JPH1095064A - Composite substrate for resin reinforcement and fiber reinforced resin using the composite substrate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve the disadvantages of the prior art, and to be a resin-reinforced composite base suitable for molding a fiber-reinforced resin which is lightweight, has excellent rigidity, and has heat insulating performance. Materials, and
A fiber reinforced resin using the composite substrate is provided. SOLUTION: The composite substrate for resin reinforcement of the present invention is characterized in that a fiber mat and a closed-cell foam sheet are integrated by needling. Further, the fiber-reinforced resin of the present invention is a resin-reinforced composite base material obtained by integrating a fiber mat and a closed-cell foam sheet by needling,
It is made of a resin applied to the composite substrate for resin reinforcement and cured, and the cured resin permeates to the opposite side via a needling portion and is cured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin-reinforced composite substrate and a fiber-reinforced resin using the composite substrate.

[0002]

2. Description of the Related Art In order to reduce the weight of a fiber reinforced resin (hereinafter abbreviated as FRP) product, to improve rigidity, and to add heat insulation performance to the product, a resin reinforced resin is used as a core material of the fiber reinforced resin. It is common to use foam.

[0003] As a method of molding such an FRP product, a fiber mat and a resin foam having solvent resistance and being familiar with an FRP molding resin are alternately formed by a hand lay-up method (HLU method). Conventionally, a resin transfer molding method (RTM method) or the like, which uses lamination or a foam wrapped or sandwiched by a mat, has been used.

[0004]

However, the above-mentioned conventional method of molding FRP products has the following disadvantages. That is, (1) the fiber mat and the resin foam are alternately laminated,
The work of wrapping and sandwiching the foam with a mat took time. (2) Since the adhesion between the FRP layer and the resin foam depends only on the chemical adhesive force of the resin, if this adhesive force is weak, peeling will occur due to a long-term difference in expansion and contraction of each material and external force, and the performance will deteriorate. Therefore, not only was there a constraint that it was necessary to use a resin foam having good compatibility with the molding resin, and the shear strength of the FRP product was also low.

(3) As one of the measures against the disadvantage of the above (2), by using a resin open-cell foam sheet, a resin for FRP molding is caused to enter the resin open-cell foam sheet. It has also been proposed to improve the adhesive strength with the FRP layer, but this has the disadvantage that the heat insulating property decreases as the density increases.

The present invention solves the above-mentioned disadvantages of the prior art, and is a resin-reinforced composite substrate suitable for use in molding a fiber-reinforced resin that is lightweight, has excellent rigidity, and has heat insulating performance. It has been made to provide a fiber reinforced resin using the composite base material.

[0007]

Means for Solving the Problems In order to achieve the above object, the structure of the composite substrate for resin reinforcement adopted by the present invention is that a fiber mat and a closed cell foam sheet are integrated by needling. It is characterized by the following.

In order to achieve the above object, the construction of the fiber reinforced resin employed in the present invention comprises a composite substrate for resin reinforcement obtained by integrating a fiber mat and a closed cell foam sheet by needling; It is made of a resin applied to the resin-reinforced composite base material and cured, and the cured resin permeates to the opposite side via the needling portion and is cured.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the present invention will be described in detail.

[0010] The resin-reinforced composite substrate of the present invention comprises a fiber mat and a closed-cell foam sheet as described above. The fiber mat includes a surfacing mat, a chopped strand mat, and a continuous mat. Single fibers and bundled fibers, such as nuanced strand mats and papers, are chemically bonded to form a sheet using resin powder or resin emulsion, or wrapped by mechanical methods such as needling or sewing. Can be used.

The fiber mat as described above has a basis weight of 2
Preferably in the range of 0~1200g / m ^2, further examples of the scope of the preferred according to the type of fiber mats used basis weight, corresponding to a range of that obtained in a following (general market from an economic point of view Do). Surface mat, paper: 20-100g /
m ² chopped strand mat, continuous strand mat: 200~1200g / m ²

Examples of the fibers constituting the above fiber mat include inorganic fibers such as glass fibers, ceramic fibers and carbon fibers, and organic fibers such as polyester fibers.

