JP2005305673A - Fiber-reinforced laminated material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fiber-reinforced laminated material capable of also certainly performing the display of a symbol mark or the like on its surface, and its manufacturing method. <P>SOLUTION: As shown by Fig. (a), the symbol mark 21a is formed on the surface of the fiber-reinforced laminated material 21 and satin-like unevenness 21b is further formed on the whole surface threreof. The fiber-reinforced laminated material 21 is a cabon fiber-reinforced plastic (CFRP) having a thickness of about 2 mm as a whole. As shown by Fig (b), the fiber-reinforced laminated material 21 is produced by thermally curing a prepreg laminated material 22. The prepreg laminated material 22 is held between release films 22 and 23 being perforated release films and both sides of the release films are further held between bleeder cloths 26 and 27 through a symbol-shaped transfer molds 25 with a thickness of about 1 mm to be further held between press plates 28 and 29. The whole held between the press plates 28 and 29 is housed in a vacuum bag to be heated and pressed in an autoclave. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a fiber-reinforced laminated material such as FRP and a method for producing the same.

  Conventionally, a synthetic resin reinforced with a fiber material is called a fiber reinforced plastic (FRP) and is widely used. Fiber reinforced plastics are often used as laminates. The laminated material is manufactured by stacking a plurality of prepreg sheets formed by impregnating a fiber base material with a thermosetting resin and heating and pressing. Heating and pressing methods are roughly classified into a press working method and an autoclave working method.

  FIG. 5 shows an outline of the press working method. In the press working method, the prepreg laminate 1 is pressed while being sandwiched between the hot plates 2 and 3 of the press from both sides in the laminating direction. By heating, the resin component in the prepreg laminate 1 once becomes a low-viscosity liquid and exudes to the outside. Both front and back surfaces of the prepreg laminate 1 are covered with a peel fly which is a porous sheet, and further covered with release films 6 and 7. Both sides of the release films 6 and 7 are sandwiched between molding jigs 8 and 9, and pressurization from the hot plates 2 and 3 of the press is performed via the buffer materials 10 and 11.

  FIG. 6 shows an outline of an example of the autoclave processing method. In the autoclave processing method shown in FIG. 6, the upper surface of the prepreg laminate 1 is covered with a porous release film 12, further covered with a bleeder cloth 13 that absorbs resin, and further covered with a release film 14 as a whole. Wrap with 15 The prepreg laminate 1 is placed on the release film 16 and wrapped with the release film 16 and the release film 14. The lower release film 16 is covered with a vacuum bag 17 and the periphery is hermetically sealed with a vacuum sealing material 18. The inside of the vacuum bag 17 is kept at a low pressure by vacuum suction from the vacuum suction port 17a, and the prepreg laminate 1 is pressurized with an external pressure. The assembly including the prepreg laminate 1 covered with the vacuum bag 17 is placed on the forming jig 19, charged in an autoclave, and heated. The heating temperature is measured with a thermocouple 20.

  FIG. 7 shows an outline of another example of the autoclave processing method. The prepreg laminate 1 is placed on a release film 16 placed on a forming jig 19. The upper surface of the prepreg laminate 1 is sequentially covered with a release film 14 bleeder cloth 15 and a vacuum bag 17. The periphery of the vacuum bag 17 is hermetically sealed with a vacuum sealing material 18.

  A technique for transferring fine irregularities onto the surface of a laminated material by sandwiching a film having fine irregularities and releasability during heating by a pressurizing method is disclosed (for example, see Patent Document 1). . A technique is also disclosed in which irregularities are formed on the surface of a mold for heating and pressurizing a prepreg and the irregularities are transferred to the surface of a molded product (see, for example, Patent Documents 2, 3, and 4). There is also disclosed a technique for manufacturing a fiber-reinforced plastic molded article by integrally molding a prepreg sheet having a pattern or a pattern with a sheet molding compound (SMC) (see, for example, Patent Documents 5 and 6). .)

  Each layer of the prepreg is also disclosed a technique in which carbon fibers are aligned in one direction, a plurality of layers are laminated so that the directions of the fibers are orthogonal, and a mesh pattern is formed on the surface by sandwiching a mesh during heating and pressurization. (For example, see Patent Document 7).

