JP2015009396A - Method for manufacturing frp molded product, and frp molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an FRP molded product which can reduce cost by increasing productivity.SOLUTION: In a method for manufacturing an FRP molded product 1, sheet-shaped FRP material 3 containing a thermoplastic resin and reinforced fibers 4 is put on a surface mat 2 so as to be superposed on it, and the surface mat 2 and the FRP material 3 are heated using a heater. Subsequently, the FRP material 3 is carried in a state of being put on the surface mat 2 and set into a mold of a press machine. The FRP material 3 and the surface mat 2 superposed on each other are pressurized using the press machine to produce an FRP molded product 1 formed by integrating the reinforced fibers 4 and the surface mat 2 by the thermoplastic resin.

Description

  The present invention relates to a method for manufacturing an FRP molded product and an FRP molded product that can reduce costs.

  Conventionally, FRP molded products are generally those in which the matrix resin is a thermosetting resin, and glass cloth, glass mat, glass surface mat, carbon surface mat, etc. have been used as reinforcing materials ( For example, see Patent Document 1).

Japanese Patent Publication No. 5-54422

  However, since the conventional FRP molded product uses a thermosetting resin as the matrix resin, it takes time and labor to manufacture the matrix resin, and the cost is high.

  The present invention has been made in order to solve the above-described conventional drawbacks, and an object of the present invention is to provide an FRP molded product manufacturing method and an FRP molded product that can increase productivity and reduce costs. It is to provide.

In order to achieve the above object, a method for manufacturing an FRP molded product and an FRP molded product according to the present invention have the following configurations. That is,
A method for manufacturing an FRP molded product according to the invention of claim 1 is a method for manufacturing an FRP molded product using a matrix resin as a thermoplastic resin, and includes the thermoplastic resin and reinforcing fibers on a surface mat. The sheet-like FRP material is placed so as to overlap, and the surface mat and the FRP material are heated using a heating device. Thereafter, the FRP material is transported and set on a die of a press machine while being placed on the surface mat. Then, by using the press machine, the FRP material and the surface mat that are overlapped are pressed to produce an FRP molded product in which the reinforcing fibers and the surface mat are integrated with the thermoplastic resin.

  According to this FRP molded product manufacturing method, prior to pressurizing a sheet-like FRP material containing a thermoplastic resin and reinforcing fibers with a press machine, the FRP material is preheated with a heating device. The cycle time for manufacturing the FRP molded product can be reduced by reducing or eliminating the heating time. In the heating device, the FRP material is placed and heated so as to overlap the surface mat, and conveyed to the press machine in a state of being placed, and the FRP material is set on the mold together with the surface mat. Thereby, the FRP material in which the thermoplastic resin is melted by heating is easily set in the mold. Moreover, by pressing the overlapped FRP material and the surface mat with a press machine and making the surface mat a part of the FRP molded product, the FRP material can be placed on a heat-resistant film, for example, and set in a mold. Unlike the case where it is adopted, it is not necessary to remove the surface-side surface mat used for conveyance after press molding, and the labor can be saved.

  Further, the FRP molded product according to the invention of claim 2 is an FRP molded product using a matrix resin as a thermoplastic resin, having a surface mat on the surface side, and having reinforcing fibers on the inside thereof, These reinforcing fibers and the surface mat are integrated with a thermoplastic resin.

  According to this FRP molded product, since the matrix resin is a thermoplastic resin and has a surface mat on the surface side, the thermoplastic resin and the reinforcing fiber are placed on the surface mat so as to overlap with each other and heated by a heating device. In this state, it can be conveyed to a press machine, set in a mold and pressurized. Thus, the heating time in the press machine can be reduced or eliminated, and the cycle time for manufacturing the FRP molded product can be reduced, and the thermoplastic resin and the reinforcing fiber melted by heating can be easily set in the mold. Furthermore, it is different from the case where the surface mat is made a part of the FRP molded product, and the thermoplastic resin and the reinforcing fiber are placed on a heat-resistant film, for example, and set in a mold. Therefore, it is not necessary to remove the surface mat used for the conveyance after the press molding, and the labor can be saved.

  According to the method for manufacturing an FRP molded product and the FRP molded product according to the present invention, in the FRP molded product using a matrix resin as a thermoplastic resin, the surface mat is disposed on the surface side, whereby the productivity of the FRP molded product is achieved. The cost can be reduced.

It is a schematic diagram which shows the order of superimposition of the FRP raw material and surface mat of one embodiment of this invention. Similarly, it is a schematic exploded perspective view of a blade. Similarly, it is an enlarged end view in a plane crossing the blade.

  Hereinafter, the manufacturing method of the FRP molded product and the form for implementing the FRP molded product which concern on this invention are demonstrated based on drawing.

  1 to 3 show an embodiment of the present invention. Reference numeral 1 in the figure indicates an FRP molded product using a matrix resin as a thermoplastic resin.

