JP2009241559A - Laminated panel and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a laminated panel by which the laminated panel obtained by laminating a core material with a curved face and reinforcing fibers is easily manufactured in a short period of time, namely, by one-time molding, while preventing an operator from inhaling VOC (Volatile Organic Compounds) gas or coming in contact with resin, and without requiring the operator to manually apply putty to slits of a core material or to deform the core material beforehand in conformity with the curved face. <P>SOLUTION: In the core material, a plurality of bulging parts are formed with small spaces apart integrally on one side of a flat plate made of synthetic resin. When the laminated body is bent along the curved face formed on the mold material surface, the small spaces do not disturb the bending of the laminated body. The small spaces also form a small flow passage for resin, allowing a liquid resin to be wholly supplied. Further, the small spaces are arranged in such a way that the resin is hardened to integrate the bulging parts into one unit. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a laminated panel in which both sides of a plate-like core material are sandwiched with reinforcing fiber sheets and a method for producing the same, and more specifically, an uneven shape is formed on a laminated body in which fiber sheets are laminated on both sides of a core material. The present invention relates to a laminated panel which is impregnated with a matrix resin in a vacuum state while being pressed against a mold material, and is formed into the uneven shape and a manufacturing method thereof.

(FRP board)
Recently, a fiber reinforced resin (hereinafter referred to as FRP) in which fibers such as carbon and glass fiber are included in a synthetic resin as a structural material that is excellent in weather resistance, heat resistance, chemical resistance, electrical insulation and light weight. Various structures such as building materials (lighting roofs, greenhouses, etc.), housing equipment (tubs, septic tanks), boats / boats, marine research boats and lighthouse towers, CNG tanks, aircraft, radar domes, etc. Has been used.

  As a method for molding FRP, for example, a vacuum impregnation method (generally called VaRTM method: Vacuum assisted Resin Transfer Molding) is known. Specifically, a molding apparatus as shown in FIG. 11 is used. (For example, Patent Document 1).

  In this molding apparatus, fibers 101, 102, 103 such as glass cloth are stacked on a mold 111, a bag 108 is covered with the fibers 101, 102, 103, and the periphery of the bag 108 is sealed by an airtight seal 109. Furthermore, a synthetic resin R introducing tube 113 communicating with the molding surface of the mold 111 is provided, and the bag 108 is provided with a suction tube 114 having a vacuum pump 116 for sucking the gas in the bag 108. It has been.

  In the molding method of the FRP plate in such a molding apparatus, the fiber materials 101, 102, 103 are laminated on the molding surface of the molding die 111, and these are covered with the bag 108. Next, the gas in the bag 108 is exhausted from the suction pipe 114 to be in a reduced pressure state, and a synthetic resin R such as unsaturated polyester or epoxy resin is introduced into the bag 108 from the introduction pipe 113. The bag 108 strongly presses the fiber materials 101, 102, 103 toward the mold 111 due to the difference between the atmospheric pressure and the pressure in the reduced pressure state, and the injected synthetic resin R is compressed as the fiber material is compressed into the fiber material. Impregnate into. The bag 108 is held in the vacuum state for a predetermined time (time until the resin is cured), and then the bag 108 is returned from the vacuum state to the atmospheric pressure state, and the compression-molded FRP plate is released from the mold. Thus, a fiber reinforced resin panel is manufactured.

  The fiber material is, for example, a fiber material such as glass fiber or carbon fiber, and a nonwoven fabric or a plain weave sheet is used. As the resin (matrix resin) to be impregnated into the fiber material, a thermosetting resin or a thermoplastic resin is used, and in particular, a resin having impact resistance and high bending strength such as polyester or polypropylene is frequently used.

