JP2015104895A - Method for manufacturing fiber-reinforced plastic molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber-reinforced plastic molding (FRP molding) that can mold an FRP molding having no defect, such as a wrinkle, and having high dimensional accuracy following the shape of a male mold even if the male mold has a complicated shape.SOLUTION: A method for manufacturing a fiber-reinforced plastic molding includes at least: a laminate arrangement step of arranging a reinforced fiber laminate 1 on a male mold 5; a molding rubber arrangement step of arranging a molding rubber 3 from above the reinforced fiber laminate 1; and a molding step of bringing the reinforced fiber laminate 1 into close contact with the male mold 5 by reducing the pressure of a closed space between the molding rubber 3 and the male mold 5. The method for manufacturing a fiber-reinforced plastic molding further includes a step of arranging a rigid sheet 2 on at least a part of the surface of the reinforced fiber laminate 1.

Description

  The present invention relates to a method for producing a fiber-reinforced plastic molded article that is suitably used to obtain a girder having a complicated shape, such as a structural member such as transportation equipment made of fiber-reinforced plastic.

  In recent years, the transportation equipment industry has been demanded to improve fuel efficiency in response to soaring crude oil fuel. In the aircraft industry in particular, there is a strong demand from airlines because fuel efficiency is directly linked to running costs. In order to reduce the weight of aircraft in each aircraft manufacturer, fiber reinforced plastics (hereinafter referred to as excellent specific rigidity and specific strength) (FRP) may be abbreviated).

  The molded body made of FRP is mainly composed of a fiber fabric made of reinforcing fibers such as glass fiber, carbon fiber and polyamide fiber and a resin material. The fiber fabric is made of a prepreg or a matrix resin previously impregnated with a matrix resin. There are dry substrates and the like to be injected later, and each is heated in an autoclave, an oven or the like, and degassed or impregnated with resin while being pressurized, and the matrix resin is cured and integrated.

  In the case of a structural member used for transportation equipment or the like, the FRP molded body obtained by the molding method as described above often has a complicated shape as typified by an aircraft C-shaped cross-section beam. Dispensing (hereinafter sometimes referred to as shaping) technology is important. When shaping a metal material, it can be machined, but FRP can be easily applied to machining because fiber cutting is directly linked to reduced rigidity and strength, and it is strengthened to a complicated mold. It is necessary to form along the fiber substrate.

  There are various problems in shaping reinforcing fibers along a complicated mold. For example, the fibers do not follow the shape of the valley of the mold, and a gap may be formed between the valley shape portion of the mold and the reinforcing fiber, and a desired shape may not be obtained. Further, when the reinforcing fiber is placed along the mold, an excessive force is applied to cause bending of the fiber or displacement of the orientation angle, and desired physical properties may not be obtained.

  In addition, in the recent aircraft industry, the demand for small and medium-sized passenger planes has increased rapidly due to an increase in regional routes that connect directly without changing between relatively short cities.

  Compared to large machines that have conventionally used composite materials, the shape of the structural members that make up small and medium machines is relatively complicated. In addition to the challenges, the technical difficulty becomes higher.

  In order to solve the problems described above, among the rubber covering the object to be shaped, the rubber at the specific position is made thicker by increasing the thickness of the rubber at a specific position, etc. Has been proposed (see Patent Document 1). However, in such a method, there is a problem that a space is easily formed between the mold and the bottom surface at a portion where the rubber tension is high in the final shaping step, and defects such as wrinkles are likely to occur on the surface of the shaping object in the space portion. Arise. In addition, for rubber with different thicknesses, it is necessary to prepare a dedicated rubber for one mold. When producing various types of rubber, a dedicated rubber is required for each, and the necessary rubber material costs, processing costs, and storage are required. It is disadvantageous in terms of location and operability.

  Separately, a method has been proposed in which a sheet material is bonded to the innermost layer of the prepreg laminate and shaped (see Patent Document 2). The purpose of this proposal was to suppress wrinkles due to the lifting of reinforcing fibers generated at the corners of the mold during shaping, and could not sufficiently follow the complex shape having a valley shape on the side of the mold.

US Patent No. 2011/0127698 Japanese Patent Application Laid-Open No. 6-071763

  However, in the above-described conventional shaping technique, the reinforcing fiber laminate cannot be sufficiently aligned with the male mold having a complicated shape, and the preform after shaping lacks dimensional accuracy.

  Accordingly, an object of the present invention is to solve the problems of the above-mentioned conventional shaping technology, and realizes shaping of an FRP molded body having good dimensional accuracy following the shape of the male mold without defects such as wrinkles. Another object of the present invention is to provide a method for producing a fiber-reinforced plastic molded body.

