversely affected.
本発明において用いられるプリプレグ用の繊維強化材あるいはドライの繊維基材としては、特に制限はない。プリプレグとしては、ガラス繊維、炭素繊維、アラミド繊維等の繊維強化材の織物、不織布等のシート状物に、熱硬化性樹脂や熱可塑性樹脂等のマトリックス樹脂を含浸させて得られたプリプレグが挙げられる。繊維強化材あるいはドライの繊維基材として好ましいのはガラス繊維であり、その織物が好ましい。織物としては、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が挙げられる。 There is no restriction | limiting in particular as a fiber reinforcement for prepregs used in this invention, or a dry fiber base material. Examples of the prepreg include a prepreg obtained by impregnating a fiber-reinforced fabric such as glass fiber, carbon fiber, or aramid fiber, or a sheet-like material such as a nonwoven fabric with a matrix resin such as a thermosetting resin or a thermoplastic resin. It is done. Glass fiber is preferred as the fiber reinforcement or dry fiber substrate, and its woven fabric is preferred. Examples of the woven fabric include, for example, a plain woven fabric, a twill woven fabric, a satin weaving fabric, and the like, a uniaxial woven fabric in which fiber bundles are aligned in one direction and stitched in a perpendicular direction with stitch yarn, Examples thereof include a multi-axis woven fabric in which a plurality of sheet-like materials aligned in the direction are stacked at different angles and stitched with a stitch thread in a perpendicular direction.
プリプレグ用のマトリックス樹脂又はＲＴＭ成形用のマトリックス樹脂としては、熱硬化性樹脂と熱可塑性樹脂を使用することができる。好ましいのは、熱硬化性樹脂であり、その例としては、エポキシ樹脂、不飽和ポリエステル樹脂、フェノール樹脂、メラミン樹脂、ポリウレタン樹脂、シリコン樹脂、マレイミド樹脂、ビニルエステル樹脂、シアン酸エステル樹脂、マレイミド樹脂とシアン酸エステル樹脂を予備重合した樹脂等が挙げられる。これらの熱硬化性樹脂は、適宜量混合配合したものでも良い。これらの樹脂のうち、耐熱性、弾性率、耐薬品性に優れたエポキシ樹脂組成物、ビニルエステル樹脂組成物が特に好ましい。これらの熱硬化性樹脂には、硬化剤、硬化促進剤等が含まれていても良い。繊維強化材（繊維基材）とマトリックス樹脂の割合は、繊維強化材が全体の３０〜７０重量％であるものが好ましい。 As the matrix resin for prepreg or the matrix resin for RTM molding, a thermosetting resin and a thermoplastic resin can be used. Preferred are thermosetting resins, examples of which include epoxy resins, unsaturated polyester resins, phenol resins, melamine resins, polyurethane resins, silicone resins, maleimide resins, vinyl ester resins, cyanate ester resins, maleimide resins. And a resin obtained by prepolymerizing cyanate ester resin. These thermosetting resins may be appropriately mixed and blended. Of these resins, epoxy resin compositions and vinyl ester resin compositions excellent in heat resistance, elastic modulus, and chemical resistance are particularly preferable. These thermosetting resins may contain a curing agent, a curing accelerator and the like. The ratio of the fiber reinforcement (fiber substrate) and the matrix resin is preferably 30 to 70% by weight of the fiber reinforcement.
本発明においては、前記発泡体コアを、成形型の内部（中心部）に配置し、前記プリプレグとチタン紙、あるいは繊維基材とチタン紙で包み込んだ形にし、その後、成形型を型締めし、通常のプレス成形法又はＲＴＭ成形法で成形する。成形型としては、アルミニウムやステンレス製のいわゆる金型、あるいはＦＲＰ製の成形型等を用いることができる。 In the present invention, the foam core is disposed inside (center part) of the mold, and is encased in the prepreg and titanium paper or fiber substrate and titanium paper, and then the mold is clamped. The molding is performed by a normal press molding method or RTM molding method. As the mold, a so-called mold made of aluminum or stainless steel, a mold made of FRP, or the like can be used.
プレス成形の場合には、具体的には、例えば、型締めした成形型を、硬化炉やオートクレーブ中で加熱する。あるいは直接、金型プレス成形する。加熱は、１００〜１３０℃で１〜２時間行うのが適当である。かかる加熱によって、マトリックス樹脂は硬化し、チタン紙と発泡体コアも一体化して所望のＦＲＰ成形品に成形される。そして、成形型を冷却することによって、所望のＦＲＰ成形品が得られる。 In the case of press molding, specifically, for example, the clamped mold is heated in a curing furnace or an autoclave. Alternatively, direct mold pressing is performed. Heating is suitably performed at 100 to 130 ° C. for 1 to 2 hours. By such heating, the matrix resin is cured, and the titanium paper and the foam core are integrated into a desired FRP molded product. And a desired FRP molded product is obtained by cooling a shaping | molding die.