Since such an FRP plate is made of a fiber material, a large amount of fiber material is laminated to form a thick FRP plate, which is laborious and costly, and increases the weight. There was a problem.
(First laminated panel)
By the way, a laminated panel in which a fiber material is laminated on both surfaces of a plate-like core material is known (for example, Patent Document 2). This laminated panel is obtained by laminating fibers 121a, core materials 122, and fibers 121b in this order as shown in FIG. 12, and impregnating the fiber material (sheet) with an epoxy resin or the like with a brush or a roller. It is manufactured by a lay-up method, a press method in which compression molding is performed in a laminated state, a heating method in which prepregs are laminated and heated in a large kiln (autoclave).

  And the manufactured laminated panel 120 can exhibit bending strength more than an FRP panel by using a high-strength core material. In addition, it is easy to obtain laminated panels with various thicknesses by simply changing the thickness of the core material, which eliminates the need for laminating a large amount of fiber sheets as in the FRP panel described above, thus reducing manufacturing time and cost. Can do.

  However, the core material used in such a laminated panel 120 has a flat plate shape, and a laminated panel having a large curvature cannot be formed. Therefore, in order to manufacture a laminated panel having a large curvature, a core material formed in advance from the manufacturing stage along a curved surface or cut by machining or the like, or a core material made of thermoplastic resin may be used. If this was heated, it had to be deformed by pressing it with a large press machine, which required labor and cost.

  In addition, if a dedicated core material is manufactured in advance for each product, there is a problem that switching to a new product takes time and the stock of core material for each product increases.

(Second laminated panel)
By the way, a method of molding a laminated panel having a curved surface with respect to the flat first laminated panel is known (Patent Document 3). An outline of the laminated panel having the curved surface is shown in FIG. As shown in this figure, a glass fiber 218, a core material (glass cloth 213, a polyvinyl chloride foam 212), a putty 216, and a glass fiber 216 are laminated in this order on a curved mold (not shown). Has been. The core material is provided with a plurality of non-through slits 214a on one surface of a foam material 212 as shown in FIG. 14 (A), and then the foam material 212 in which the slit 14 is opened as shown in FIG. (B). A porous sheet (glass cloth 213 or the like) is attached to one surface with an adhesive, and a slit 214b wider than the slit 214a is provided from the other surface of the foam material 212 as shown in FIG. Is formed.

  And this laminated panel is manufactured while applying the putty 216 manually by skilled craftsmen, and is manufactured through a plurality of processes as described above. It is not suitable for mass production. Therefore, the laminated panel becomes expensive.

  In addition, the putty is easily absorbed by the foam material, and there is a variation in the absorption. Therefore, there is a drawback that the strength of the laminated panel is likely to vary. Furthermore, when heated to promote the curing of the putty, the air in the putty expands to form voids, and the bending strength is significantly reduced.

  Further, it takes time and effort to knead the putty and the curing agent carefully and uniformly, and the curing time and the shrinkage after curing differ depending on the blending ratio, thereby causing the problem of uneven strength of the laminated panel.

  Furthermore, since the putty has to be applied in the slits by manual work, the work itself is very troublesome, and there is a problem that the intensity varies due to uneven application. In addition, since a skilled worker is required to apply the putty uniformly, there is a problem that a construction period and cost are required and mass production cannot be performed.

  Moreover, the core material which consists of a foam material connected with the thin glass cloth becomes a thing without a firmness at all. Accordingly, there is a problem that workability is not good because the core material moves due to unevenness on the mold and is not stable. Also, when manufacturing the core material, the stability is not good and must be handled with care.

  In addition, there are some foams made with a large number of cuts, and the cuts are enlarged or reduced to give the foams flexibility. However, the work of applying the putty into the cuts has the above-mentioned problems.

And since it is manufactured by hand, there is a problem that volatile organic compounds (hereinafter referred to as VOC) in putty are released into the work environment and the worker may inhale it. It was.
JP 2006-272911 A JP 2005-313613 A JP-A-5-471

  In the present invention, in view of the drawbacks of the prior art, the operator does not inhale the VOC gas, and further puts the putty on the slit of the core material manually, or deforms the core material in advance according to the curved surface. The present invention provides a method for producing a high-strength FRP sandwich panel having a curved surface easily and in a short time without causing it to occur.