  The method for producing a fiber-reinforced plastic molded body of the present invention includes a laminate arranging step of arranging a reinforcing fiber laminate on a male mold, and a shaping rubber arranging step of arranging a shaped rubber from above the reinforcing fiber laminate. And a method for producing a fiber-reinforced plastic molded article comprising at least a shaping step of closely attaching the reinforcing fiber laminate to the male mold by depressurizing a sealed space between the shaping rubber and the male mold. A method for producing a fiber-reinforced plastic molded body including a step of arranging a rigid sheet on a part of the surface of the reinforcing fiber laminate.

  The method for producing a fiber-reinforced plastic molded body of the present invention includes a laminate arranging step of arranging a reinforcing fiber laminate on a male mold, and a shaping rubber arranging step of arranging a shaped rubber from above the reinforcing fiber laminate. And a method for producing a fiber-reinforced plastic molded article comprising at least a shaping step of closely attaching the reinforcing fiber laminate to the male mold by depressurizing a sealed space between the shaping rubber and the male mold. A method for producing a fiber-reinforced plastic molded body including a step of disposing a rigid sheet processed body whose bending rigidity changes in an in-plane direction on at least a part of the surface of the reinforcing fiber laminate.

According to a preferred aspect of the method for producing a fiber-reinforced plastic molded body of the present invention, the rigid sheet processed body in which the bending rigidity changes in the in-plane direction,
A. Increase the thickness of the rigid sheet where you want to give rigidity.
B. Stack multiple sheets of rigid sheets where you want to add rigidity.
C. Change the material of the rigid sheet where you want to give rigidity to a material with a high Young's modulus.
D. Reduce the thickness of the rigid sheet at the site where rigidity is desired to be reduced; Cut out the rigid sheet where you want to weaken the rigidity.
It is created by either method.

  According to the preferable aspect of the manufacturing method of the fiber reinforced plastic molding of this invention, a rigid sheet processed body combines another sheet material with a rigid sheet.

  According to the preferable aspect of the manufacturing method of the fiber reinforced plastic molding of this invention, the Young's modulus of a rigid sheet is 3 GPa or more, and thickness is 0.1-0.5 mm.

  According to a preferable aspect of the method for producing a fiber-reinforced plastic molded body of the present invention, the male mold includes a top surface portion and a planar side surface portion substantially perpendicular to the top surface portion, and at least one location on the side surface portion. It has a valley shape.

  According to a preferable aspect of the method for producing a fiber-reinforced plastic molded body of the present invention, the bending rigidity of the rigid sheet or the rigid sheet processed body is distributed substantially in parallel to the valley shape of the male side surface. That is.

  According to the preferable aspect of the manufacturing method of the fiber reinforced plastic molding of this invention, it is arrange | positioning so that the said rigid sheet or a rigid sheet processed body may not be hung on the trough-shaped part of the said male type | mold side surface.

  According to a preferred aspect of the method for producing a fiber-reinforced plastic molded body of the present invention, the rigid sheet or the rigid sheet processed body is disposed between the reinforcing fiber laminate and the rubber.

  According to a preferred aspect of the method for producing a fiber-reinforced plastic molded body of the present invention, the reinforcing fiber laminate is composed of a dry base material or prepreg provided with a resin material on at least one surface.

  According to the present invention, it is possible to shape a reinforced fiber laminate excellent in dimensional accuracy following the shape of the valley of the mold without causing defects such as wrinkles and bridges on the surface of the laminate. Thus, a fiber-reinforced plastic molded article having excellent surface quality and mechanical strength can be obtained with certainty.

FIG. 1 is a schematic cross-sectional view for explaining one embodiment of a method for producing a fiberized plastic molded body of the present invention. FIG. 2 is a plan view of the configuration of FIG. 1 viewed from the vertical direction. FIG. 3 is a perspective view for illustrating the male mold used in the present invention. FIG. 4 is a perspective view for illustrating the shape of the reinforcing fiber laminate in the shaping step.

  By appropriately using a rigid sheet at the time of shaping of the reinforcing fiber laminate, the present inventors can form an FRP molded body having good dimensional accuracy that follows the shape of the male mold without defects such as wrinkles. We have found that it can be realized and have reached the present invention.

  That is, in the method for producing an FRP molded body according to the present invention, by using a rigid sheet when shaping the reinforcing fiber laminate, the order in which the reinforcing fiber laminate contacts the male mold by pressure reduction is arbitrarily controlled. Thus, an FRP molded body with good dimensional accuracy can be obtained.

  The method for producing a fiber-reinforced plastic molded body of the present invention includes a laminate arranging step of arranging a reinforcing fiber laminate on a male mold, and a shaping rubber arranging step of arranging a shaped rubber from above the reinforcing fiber laminate. And a method for producing a fiber-reinforced plastic molded article comprising at least a shaping step of closely attaching the reinforcing fiber laminate to the male mold by depressurizing a sealed space between the shaping rubber and the male mold. A method for producing a fiber-reinforced plastic molded body, comprising a step of disposing a rigid sheet on at least a part of the surface of the reinforcing fiber laminate.