As described above, the fiber mat used in the present invention may be formed into a sheet by chemically bonding a single fiber or a bundled fiber using a resin powder or a resin emulsion or the like, needling or sewing. In addition to those formed into sheets by mechanical methods such as mechanical bonding, single fibers and bunched fibers constituting the mat are sprayed on the closed cell foam sheet in advance on the production line of the composite substrate for resin reinforcement of the present invention. A mat formed by needling can also be used.

In particular, the fiber mat formed on the production line as described above is preferably used when a large number of fibers are to be contained in the closed-cell foam sheet or when the thickened closed-cell foam sheet is used to enhance ripening. When needling is performed, use of a sheet formed by bonding or the like is effective when fibers do not sufficiently follow only the needle of the needling and do not enter the closed cell foam sheet.

On the other hand, the closed cell foam sheet used with the above fiber mat in the present invention has a thickness of 1 to 5
The closed cell foam sheet may have a color of 0 m / m, preferably 3 to 10 m / m. The color of the closed cell foam sheet is not limited. This is preferable because the state of the foam is easily visible.

Examples of the material of the closed cell foam sheet include acrylic resin, vinyl chloride resin, polyethylene, polypropylene, polyurethane, polyethylene / polystyrene copolymer, acrylonitrile / butadiene / styrene copolymer (ABS), rubber and the like. That is, any resin that can provide a closed-cell foam can be used. However, since a resin is used at the time of FRP molding, the resin for this foam has solvent resistance ( The type of solvent resistance differs depending on the molding resin used).

The expansion ratio of the closed-cell foam sheet may be in the range of 5 to 50 times, preferably 10 to 30 times. If the expansion ratio is low, the weight reduction and the heat insulating effect are reduced. Conversely, if the magnification is too high, the foam acts as a cushion material during FRP molding, and the workability is reduced.

The composite substrate for resin reinforcement of the present invention is prepared by, for example, needling a fiber mat 1 and a closed-cell foam sheet 2 using a needling machine 3 as shown in FIG. As shown in FIG. 2, by causing at least a part of the fibers 4 of the fiber mat 1 to penetrate the needling portion 5 in the closed-cell foam sheet 2,
It is one that is integrated.

For example, as shown in FIG. 3, the fiber mat 1 may be disposed on the upper and lower surfaces of the closed-cell foam sheet 2 and integrated by needling. One or more of the fiber mat 1 and the closed-cell foam sheet 2 may be used. When a plurality of different types of fiber mats are used in combination, the surface is smooth like a facing mat. By needling the material as an outer layer, the FRP surface after molding can be finished smoothly.

In the above needling, the number of needlings to be implanted is 1 to 100 per cm ^2.
The range is preferably 3 to 50 per book, preferably 3 to 50 per 1 cm ^2. However, when it is necessary to consider the heat insulating performance, it is desirable to keep it to a minimum.

In order to increase the bonding property, an adhesive is provided between the fiber mat 1 and the closed-cell foam sheet 2, or the fiber mat 1 and the closed-cell foam sheet 2 are sewn with an appropriate thread. In the latter case, the sewing thread does not necessarily have to be the same fiber as the fiber sheet.

The composite substrate for resin reinforcement of the present invention thus constructed can be manufactured even if it is manufactured by needling the fiber mat 1 and the closed-cell foam sheet 2 in advance on a production line using a needling machine. At the site, an appropriate roller may be provided with a needle capable of needling, and the needle may be manufactured by needling.The diameter of the needling portion in the obtained resin-reinforced composite base material of the present invention may be determined by the needle. It can be changed appropriately by adjusting the diameter of the object.

As described above, the resin-reinforced composite substrate of the present invention is obtained by integrating a fiber mat and a closed-cell foam sheet by needling. Alternatively, when an FRP product is manufactured, the following effects are exhibited.