The present invention was made to solve the conventional problems as described above, and the method for manufacturing a laminated panel according to the present invention includes:
1) A laminated body in which reinforcing fiber layers are disposed on both surfaces of a core material is placed on the surface of a vacuum molding mold material, and a liquid resin is supplied to the laminated body to form a laminated panel for a structure having a curved surface. In the method of molding in a pressed state, the core material is formed integrally with a plurality of bulging portions on one side or both sides of a flat plate with a small gap, and the small gap is formed from the laminate. When the resin is bent along the curved surface formed on the surface of the mold material, the resin does not prevent bending of the laminate, and the resin small flow path can supply the liquid resin as a whole. It is characterized in that the resin is cured and arranged so that the bulging portions are integrated with each other.

The laminated panel according to the present invention is
2) A laminated body in which reinforcing fiber layers are arranged on both surfaces of the core material is placed on the surface of a vacuum molding mold material, a liquid resin is supplied to the laminated body, and a curved surface molded in a pressed state on the mold material is formed. A laminate panel for a structure having the core material, wherein a plurality of bulging portions are formed integrally with a small gap on one side or both sides of a flat plate-like body, Is a resin small flow path that can prevent the bending of the laminated body and supply the entire liquid resin when bent along the curved surface formed on the mold surface. And the resin is cured and arranged so that the bulging portions are integrated with each other.

  When the matrix resin is cured, the matrix resin cured body and the bulging portion of the core material are integrated, and this is like a single plate, so that the strength of the laminated panel can be improved.

  The operation of painting putty manually is not necessary, and a laminated panel is manufactured in a short period of time. As a result, it can be provided at low cost by mass production.

  In the conventional vacuum forming, the laminated panel in which the core material and the reinforcing fiber are laminated is limited to a flat plate, but a plurality of the core materials are formed on one side of the flat body with a small gap. Thus, a laminated panel having a curved surface can be easily manufactured by vacuum forming.

  By vacuum forming, the gap between the bulging part of the core material is filled with a matrix resin, and the reinforcing fiber layer sandwiching the core material is simply impregnated with the resin to form a laminated panel having a curved surface. It is molded once. As a result, the manufacturing period can be significantly shortened.

  In addition, by forming a plurality of bulging portions with a small gap on one side of the flat plate, the small gap expands or contracts along the concave or convex surface, so that the concave and convex surfaces Can be manufactured at the same time.

  It is prevented that the putty is absorbed by the core material made of the foam material, or a gap is generated in the slit due to the non-uniformity of the work, and the variation in the panel strength is prevented.

  Compared with the application of putty, filling the liquid resin by evacuation allows the resin to spread to every corner, not only reducing the voids, but also improving the bonding strength with the core material.

  The process of attaching the glass fiber sheet to the foam material or forming the through slit is omitted, and the cost and time required for this are reduced. A polyhedron is formed by a collection of small pieces of foam material, and the resin is filled in the gap between the reinforcing fiber and the core material at the same time, so that it easily follows the mold surface and approaches the intended ideal curved surface.

  Moreover, a laminated panel having a desired thickness can be easily obtained by using a core material having a predetermined thickness without laminating a large amount of reinforcing fibers. In addition, since the core material is very inexpensive as compared with the reinforcing fiber, the produced laminated panel is also inexpensive.

  Since there is no need to assemble a laminated panel by a skilled craftsman, there is no variation in manual work, which is suitable for industrial production. Therefore, the thing of stable quality can be provided with the stable supply amount.

  Suction is stopped when the resin gels in the vacuum state, and the strength can be improved by heating in a drying furnace or autoclave. It is possible to obtain

  Furthermore, since the opportunity for the operator to directly handle putty, matrix resin, prepreg and the like by hand is greatly reduced, it is possible to prevent the health damage of the worker.