JP-A-7-214713 JP-A-7-314474 JP 2001-269956 A JP 2001-269957 A JP-A-9-109167 JP-A-9-109167 JP-A-9-254265

  Since the fiber reinforced laminated material is lightweight and has high strength, it is suitably used as an interior material for moving bodies such as automobiles, trains, and airplanes. However, in these interior materials, it is often necessary to display symbols such as guidance for passengers and logo marks such as operation service providers. In each of the aforementioned patent documents, it is possible to form irregularities on the surface, but it is not possible to effectively display various marks and symbols. For this reason, if it is necessary to display a symbol or the like, a label or the like for displaying the symbol or the like is separately prepared and pasted. It takes time and effort to apply labels. In addition, once affixed labels or the like may fall off.

  An object of the present invention is to provide a fiber-reinforced laminated material capable of reliably displaying symbols and the like on the surface and a method for producing the same.

The present invention is a fiber-reinforced laminated material obtained by reinforcing a base material of a synthetic resin with a plurality of fiber layers,
The fiber-reinforced laminate material is characterized in that the surface is a concavo-convex pattern surface and a predetermined symbol shape is formed with concavo-convex larger than the concavo-convex pattern.

  According to the present invention, since the fiber-reinforced laminated material is reinforced with a synthetic resin base material by a plurality of fiber layers, high strength can be easily obtained even with a light weight. Since the surface of the fiber reinforced laminated material is a concavo-convex pattern surface and the predetermined symbol shape is formed with a concavo-convex pattern larger than the concavo-convex pattern, the symbol shape is made more conspicuous than the concavo-convex pattern, and the symbol Display can be made.

  In the present invention, the fiber layer may occupy 20 to 70% of the total volume.

  According to the present invention, the fiber layer occupies 20 to 70% of the total volume, and the remaining synthetic resin can be molded corresponding to the formation of surface irregularities and the display of symbol shapes.

  In the present invention, the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle.

  According to the present invention, the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle, so that even if the thickness is thin, the fiber layer can be reinforced to have sufficient strength, The moldability can be improved by increasing the proportion of the synthetic resin.

Furthermore, the present invention sandwiches both sides of a plate-shaped synthetic resin material including a plurality of fiber layers with a porous release film,
Place a symbol shape transfer mold on a part of at least one of the release films,
Hold both sides of the release film including the symbol shape transfer mold with the resin absorption layer,
It is a manufacturing method of the fiber reinforced laminated material characterized by shape | molding by pinching with a hard board from the both sides of a resin absorption layer.

  According to the present invention, since both sides of a plate-shaped synthetic resin material including a plurality of fiber layers are sandwiched between porous release films, the resin component is allowed to permeate even if the resin component protrudes from the synthetic resin material during molding. After the synthetic resin material is cured, the release film can be easily peeled off to obtain a fiber-reinforced laminated material. A symbol shape transfer mold is arranged on at least one part of the release film, and both sides of the release film including the symbol shape transfer mold are sandwiched between resin absorption layers and molded between both sides of the resin absorption layer with a hard plate. To do. Since the molded fiber reinforced laminate material has the surface irregularities of the resin absorption layer transferred to the surface, and the symbol shape is transferred from the symbol shape transfer mold, the symbol shape can be displayed on the surface of the fiber reinforced laminate material. it can. Since the symbol shape or the like is directly formed on the surface of the fiber reinforced laminate, it is possible to eliminate the possibility of peeling off like a label.

  In the present invention, the synthetic resin material is a prepreg of a thermosetting resin.

  According to the present invention, when the thermosetting resin prepreg is heated and cured, surface unevenness formation and symbol shape formation can be easily performed.

  According to the present invention, the surface of the fiber reinforced laminate is an uneven pattern surface, and the predetermined symbol shape is formed with an unevenness larger than the uneven pattern, so that the symbol shape stands out from the uneven pattern. , A reliable display of symbols can be performed.

  Moreover, according to this invention, a fiber layer occupies 20 to 70% by the volume with respect to the whole, and shaping | molding corresponding to surface unevenness formation, a symbol shape display, etc. can be performed with the remaining synthetic resin.