That is, by simply applying a resin for FRP molding to the composite substrate for resin reinforcement of the present invention, the FR
Since it becomes possible to manufacture P-molded or FRP products, the setting time of the closed cell foam and the fiber mat is not required,
In addition, since the resin spreads through the needling portion during FRP molding, the FRP molding time is shortened, and therefore,
The work can be faster than using the fiber mat and the closed-cell foam sheet alone.

The resin used in the FRP molding or the production of the FRP product is a generally known liquid thermosetting resin, and is preferably an unsaturated polyester resin, a vinyl ester resin, a phenol resin, a methyl methacrylate. Resins, epoxy resins, dicyclopentadiene resins, and furan resins can be mentioned, and among them, unsaturated polyester resins are most preferable in terms of impregnation, moldability and the like.

The fiber-reinforced resin of the present invention obtained as described above comprises a resin-reinforced composite base material obtained by integrating a fiber mat and a closed-cell foam sheet by needling;
It is made of a resin applied to the resin-reinforced composite base material and cured, and the cured resin penetrates to the opposite side via a needling portion and is cured, and is between the closed-cell foam sheet and the FRP layer. The adhesion does not depend only on the chemical adhesive force, but the resin for FRP molding penetrates and hardens into the needling portion, and the anchor effect is brought about by a part of the resin entering the cells in the closed-cell foam sheet. Since mechanical bonding has been provided, only the solvent resistance performance needs to be considered as the material of the closed-cell foam sheet, and in particular, the chemical bonding performance with the FRP molding resin need not be selected.

Further, since the resin-reinforced composite substrate in the fiber-reinforced resin of the present invention is obtained by integrating a fiber mat and a closed-cell foam sheet by needling, if the resin is supplied to the upper fiber mat, Since the resin is impregnated to the bottom through the needling portion (holes of the closed-cell foam sheet formed by needling) and hardened, the molding cycle can be increased.

In addition, since the resin-reinforced composite substrate uses a closed-cell foam sheet, a rigid FRP product can be obtained as before, and the number of needlings to be driven can be changed. Thus, a part of the closed-cell foam sheet can be freely replaced with resin, and as a result, the density of the closed-cell foam sheet portion can be adjusted, so that an FRP product having an arbitrary rigidity can be obtained.

In the needling portion of the closed cell foam sheet of the fiber reinforced resin of the present invention, a part of the fiber of the fiber sheet penetrates, and the resin is supplied to the fiber sheet and the FR is fed.
Since P is formed into a columnar shape, the compressive strength is improved, and peeling is less likely to occur at the interface between the FRP layer and the closed-cell foam sheet even when subjected to an impact. In addition, in order to improve rigidity and heat insulating performance, a plurality of resin-reinforced composite substrates of the present invention may be used.

[0030]

The present invention will be described in more detail with reference to the following examples.

Example 1 Production of a composite base material for resin reinforcement A 3 m / m thick closed cell foam made of polyethylene was used.
Glass chopped strand mat with a basis weight of 450 g / m ² (made by Asahi Fiber Glass) on the upper and lower surfaces of a 0-fold foam sheet (trade name: Softlon [manufactured by Sekisui Chemical Co., Ltd.])
And these were integrated by needling to produce a resin-reinforced composite substrate of the present invention. The number of needlings was 22 / cm ² .

FRP molding A resin having the following composition was applied to the composite substrate for resin reinforcement, and FRP molding was performed. Ortho polyester resin (Cobalt naphthenate added) 100 parts Methyl ethyl ketone peroxide 1 part

Example 2 A composite substrate for resin reinforcement was prepared in the same manner as in Example 1 except that the 30-fold foam sheet of the closed-cell foam was made 5 m / m in thickness, and FRP molding was performed in the same manner. went.

Example 3 A composite substrate for resin reinforcement was prepared in the same manner as in Example 1 except that the glass chopped strand mat was disposed only on the upper surface of the 30-fold foam sheet of the closed-cell foam.
P molding was performed.