  The form of the rigid sheet used in the present invention can be appropriately selected from a form that covers at least one side of the reinforcing fiber laminate, or a form that partially covers only a portion where bending rigidity is desired.

When taking the form which covers all the at least one side of a reinforced fiber laminated body, in order to control a shaping order, it is preferable to use the rigid sheet | seat processed body from which bending rigidity changes to an in-plane direction. As a means for changing the bending rigidity in the in-plane direction, for example,
A. Increase the thickness of the rigid sheet where you want to give rigidity.
B. Stack multiple sheets of rigid sheets where you want to add rigidity.
C. Change the material of the rigid sheet where you want to give rigidity to a material with a high Young's modulus.
D. Reduce the thickness of the rigid sheet at the site where rigidity is desired to be reduced; Cut out the rigid sheet where you want to weaken the rigidity.
It is possible to take a method such as

  Moreover, the rigid sheet processed body can also combine other sheet materials with the rigid sheet. At this time, the other sheet material does not need to be a rigid sheet, and since the Young's modulus of at least a part of the surface of the rigid sheet processed body is 3 GPa or more, a distribution of bending rigidity can be created as will be described later. Therefore, it is possible to obtain an FRP molded body with high accuracy.

In the manufacturing method of the FRP molded object which concerns on this invention, it is preferable that the Young's modulus of said rigid sheet is 3 GPa or more and thickness is 0.1-0.5 mm. The bending rigidity of a sheet-shaped member such as a rigid sheet is represented by Young's modulus × (thickness) ^3. The Young's modulus of the rigid sheet can be measured using ASTM-D-882.

  When the Young's modulus of the rigid sheet is less than 3 GPa, the bending rigidity necessary for controlling the shaping order may be insufficient. Further, even when the rigid sheet thickness is less than 0.1 mm, the bending rigidity may be insufficient. On the other hand, if the thickness of the rigid sheet is larger than 0.5 mm, the bending rigidity becomes too high and shaping becomes difficult, or a large trace of the rigid sheet remains on the surface of the reinforcing fiber laminate after shaping, and the FRP molded product There is a risk that the surface design of the glass will be impaired. Therefore, the thickness of the rigid sheet is preferably 0.1 to 0.45 mm, more preferably 0.1 to 0.4 mm.

  The rigid sheet can be made of various materials such as a metal sheet such as a shape memory alloy and a super elastic alloy, and a rubber sheet in addition to a resin film. However, a resin film is used from the viewpoint of ease of processing. The Young's modulus is preferably in the range of 3 to 5 GPa. Examples of the rigid sheet satisfying the Young's modulus and thickness within the above range include polyester films (for example, “Lumirror” (registered trademark) manufactured by Toray Industries, Inc.) and polyphenylene sulfide films (for example, “Torelina manufactured by Toray Industries, Inc.). "(Registered trademark)), and polyimide film (for example," Kapton "(registered trademark) manufactured by Toray DuPont Co., Ltd.).

  By using these rigid sheets, it is possible to efficiently create a distribution of bending stiffness in the plane of the reinforcing fiber laminate, with a portion that contacts the male mold preferentially and a portion that contacts the male mold with a delay. It becomes possible to obtain a highly accurate FRP molded body with a difference in the time required for shaping, and more reliably without defects.

  The shaping method using the above-described rigid sheet or rigid sheet processed body (hereinafter sometimes collectively referred to as “rigid sheet group”) includes an upper surface portion and a planar side surface portion substantially perpendicular to the upper surface portion. Therefore, when performing shaping using a male mold having at least one valley shape on the side surface, a great effect is brought about. The trough shape of the male side surface in the present invention is a concave portion present at a side lower than the surroundings or at the side of the step shape when the side surface with which the reinforcing fiber laminate contacts after forming is viewed as one surface. Refers to the side bent.

  That is, when the male side surface portion has a valley shape as described above, the reinforcing fiber laminate causes stretching of reinforcing fibers called bridging between the mountain-shaped portion on both sides of the valley-shaped portion and the mountain-shaped portion. In the valley-shaped part, the reinforcing fiber laminate tends to float from the mold, and it cannot be sufficiently along the male mold, causing defects such as defective dimensions and deterioration of physical properties of the molded product. Therefore, by controlling the order in which the reinforcing fiber laminate contacts the male mold by the above method and preferentially shaping from the valley-shaped portion, bridging can be suppressed and the FRP molded body with good dimensional accuracy. Can be obtained.