  Hereinafter, the manufacturing method of the laminated panel concerning this invention is illustrated and demonstrated.

Example 1
FIG. 1 is a schematic view of an apparatus for producing a laminated panel by the production method according to the present invention. The laminated panel vacuum forming machine A has a forming die 5 (mold material), a sheet-like bag 6 covering the forming die 5, and a packing 7 for keeping the forming die 5 and the bag 6 airtight. ing. Furthermore, a supply path L1 for the matrix resin R that communicates with the molding surface 5a of the mold 5 and an exhaust path L2 that includes a vacuum pump that communicates with the bag 6 and exhausts gas are provided. The molding surface 5a of the mold 5 is formed into a curved surface along the shape of the laminated panel to be manufactured.

  The core material 1 is made of, for example, a synthetic resin such as vinyl chloride, and is poured into a mold to be foamed. As shown in FIGS. 2 to 4, a plurality of bulged portions 1a (projections) are formed on the flat plate-like body 1f. Article) is formed. The gap between the bulging portions 1 a is a flow path 1 e of the matrix resin R, and the flow path 1 e portion is formed thinner than the thickness bulging portion 1 a of the core material 1. In addition, the thickness of the flat plate-like body 1f located in the flow path 1e is formed so as to be flexible, so that the core material 1 can be easily bent.

  A member having higher strength than the conventional putty can be obtained by kneading the reinforcing fibers cut short in advance in the matrix resin.

  Specifically, the bulging portion 1a is 10 to 100 mm, and the flow path 1e is about 50 to 95% of the thickness. As described above, the thickness can be changed within a range that allows the core material 1 to be easily deformed and provides a firmness that is easy to handle and work. Therefore, the above-mentioned thickness is appropriately adjusted depending on the synthetic resin used as the core material. Further, as shown in FIG. 5, the width of the bulging portion 1a is a gap that can secure a bending angle θ so that it can be deformed along the curved surface of the laminated panel P to be manufactured.

  As the fiber material, glass fiber, carbon fiber, polyamide fiber, polyester fiber, acrylic fiber, metal fiber, and the like are used, and a cloth having a plain weaving (roving cloth) or a cloth such as a chopped strand mat is used. in use. In view of ease of construction, the fiber material having a thickness of 0.5 mm to 10 mm is used.

  As the matrix resin, an epoxy resin, a phenol resin, an unsaturated polyester resin, an ABS resin, a polyethylene terephthalate resin, a nylon resin, a polyimide resin, or the like is used, and an optimum one is used according to the use or strength of the laminated panel. . Therefore, it is not limited to the above-mentioned resin.

  Next, an operation for manufacturing the laminated panel according to the present invention using the vacuum forming machine A will be described.

  A release sheet (not shown) is laid on the molding surface 5a of the molding die 5, a predetermined number of reinforcing fiber sheets 2b such as glass fibers are laminated thereon, the core material 1 is placed thereon, and further thereon. A laminate T is formed by laminating a predetermined number of reinforcing fiber sheets 2a. Next, the hermetic packing 7 is disposed around the laminate T placed on the molding surface 5 a, and the molding surface 5 a and the laminate are covered with the vacuum bag 6.

  The gas in the bag 6 is exhausted from the exhaust line L2, and the bag 6 is evacuated. When the valve of the supply line L1 is opened, the resin R is introduced from the tank (not shown) into the molding surface 5a via the supply line L1. The introduced resin R is supplied to the entire molding surface 5a through the gaps between the fibers of the reinforcing fiber sheet 2b and impregnated into the reinforcing fiber sheet 2b.

  Further, the resin R spreads while flowing in the flow path 1e of the core material 1 and is filled in the flow path 1e, and the resin R is impregnated into the core material 1 and the upper reinforcing fiber sheet 2a.