  As shown in FIG. 1, first, the FRP molded product 1 is manufactured by placing a sheet-like FRP material 3 containing a thermoplastic resin and a reinforcing fiber 4 on a surface mat 2 so as to overlap with each other. The surface mat 2 and the FRP material 3 are heated using a heating device. Thereafter, the FRP material 3 is transported while being placed on the surface mat 2 and set in a die of a press machine. Then, using the press machine, the FRP material 3 and the surface mat 2 that are overlapped are pressed to have the surface mat 2 on the surface side, the reinforcing fibers 4 on the inner side, and the reinforcing fibers 4 FRP molded product 1 in which the surface mat 2 and the surface mat 2 are integrated with a thermoplastic resin is manufactured.

  Specifically, in the illustrated embodiment, the FRP molded product 1 is divided bodies 5a and 5a ′ constituting the blade 5 in the wind turbine for wind power generation (see FIGS. 2 and 3). That is, the two divided bodies 5a and 5a ′ are overlapped in the thickness direction so that the surface mat 2 is on the outer surface side and joined together to form the blade 5. In addition, each of the divided bodies 5a and 5a ′ has ribs 5b and 5b ′ on the inner surface of the blade 5. And when both division body 5a, 5a 'is combined, each rib 5b, 5b' is faced | matched. Also, engaging portions 5c and 5c ′ for positioning (specifically, convex portions and concave portions) are provided at appropriate positions at the ends of the ribs 5b and 5b ′ of both the divided bodies 5a and 5a ′. When combining 5a and 5a ', the engaging portions 5c and 5c' are engaged with each other.

  In the illustrated embodiment, the FRP material 3 includes first to third FRP materials 301, 302, and 303, which are sequentially stacked on the surface mat 2 (see FIG. 1). The first FRP material 301 and the third FRP material 303 are made of discontinuous fiber reinforced sheet bodies in which discontinuous reinforcing fibers 4a (reinforcing fibers 4) made of short fibers are randomly dispersed in a thermoplastic resin. The second FRP material 302 is made of a continuous fiber reinforced sheet body in which continuous reinforcing fibers 4b (reinforcing fibers 4) made of long fibers are arranged in one direction or crossed and impregnated with a thermoplastic resin. In particular, in the illustrated embodiment, the second FRP material 302 is made of a UD sheet body in which continuous reinforcing fibers 4b (reinforcing fibers 4) made of long fibers are arranged in one direction and impregnated with a thermoplastic resin. . And the 2nd FRP raw material 302 which consists of this UD sheet | seat body is arrange | positioned so that the continuous reinforcement fiber 4b may face the longitudinal direction of the division bodies 5a and 5a '(blade 5) which are the FRP molded products 1. FIG. Further, the ribs 5 b and 5 b ′ in the divided bodies 5 a and 5 a ′ are mainly formed by the third FRP material 303.

  Here, the reinforcing fibers 4 in the FRP material 3 are made of, for example, carbon fiber, glass fiber, aramid fiber, and the like. The first to third FRP materials 301, 302, and 303 are the same or different. May be. Further, as the thermoplastic resin, for example, engineering plastic such as polyamide such as nylon 6 or polyethylene terephthalate, polyethylene, ABS, or the like is used.

  The surface mat 2 is a thin sheet-like mat formed by disposing short fibers (including those cut into short fibers) or fiber materials 2a made of long fibers in a non-directional direction. As this surface mat 2, for example, there is a filament mat, MF30P104, manufactured by Nitto Boseki Co., Ltd. Glass fiber is used as the fiber material 2a of this surface mat 2.

  In the heating device, the FRP material 3 is placed on the surface mat 2 and further placed on a receiving tool (not shown) made of an iron plate or the like, and is transported to the press machine together with the receiving tool. Then, the FRP material 3 is transferred together with the surface mat 2 from the receptacle to the die of the press machine.

  Next, the manufacturing method of the FRP molded product 1 having the above configuration and the operational effects of the FRP molded product 1 will be described. First, according to the manufacturing method of the FRP molded product 1, the sheet-like FRP material 3 including the thermoplastic resin and the reinforcing fibers 4 (in the illustrated embodiment, the first to third FRP materials 301, 302, and 303 are used. ) Prior to pressurization with a press, the FRP material 3 is preheated with a heating device, thereby reducing or eliminating the heating time in the press and reducing the cycle time of manufacturing the FRP molded product 1. can do.