ＲＴＭ成形の場合には、成形型のキャビティ内にマトリックス樹脂を注入するに際して、成形型の一端側に形成された樹脂注入口から樹脂を注入すると共に、成形型の他端側に形成された樹脂排出口からキャビティ内を排気するのが好ましい。その際、樹脂注入時のキャビティ内の真空度が−０．１０〜−０．０８ＭＰａであり、樹脂を硬化させる時の真空度が−０．０８〜−０．０２ＭＰａであるのが好ましい。また、樹脂注入時の樹脂の粘度が０．０１〜１Ｐａ・ｓであるのが好ましい。以下、実施例により本発明を詳述する。 In the case of RTM molding, when the matrix resin is injected into the cavity of the mold, the resin is injected from the resin injection port formed at one end of the mold and the resin formed at the other end of the mold It is preferable to exhaust the inside of the cavity from the discharge port. At that time, the degree of vacuum in the cavity at the time of resin injection is preferably −0.10 to −0.08 MPa, and the degree of vacuum when the resin is cured is preferably −0.08 to −0.02 MPa. Moreover, it is preferable that the viscosity of the resin at the time of resin injection is 0.01 to 1 Pa · s. Hereinafter, the present invention will be described in detail by way of examples.
発泡体としては、ポリウレタン硬質発泡体（サンコーウレタン社製）を用いた。分割型の成形型のキャビティ内面に、先ずチタン紙を１枚敷設した。チタン紙としては着色タイプのチタン紙（日本デコール社の品番：ＢＫ−５０８）を用いた。次いで、チタン紙の上にガラス基材を重ねて敷設した。ガラス基材（日東紡社製、汎用グレードのガラス基材）は、積層パターンを（±４５）又は（０／９０）のように角度をつけて、２枚重ねて敷設・積層した。 A polyurethane rigid foam (manufactured by Sanko Urethane Co., Ltd.) was used as the foam. First, one sheet of titanium paper was laid on the inner surface of the cavity of the split mold. As the titanium paper, colored type titanium paper (Nippon Decor's product number: BK-508) was used. Next, a glass substrate was laid on the titanium paper. A glass substrate (manufactured by Nittobo Co., Ltd., a general-purpose grade glass substrate) was laid and laminated with two laminated layers with an angle such as (± 45) or (0/90).
次いで、成形型のキャビティ内部に、前記発泡体コアを、前記ガラス基材及びチタン紙を介して配置した。そして、成形型を型締めし、キャビティ内を真空にした。そして樹脂を加圧下に注入し、金型ヒーターにより８０〜１３０℃で１時間加熱して樹脂を硬化させた。そして、金型を冷却して成形品を取り出した。得られたＦＲＰ成形品は、表面状態が非常に滑らかな高品質のものであった。 Subsequently, the said foam core was arrange | positioned through the said glass base material and titanium paper inside the cavity of a shaping | molding die. Then, the mold was clamped and the cavity was evacuated. And resin was inject | poured under pressure, and it heated at 80-130 degreeC with the die heater for 1 hour, and hardened resin. Then, the mold was cooled and the molded product was taken out. The obtained FRP molded product was of high quality with a very smooth surface state.
ガラス繊維プリプレグを使用した場合は、分割型の成形型のキャビティ内面に、先ずガラス繊維プリプレグ（東邦テナックス社製、汎用グレードのガラス繊維プリプレグ）を１枚敷設した。次いで、チタン紙を重ねて敷設した。チタン紙としては、実施例１のものと同じものを用いた。次いで成形型のキャビティ内部に、実施例１と同じ発泡体コアを、前記ガラス繊維プリプレグ及びチタン紙を介して配置した。そして、分割型を型締めし加圧下に金型ヒーターにより８０〜１３０℃で２時間加熱して樹脂を硬化させた（プレス成形）。そして、成形型を冷却して成形品を取り出した。このものも表面状態が非常に滑らかな高品質のものであった。
When a glass fiber prepreg was used, a glass fiber prepreg (manufactured by Toho Tenax Co., Ltd., general-purpose grade glass fiber prepreg) was first laid on the cavity inner surface of the split mold. Next, titanium paper was laid on top of each other. The same titanium paper as in Example 1 was used. Next, the same foam core as in Example 1 was placed inside the cavity of the mold through the glass fiber prepreg and titanium paper. The split mold was clamped, and the resin was cured by heating at 80 to 130 ° C. for 2 hours under pressure with a mold heater (press molding). Then, the mold was cooled and the molded product was taken out. This was also high quality with a very smooth surface.
Claims (8)
The method for molding an FRP molded article having a foam core according to any one of claims 5 to 7, wherein the titanium paper is a colored titanium paper.
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