  The bag 6 is maintained at a pressure lower than the atmospheric pressure, and the bag 6 presses the laminate T against the molding surface 5a due to the differential pressure between the atmospheric pressure and the low pressure, and a compressive force acts on the laminate T. is doing. This low pressure state is maintained until the resin R is cured.

  The vacuum molding machine may be provided with temperature control means including an electric heater or a cooler (not shown) so as to keep the resin R at the optimum curing temperature.

  When the curing of the matrix resin R is completed, the exhaust through the exhaust line L2 is stopped, the interior of the bag 6 is returned to atmospheric pressure, and the bag 6 is removed. Next, the laminated panel P is taken out from the mold 5 to complete the laminated panel P having a curved surface (FIG. 6). The laminated panel P is manufactured by repeating the above operations.

  According to the present embodiment, a laminated panel having a curved surface and a thickness and having high strength can be easily manufactured, and further, the core material is automatically impregnated without manually putting the putty into the core material. The time and labor for manufacturing the panel can be reduced, and the manufacturing cost can be reduced.

  The resin R in the flow path 1e of the core material 1 is cured and the bulging portions 1a are connected to be integrated. Therefore, the strength of the ridge is improved as if it is a single plate.

  In addition, in the present Example, although the core material in which the bulging part was formed in one direction was demonstrated, it is not limited to this. For example, as shown in FIGS. 7 and 8, a plurality of intersecting protrusions 1a and 1d formed can be used. The core material 1 as shown in FIGS. 7 and 8 is easily deformed into a bowl shape or a dome shape, for example. In addition, a core material in which the bulging portion is formed on both surfaces of the thin plate portion, that is, the flow path of the resin R is formed on both surfaces can be used. Fills evenly and quickly.

  Since the laminated panel according to the present invention is molded by vacuum impregnation into a core material, glass cloth or the like, the position of the resin inlet or the exhaust line of the vacuum molding machine can be changed, for example, as shown in FIG. The supply port and the exhaust port can be provided above. By providing the supply port and the exhaust port upward, the opening is prevented from being blocked by the laminated body. In addition, it is possible to change the supply port / exhaust port pair according to the curing time of the resin to enable a large area operation.

(Example 2)
In this embodiment, the hull of a ship is molded, and an outline of a mold used for this is shown in FIG. The molding surface 15a of the molding die 15 is formed in a shape along the outer shape of the hull, and a supply pipe L1 to which a matrix resin such as an epoxy resin is supplied from one side of the molding die 15 is connected to the suction pump. The suction pipe L2 to which is connected is connected. Further, a bag 6 that covers the entire mold 15 and a seal (not shown) are provided for maintaining airtightness when the bag 6 is evacuated. Since the manufacturing method of the laminated panel is the same as that of the first embodiment, the description thereof is omitted.

  According to the present embodiment, the hull was conventionally formed only from the FRP without the core material. However, the hull having the core material can be formed easily and accurately, and its strength is remarkably improved. Furthermore, a lighter and higher strength hull can be obtained. Large structures such as ship hulls can be integrally molded in a single resin filling process, which has a great effect on cost reduction. In addition, even if a crack occurs in the outer FRP, the structural material in which the core material and the resin are integrated maintains watertightness, so there is no water leakage, and the hull is firmly supported by the structural material. , Improve safety. Therefore, even if an accident such as contact between ships or contact with the quay of the ship occurs, damage to the hull is smaller than that of the FRP ship.

(Example 3)
In this embodiment, the core material having transparency is made thick enough to transmit sunlight, and a roof such as a dome shape is formed by the manufacturing method of the present invention described above.

  According to this embodiment, a glass fiber is used as the reinforcing fiber, and a light-transmitting roof having high light transmittance is obtained by using a synthetic resin (for example, vinyl chloride resin) having translucency for the core material. be able to. Moreover, the roof which can take in sunlight can be formed, without using a glass plate conventionally. In addition, it does not break like glass and shards do not scatter or become heavy.