Example 4 A glass chopped strand mat was placed only on the upper surface of a 30-fold foam sheet of closed-cell foam, and the 30-fold foam sheet of closed-cell foam was 5 m / m thick. A composite substrate for resin reinforcement was prepared in the same manner as in Example 1, and FRP molding was performed in the same manner.

Example 5 A composite substrate for resin reinforcement was prepared in the same manner as in Example 1 except that the number of needlings was set to 6.5 / cm ^2, and FRP molding was performed in the same manner.

Example 6 A monofilament having a thickness of about 11 μm was formed on a 30-fold foam sheet (trade name: SOFTRON, manufactured by Sekisui Chemical Co., Ltd.) of 3 m / m thick closed cell foam made of polyethylene.
The raw yarn that has been collected and wound into a cake is dried after being cut to about 50 m / m by a cutter, and a uniform weight of 450 g / m ² is uniformly dispersed, and then foamed by needling. It was integrated with the body sheet to produce the composite substrate for resin reinforcement of the present invention. The number of needlings was 22 / cm ² .

Using the above composite substrate for resin reinforcement, FRP molding was performed in the same manner as in Example 1.

Comparative Example 1 A composite substrate for resin reinforcement was prepared in the same manner as in Example 1 except that needling was not performed, and FRP molding was performed in the same manner.

Comparative Example 2 A composite substrate for resin reinforcement was prepared in the same manner as in Example 3 except that needling was not performed, and FRP molding was performed in the same manner.

Comparative Example 3 The procedure of Example 3 was repeated, except that needling was not performed, and a 30-fold foam sheet of an open-cell foam was used instead of the 30-fold foam sheet of a closed-cell foam. A composite substrate for resin reinforcement was prepared, and FRP molding was performed in the same manner.

COMPARATIVE EXAMPLE 4 ^Two glass chopped strand mats (made by Asahi fiberglass) with a basis weight of 450 g / m ² were stacked without using a 30-fold foam sheet of a closed-cell foam, and used in the same manner as in Example 1. FRP molding was performed.

Comparative Examples 5 and 6 Comparative Examples 1 (this is referred to as Comparative Example 5) and Comparative Example 2 (this is referred to as Comparative Example 5) except that the 30-fold foamed sheet of the closed-cell foam was made to have a thickness of 5 m / m. 6), a composite substrate for resin reinforcement was prepared, and FRP molding was performed in the same manner.

Comparative Example 7 A composite substrate for resin reinforcement was prepared in the same manner as in Comparative Example 3 except that the 30-fold expanded sheet of the open-cell foam was changed to a sheet having a thickness of 5 m / m. went.

Comparative Tests Various comparative tests were performed on the FRP products manufactured as described above. The results are shown in Tables 1 and 2. Table 1
And blanks in Table 2 indicate that no measurement was performed.

[Table 1]

[Table 2]

As is clear from Tables 1 and 2, the FRP products of Examples 1 to 6 are the same as those of Comparative Examples 1 to 7.
It turns out that it is excellent in rigidity and has high heat insulation performance as compared with the product.

The test method is as follows. Shear strength A test piece having a width of 25 m / m and a length of 200 m / m was prepared from the FRP product, and a cut was made in the width direction in the FRP layer on the upper surface at the center, and 25 m from the cut on the upper surface with the FRP layer on the lower surface. An incision in the width direction was also made at a position apart from the FRP layer by 50 m / m from both ends and pulled in the length direction to measure the strength until the FRP layer peeled off from the foam sheet.

Compressive strength According to 5.19 of JIS K 6911, diameter 25 m /
The plate was compressed as it was with the m compression terminal. Thermal resistivity It was determined from the thermal conductivity measured according to JIS A 1412 and the actually measured thickness. Flexural rigidity test According to JIS K 7055, the amount of deflection under a load of 10 kg was measured using a test piece having a width of 25 m / m.