  Further, according to the present invention, the fiber layer is formed of a woven fabric using a spread yarn, so that the fiber layer can be reinforced to have sufficient strength even if the thickness is thin.

  Furthermore, according to the present invention, the molded fiber reinforced laminate material has the surface irregularities of the resin absorbent layer transferred to the surface, and the symbol shape is transferred from the symbol shape transfer mold. The symbol shape can be displayed. Since the symbol shape or the like is directly formed on the surface of the fiber reinforced laminate, it is possible to eliminate the possibility of peeling off like a label.

  Further, according to the present invention, when the thermosetting resin prepreg is heated and cured, surface unevenness and symbol shape can be easily formed.

  FIG. 1 shows a fiber-reinforced laminated material 21 and a method for manufacturing the same according to an embodiment of the present invention. FIG. 1A shows a state manufactured as a fiber reinforced laminate 21, and FIG. 1B shows a heating and pressurizing state in a step of molding by an autoclave processing method.

  As shown in FIG. 1A, the fiber reinforced laminated material 21 has, for example, a symbol mark 21a such as “A” formed as a recess on the surface, and further a satin-like unevenness 21b formed on the entire surface. . The fiber reinforced laminated material 21 is a carbon fiber reinforced plastic (CFRP) having a thickness of about 2 mm as a whole. That is, the fiber reinforced laminated material 21 is a fiber reinforced laminated material obtained by reinforcing a base material of a synthetic resin with a plurality of fiber layers, and is a concavo-convex pattern surface on which a satin-like concavo-convex 21b is formed, and a predetermined symbol. The symbol shape by the mark 21a is formed with a larger unevenness than the uneven pattern.

  Since the fiber-reinforced laminated material 21 is made of a synthetic resin base material reinforced with a plurality of fiber layers, high strength can be easily obtained even if it is lightweight. Since the surface of the fiber reinforced laminated material 21 is a concavo-convex pattern surface, and the predetermined symbol shape is formed with a concavo-convex pattern larger than the concavo-convex pattern, the symbol shape is more conspicuous than the concavo-convex pattern, so Display can be made. Since the symbol mark 21a is not formed by mechanical cutting or the like, the reinforcing fiber is not cut and the strength can be maintained.

  As shown in FIG.1 (b), the fiber reinforced laminated material 21 is manufactured by thermosetting the prepreg laminated material 22. As shown in FIG. The prepreg laminate 22 is sandwiched between release films 23 and 24, which are porous release films, further sandwiched between symbol shape transfer molds 25 having a thickness of about 1 mm, both sides are sandwiched between bleeder cloths 26 and 27, and a press plate 28, 29. A non-porous release film 40 is interposed between the bleeder cloth 26 and the presser plate 28 in order to prevent the resin from adhering to the presser plate 28. The holding plates 28 and 29 are aluminum plates having a thickness of about several mm to several tens mm. The surfaces of the symbol shape transfer mold 25 and the pressing plates 28 and 29 are covered with a thin film made of polytetrafluoroethylene (trade name Teflon) in order to prevent adhesion of resin.

  Similar to the autoclave processing method as shown in FIGS. 6 and 7, the whole sandwiched between the presser plates 28 and 29 is housed in a vacuum bag and is pressurized to, for example, about 0.4 MPa, for example, 120 ° C. Heat for 2 hours.

  The prepreg laminated material 22 is formed by, for example, laminating eight base materials obtained by weaving open fibers obtained by opening a bundle of carbon fibers into a plain weave shape, impregnating with an epoxy resin, and proceeding the curing reaction halfway. The volume ratio of the fiber material to the resin is set to 40%. In a general fiber reinforced composite material, the proportion of resin can be increased by laminating thin substrates using spread yarns, although the proportion of resin is relatively small.

  The bleeder cloths 26 and 27 are used to absorb liquid resin that oozes out from holes provided in the release films 23 and 24. As the bleeder cloths 26 and 27, a nonwoven fabric can be suitably used. Although the surface of the nonwoven fabric is not smooth, the unevenness is transferred to the surface of the fiber-reinforced laminated material 21 via the release films 23 and 24 to form a textured unevenness 21b. Further, the shape of the symbol shape transfer mold 25 is transferred to the surface of the fiber reinforced laminated material 21 to form a symbol mark 21a.