  In Examples 1 to 3, a foam material is used as the core material, but balsa or honeycomb can be used. Further, the core materials themselves can be laminated, or core materials having different heights can be used according to the application.

  In addition, although the flow path is formed on one surface of the core material, the flow path is formed on both surfaces so as to face each other, and the thin plate-like connection body is formed at the substantially central portion of the core material. You can also Since the flow paths are formed on both sides, it becomes more suitable for diffusion of the matrix resin.

  Further, the production method of the present invention is not limited to the above-described embodiment, and it is also preferably used for a structure having a curved surface (for example, an automobile body / bonnet, a frontal head of a high-speed railway vehicle, etc.). Can do.

  Furthermore, the fiber layer and matrix resin suitable for UV resistance, weather resistance, impact resistance, etc. can be used for the reinforcing fiber layers provided on both sides of the core material according to the panel application, and the core material can be changed. By simply doing so, it is possible to produce a laminate panel with modified characteristics according to various applications.

  Furthermore, since the core material is sufficiently impregnated with the matrix resin, when the resin is solidified, the core material exhibits high strength like a single plate, and the strength of the manufactured FRP laminated panel is also improved. .

  In addition, it can be made to connect by the connection part formed in the intermediate part of these core materials by making a core material into a substantially block shape. That is,

It is the schematic of the apparatus which manufactures a sandwich panel with the manufacturing method which concerns on this invention. It is a perspective view which shows embodiment of the core material used in the manufacturing method which concerns on this invention. It is a perspective view which shows the back surface of the core material of FIG. It is a front view of the state which deform | transformed the core material of FIG. It is a principal part enlarged view of the core material used in the manufacturing method which concerns on this invention. It is a principal part cross-sectional enlarged view of the sandwich panel shape | molded by the manufacturing method which concerns on this invention. It is a perspective view which shows embodiment of the other core material used in the manufacturing method which concerns on this invention. It is a perspective view which shows the back surface of the core material of FIG. It is the schematic which shows the apparatus which shape | molds a hull with the manufacturing method which concerns on this invention. It is the schematic of the other apparatus which manufactures a laminated panel with the manufacturing method which concerns on this invention. It is the schematic of the apparatus which shape | molds FRP by a vacuum bag shaping | molding method. It is a figure which shows the conventional sandwich panel. It is the schematic of the laminated panel which has the conventional curved surface. It is a figure which shows the manufacturing method of the conventional core material.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Core material 1a Expanding part 1d, 1e Flow path 1f Flat body 2, 2a, 2b Reinforcing fiber sheet 5 Mold (mold material)
5a Molding surface 6 Bag 7 Packing L1 Supply line L2 Exhaust line G Gas R Matrix resin

Claims (2)

A laminated body in which reinforcing fiber layers are arranged on both surfaces of the core material is placed on the surface of a vacuum molding mold material, and a liquid resin is supplied to the laminated body to press a laminated panel for a structure having a curved surface against the mold material. In the method of molding in the state,
The core material is formed integrally with a plurality of bulging portions on one side or both sides of a flat plate with a small gap, and the small gap has a curved surface formed on the surface of the mold material. When it is bent along, it is formed in a small resin flow path that does not prevent bending of this laminate and can supply liquid resin as a whole. A method for producing a laminated panel, wherein the bulging portions are arranged so as to be integrated with each other. A structure having a curved surface formed by placing a laminated body in which reinforcing fiber layers are disposed on both surfaces of a core material on the surface of a vacuum molding mold material, supplying a liquid resin to the laminated body and pressing the mold material in a pressed state A laminated panel for objects,
The core material is integrally formed with a plurality of bulging portions on one side or both sides of a flat plate with a small gap, and the small gap is formed on a curved surface formed on the surface of the mold material. When it is bent along, it is formed in a small resin flow path that does not prevent bending of this laminate and can supply liquid resin as a whole. A laminated panel characterized by being arranged so that the bulging portions are integrated.

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