[0049]

As described above, the composite substrate for resin reinforcement of the present invention in which the fiber mat and the closed-cell foam sheet are integrated by needling eliminates the disadvantages of the prior art, and is lightweight and rigid. Further, it is excellent in adhesiveness between the molded FRP layer and the closed-cell foam sheet, and is preferably used when molding a fiber-reinforced resin having heat insulating performance.

In the composite substrate for resin reinforcement of the present invention, a part of the closed-cell foam sheet can be freely replaced by a resin by changing the number of needlings to be driven. Since the density of the FRP can be adjusted, an FRP product having an arbitrary rigidity can be obtained.

[Brief description of the drawings]

FIG. 1 is a conceptual view showing an example of a method for producing a resin-reinforced composite base material of the present invention.

FIG. 2 is a side view showing a state in which fibers of a fiber mat penetrate a needling portion of a closed-cell foam sheet in the composite substrate for resin reinforcement of the present invention.

FIG. 3 is a conceptual diagram showing another example of the method for producing a resin-reinforced composite base material of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiber mat 2 Closed-cell foam sheet 3 Needling machine 4 Fiber mat fiber 5 Needling part

 ──────────────────────────────────────────────────の Continuation of the front page (72) Inventor Yoshinobu Yasuda 2-52-9, Seiwadai, Kita-ku, Kobe-shi, Hyogo (72) Inventor Shuya Tsuji 1-19-10, Koyodai, Hannan-shi, Osaka

Claims (14)

[Claims] 1. A composite substrate for resin reinforcement, wherein a fiber mat and a closed-cell foam sheet are integrated by needling. 2. The resin-reinforced composite substrate according to claim 1, wherein the fiber mat is disposed on the upper surface and the lower surface of the closed-cell foam sheet, and they are integrated by needling. 3. The composite substrate for resin reinforcement according to claim 1, wherein the fiber mat is any one of a surface mat, a chopped strand mat, a continuous strand mat, and a paper. 4. The fiber mat has a basis weight of 20 to 120.
Resin reinforced composite substrate according to any one of claims 1 to 3 is of the 0 g / m ^2. 5. The composite substrate for resin reinforcement according to claim 1, wherein the fibers of the fiber mat are inorganic fibers such as glass fibers, ceramic fibers or carbon fibers, or organic fibers such as polyester fibers. Wood. 6. The fiber mat according to claim 1, wherein the constituent fibers are formed into a mat on a closed-cell foam sheet.
6. The resin-reinforced composite substrate according to any one of items 1 to 5. 7. The closed cell foam sheet is made of acrylic resin, vinyl chloride resin, polyethylene, polypropylene,
Polyurethane, polyethylene / polystyrene copolymer,
The resin-reinforced composite substrate according to claim 1, wherein the composite substrate is made of an acrylonitrile / butadiene / styrene copolymer or rubber. 8. At least a part of the fibers of the fiber mat,
The resin-reinforced composite substrate according to claim 1, wherein the composite substrate penetrates a needling portion of the closed-cell foam sheet. 9. The needling driving number is 1 cm.
^{2. The} composite substrate for resin reinforcement according to claim 1, wherein the number is 1 to 100 per ² . 10. The resin-reinforced composite substrate according to claim 1, wherein an adhesive is provided between the fiber mat and the closed-cell foam sheet. 11. The resin-reinforced composite substrate according to claim 1, wherein the fiber mat and the closed-cell foam sheet are sewn with an appropriate thread. 12. A resin-reinforced composite substrate obtained by integrating a fiber mat and a closed-cell foam sheet by needling, and a resin applied and cured to the resin-reinforced composite substrate. A fiber reinforced resin characterized in that the resin penetrates to the opposite side through the needling portion and is cured. 13. The resin-reinforced composite base material is obtained by disposing fiber mats on the upper and lower surfaces of a closed-cell foam sheet and integrating them by needling.
3. The fiber-reinforced resin according to 2. 14. The cured resin permeates to the opposite side via the fiber mat fiber penetrating the needling portion,
The fiber-reinforced resin according to claim 12, which is cured.