  As described above, the fiber layer in the prepreg laminated material 22 is about 40% in terms of the volume ratio with respect to the whole, but if it is in the range of 20 to 70%, a good symbol mark 21a can be transferred. When the ratio of the fiber layer is increased, the ratio of the resin is decreased, and molding with unevenness becomes difficult. Further, when the ratio of the fiber layer is reduced, the symbol shape transfer mold 25 sinks into the prepreg laminated material 22 during the heating and pressurizing process in the autoclave, and a good symbol mark 21a cannot be left on the surface. In particular, if the proportion of the resin is large at 30 to 50%, the symbol marks 21a and 31a can be formed with sufficient unevenness.

  As the thermosetting resin material as the prepreg, not only the epoxy resin but also polyester, phenol, and the like can be used. Moreover, a filler etc. can also be mixed in resin. When an epoxy resin or the like is used as a base material in a nearly transparent state, the design of the fiber layer can be seen from the surface. When the carbon fiber spread yarn is used, a texture such as a plain weave is formed in a state where the black and thin fibers are in a band shape in the same direction, so that a unique texture can be obtained. Moreover, as a fiber, a glass fiber, an aramid fiber, etc. can also be used, and the fiber reinforced laminated material 21 can be formed by coloring peculiar to the fiber, such as white in a glass fiber and yellow in an aramid fiber. If different types of fibers are mixed, color patterns can be combined.

  Note that not only carbon fibers but also glass fibers and aramid fibers can be used as reinforcing fibers in fabrics that use single yarns bundled to open fiber bundles that have been subjected to fiber opening treatment. Since the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle, the fiber layer can be reinforced to have sufficient strength even if the thickness is thin. The moldability can be increased by increasing the size.

  FIG. 2 shows a fiber reinforced laminate 31 and a symbol shape transfer mold 35 for manufacturing the same, which are another embodiment of the present invention. As shown in FIG. 2A, on the surface of the fiber reinforced laminated material 31, a floating symbol mark 31 a and a satin-like unevenness 31 b are formed. Such a floating symbol mark 31a can be formed by using a symbol shape transfer mold 35 as shown in FIG. 2B instead of the symbol shape transfer mold 25 of FIG. 1B. That is, in the symbol shape transfer mold 35, a shape corresponding to the symbol mark 31a is formed as a recess, and the periphery is substantially flat. If irregularities such as a satin finish are formed, the irregularities are also transferred. The symbol shape transfer mold 35 is also covered with polytetrafluoroethylene (trade name Teflon) in order to prevent adhesion of the resin, similarly to the symbol shape transfer mold 25 of the above-described embodiment.

  FIG. 3 shows the shape of a presser plate 38 for manufacturing a fiber-reinforced laminate material according to still another embodiment of the present invention. If unevenness corresponding to the symbol shape is formed on the surface of the presser plate 38 and the presser plate 38 is used instead of the presser plate 28 without using the symbol shape transfer mold 25 of FIG. The same fiber-reinforced laminated material 21 can be formed.

  FIG. 4 shows a schematic manufacturing process for manufacturing the fiber-reinforced laminated materials 21 and 31 in the embodiment shown in FIGS. In step s0, preparations necessary for molding are performed, including preparation of a symbol mark transfer mold 25, 35 or a pressing plate 38, which can transfer a symbol mark. In step s1, a step of laminating a prepreg is performed. In step s2, as shown in FIG. 1B, a step of sandwiching the prepreg laminated material 22 between the pressing plates 28 and 29 is performed. In this step, the symbol shape transfer mold 25 and the bleeder cloths 26 and 27 are sandwiched between the prepreg laminated material 22 and the pressing plates 28 and 29. In step s3, the process of enclosing in a vacuum bag is performed like FIG. In step s4, a process of heating and pressing in an autoclave is performed. In step s5, a process of taking out the fiber reinforced laminated material 21 and the like from the vacuum bag is performed, and the manufacturing process is ended in step s6.