  In the heating device, the FRP material 3 is placed on the surface mat 2 so as to be overlaid and heated. The FRP material 3 is transported to the press machine in the state of being placed, and the FRP material 3 is put together with the surface mat 2 in a mold. set. Thereby, it becomes easy to set the FRP material 3 in which the thermoplastic resin is melted by heating to the mold. In addition, the FRP material 3 and the surface mat 2 that are overlapped are pressed by a press machine, and the surface mat 2 is made a part of the FRP molded product 1 so that the FRP material 3 is placed on a heat-resistant film such as a polyimide film. Unlike the case of adopting conveyance and setting in a mold, it is not necessary to remove the surface-side surface mat 2 used for conveyance after press molding, and the labor can be saved.

  Further, according to the FRP molded product 1, since the matrix resin is a thermoplastic resin and has the surface mat 2 on the surface side, as described above, the FRP material 3, that is, the thermoplastic resin and the reinforcing fiber 4, It is placed on the surface mat 2 so as to be overlaid, heated by a heating device, and in the state of being placed, it can be conveyed to a press machine, set in a mold and pressurized. In this way, the heating time in the press machine can be reduced or eliminated, and the cycle time for manufacturing the FRP molded product 1 can be reduced. Also, the thermoplastic resin and the reinforcing fiber 4 (FRP material 3) melted by heating. Can be easily set in the mold. Furthermore, by making the surface mat 2 a part of the FRP molded product 1, the thermoplastic resin and the reinforcing fiber 4 (FRP material 3) can be made of, for example, a polyimide film or the like. Unlike the case where it is carried on a heat-resistant film and set on a conveyance and mold, it is not necessary to remove the surface mat 2 used for conveyance after press molding, and the labor can be saved.

  That is, according to the manufacturing method of the FRP molded product 1 and the FRP molded product 1, in the FRP molded product 1 in which the matrix resin is a thermoplastic resin, the surface mat 2 is disposed on the surface side thereof, thereby the FRP molded product. The productivity of 1 can be increased and the cost can be reduced.

  The FRP material 3 is composed of first to third FRP materials 301, 302, and 303. Here, the first FRP material 301 stacked on the surface mat 2 is a discontinuous reinforcing fiber 4a made of short fibers randomly dispersed in a thermoplastic resin, and in particular, the thermoplastic resin is applied to the surface mat 2. The FRP material 301 and the surface mat 2 are integrated. Since the third FRP material 303 located on the inner surface side is similar to the first FRP material 301, the discontinuous reinforcing fibers 4a made of short fibers are randomly dispersed in the thermoplastic resin. Complex shapes such as the ribs 5b and 5b 'can be easily formed from the discontinuous reinforcing fibers 4a constituting the FRP material 303 and the thermoplastic resin. The second FRP material 302 sandwiched between the first and third FRP materials 301 and 303 is arranged so that the continuous reinforcing fibers 4b are unidirectionally or crossed (in the illustrated embodiment, unidirectionally). Since it consists of the made continuous fiber reinforced sheet body, the intensity | strength of the FRP molded product 1 can fully be ensured.

  In addition, this invention is not necessarily limited to embodiment mentioned above, A various other change is possible. For example, glass fibers are used as the fiber material 2a of the surface mat 2, but fiber materials other than glass fibers such as carbon fibers or aramid fibers may be used.

  The second FRP material 302 is made of a UD sheet, but the reinforcing fibers 4 made of continuous reinforcing fibers 4b are arranged so as to cross and are made of a cloth sheet impregnated with a thermoplastic resin. Good.

  Further, the FRP material 3 may be provided with a plurality of any one of the first to third FRP materials 301, 302, and 303, or on the contrary, any of them may be removed, and the combination thereof is arbitrary. is there. Further, the FRP material 3 may be combined with a fiber mat that does not include a thermoplastic resin and includes only a reinforcing fiber, or a sheet material that includes only a thermoplastic resin but does not include a reinforcing fiber.

  Further, the FRP molded product 1 is not a divided body 5a, 5a 'constituting the blade 5, but a covering material such as a cover, a member constituting a body or interior of a vehicle, an aircraft or a ship, a structural member, or the like. There may be.

DESCRIPTION OF SYMBOLS 1 FRP molded product 2 Surface mat 3 FRP material 301 1st FRP material 302 2nd FRP material 303 3rd FRP material 4 Reinforcing fiber

Claims (2)

A method for producing an FRP molded product using a matrix resin as a thermoplastic resin,
On the surface mat, the sheet-like FRP material containing the thermoplastic resin and the reinforcing fiber is placed so as to overlap, and the surface mat and the FRP material are heated using a heating device,
While the FRP material is placed on the surface mat, it is transported and set in a die of a press machine,
By pressing the FRP material and the surface mat that overlap each other using the press machine,
A method for producing an FRP molded product, comprising producing an FRP molded product in which the reinforcing fibers and the surface mat are integrated with the thermoplastic resin. An FRP molded product using a matrix resin as a thermoplastic resin,
An FRP molded article having a surface mat on the surface side, reinforcing fibers on the inside thereof, and these reinforcing fibers and the surface mat are integrated by a thermoplastic resin.

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