  In the step of sandwiching with the holding plate in step s2, both sides of the prepreg laminated material 22 which is a plate-like synthetic resin material including a plurality of fiber layers are released with the release films 23 and 24 which are porous release films as described above. Pinch. Further, the symbol shape transfer molds 25 and 35 are arranged on at least one part of the release film, and both sides of the release film including the symbol shape transfer molds 25 and 35 are placed on the bleeder cloths 26 and 27 which are resin absorption layers. Put it in. Further, the resin absorbing layer is sandwiched between the pressing plates 28 and 29 which are hard plates from both sides. First, since both sides of the prepreg laminate 22 are sandwiched between release films 23 and 24 that are porous release films, even if the resin component protrudes from the prepreg laminate 22 during molding, the resin component is permeated and the synthetic resin material After curing, the release films 23 and 24 can be easily peeled off to obtain the fiber reinforced laminate 21. Symbol shape transfer molds 25 and 35 are arranged on at least one part of the release films 23 and 24, and both sides of the release films 23 and 25 including the symbol shape transfer molds 25 and 35 are sandwiched between freeder cloths 26 and 27. The bleeder cloths 26 and 27 are formed by being sandwiched by pressing plates 28 and 29 from both sides. The molded fiber reinforced laminated material 21 has the surface irregularities of the bleeder cloths 26 and 27 transferred to the surface, and the symbol shape is transferred from the symbol shape transfer molds 25 and 35. The symbol marks 21a and 31a can be displayed on the surface. Since the symbol shape or the like is directly formed on the surface of the fiber reinforced laminated material 21, 31, it is possible to eliminate the possibility of peeling off like a label.

  Note that the symbol shape can be transferred by the presser plate 38 instead of the symbol shape transfer molds 25 and 35. The heating and pressurization can be performed not only using an autoclave but also using a press.

  Further, since the synthetic resin material uses a prepreg of a thermosetting resin, it is possible to easily perform surface irregularity formation and symbol shape formation when heated and cured. However, even if a laminated material reinforced with fibers of a thermoplastic resin such as nylon, olefin, or ester is used, it is at least softened when heated, and the shape can be transferred by pressurization. can do.

It is the perspective view and decomposition | disassembly side view which show the fiber reinforced laminated material 21 which is one Embodiment of this invention, and its manufacturing method. It is a perspective view which shows the fiber shape laminated material 31 which is the other form of implementation of this invention, and the symbol shape transcription | transfer type | mold 35 for the manufacture. It is a perspective view which shows the shape of the pressing board 38 for the fiber reinforcement laminated material manufacture which is further another form of implementation of this invention. It is a rough manufacturing-process figure for manufacturing the fiber reinforced laminated material 21 and 31 by embodiment as shown in FIGS. 1-3. It is a decomposition | disassembly side view which shows the manufacturing method of the fiber reinforced laminated material by the conventional press work. It is side surface sectional drawing which shows an example of the manufacturing method of the fiber reinforced laminated material by the conventional autoclave process. It is side surface sectional drawing which shows the other example of the manufacturing method of the fiber reinforced laminated material by the conventional autoclave process.

Explanation of symbols

21, 31 Fiber reinforced laminated material 22 Prepreg laminated material 25, 35 Symbol shape transfer mold 26, 27 Bleeder cloth 28, 29, 38 Presser plate

Claims (5)

A fiber reinforced laminate in which a synthetic resin matrix is reinforced with a plurality of fiber layers,
A fiber-reinforced laminated material, wherein the surface is a concavo-convex pattern surface, and a predetermined symbol shape is formed with concavo-convex larger than the concavo-convex pattern.   The fiber-reinforced laminated material according to claim 1, wherein the fiber layer occupies 20 to 70% by volume with respect to the whole.   The fiber-reinforced laminated material according to claim 1 or 2, wherein the fiber layer is formed of a woven fabric using a spread yarn obtained by opening a fiber bundle. Sandwiching both sides of a plate-shaped synthetic resin material containing a plurality of fiber layers with a porous release film,
Place a symbol shape transfer mold on a part of at least one of the release films,
Hold both sides of the release film including the symbol shape transfer mold with the resin absorption layer,
A method for producing a fiber-reinforced laminated material, comprising molding between both sides of a resin absorption layer with a hard plate.   The said synthetic resin material is a prepreg of a thermosetting resin, The manufacturing method of the fiber reinforced laminated material of Claim 4 characterized by the above-mentioned.

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