  In addition, it is necessary to eliminate the rigid sheet group by appropriately cutting in places where it is predicted that overlapping or gaps of the rigid sheet group due to the shape or valley shape of the mold will occur after shaping. Can do. Moreover, when taking the form which covers only the site | part which wants to give bending rigidity, the rigidity sheet | seat with uniform bending rigidity may be sufficient as long as the rigidity of the said part can be improved, and the above-mentioned As described above, a rigid sheet processed body in which the bending rigidity is changed in the rigid sheet may be used.

  Further, it is preferable that the bending rigidity of the rigid sheet group is distributed substantially in parallel (preferably within ± 10 °, more preferably within ± 5 °) with respect to the valley shape of the male side surface. As a result, the shaping order can be controlled more accurately, the reinforcing fiber laminate is more closely attached to the male mold along the valley shape, and the FRP molded article can be shaped with higher accuracy.

  Moreover, it is preferable to arrange | position so that the part with high bending rigidity of said rigid sheet group may not be applied to the trough-shaped part of the said male side. In other words, by increasing the bending rigidity of the reinforcing fiber laminate in the portion that is in close contact with the mountain-shaped portion on the male side surface, the shaping sequence of the mountain-shaped portion can be intentionally delayed, Since it is possible to preferentially shape from the portion, bridging can be suppressed and an FRP molded body with good dimensional accuracy can be obtained.

  The rigid sheet group is preferably disposed between the reinforcing fiber laminate and the shaped rubber. That is, by arranging a rigid sheet group on the upper surface (outer surface) of the reinforcing fiber laminate, it is possible to shape the FRP molded body with high dimensional accuracy without disturbing the follow-up of the inner surface of the reinforcing fiber laminate to the male mold. it can.

  However, even when the rigid sheet group is arranged on the lower surface (inner surface) of the reinforcing fiber laminate, the effect of controlling the shaping order of the present invention can be obtained. When the rigid sheet group is arranged on the lower surface of the reinforcing fiber laminate, the shape of the rigid sheet group is transferred to the reinforcing fiber laminate after shaping, and there is a concern about the deterioration of the surface quality. It is desirable to cut the surface of the male mold where the rigid sheet group is in close contact after shaping, by the thickness of the rigid sheet group, and apply a process to eliminate the step at the end of the rigid sheet group .

  Alternatively, the reinforcing fiber laminate and the rigid sheet group may be sandwiched from above and below by two shaping rubbers and then placed on the male upper surface to be shaped. After sandwiching the reinforcing fiber laminate between the two shaped rubbers, it is possible to apply surface pressure from the out-of-plane direction of the reinforcing fiber laminated body by sucking between the two shaped rubbers. Therefore, it is possible to obtain an FRP molded body having a superior surface quality.

  In the manufacturing method of the fiber reinforced plastic molding of this invention, the process of heating the said reinforced fiber laminated body and the process of cooling the said reinforced fiber laminated body can be included before and after said shaping process. When the reinforcing fiber laminate is a dry substrate described later, the resin material applied to the surface is heated at a temperature that does not decompose, and when the reinforcing fiber laminate is a prepreg described later, the matrix resin is cured or By heating at a temperature at which decomposition does not proceed excessively, the resin material and the matrix resin can be softened, the time required for the shaping step can be shortened, and the quality of the reinforcing fiber laminate after shaping can be improved. The heating temperature is preferably 40 ° C to 120 ° C, more preferably 50 ° C to 100 ° C, and further preferably 60 to 80 ° C.

  As a heating mechanism, a means for arranging a heat medium pipe or an electric heater in a tool plate or a male mold, a means for heating the whole apparatus with a heating furnace or an IR heater, or the like can be used. At this time, it is preferable that the material of the shaping rubber is not permanently deformed by the heating. Specific examples of the material of the shaped rubber include neoprene, ethylene propylene rubber, silicon rubber and fluorine rubber, which can be shaped into a desired shape during heating or vacuum suction and can be used repeatedly. If it is, it will not be restricted to these.

  Moreover, in said shaping process, a vacuum pump can be used as a means for decompressing the sealed space between the shaping rubber and the male mold. Since this shaping process ends when the force generated by vacuum suction and the tension of the shaping rubber are balanced, the adhesion height of the side surface to be brought into close contact with the male mold and the reinforcing fiber laminate at the time of shaping is It is desirable that at least the line used as a product is formed after molding. Furthermore, considering the form stability and consistency of a molded product obtained by shaping the reinforcing fiber laminate, it is preferable that the entire surface of the reinforcing fiber laminate is in close contact with the male side surface. Therefore, it is preferable that the tension of the shaped rubber is in a range where the entire surface of the reinforcing fiber laminate can be in close contact with the male side surface as described above.

  In the method for producing a fiber-reinforced plastic molded body of the present invention, when the step of cooling the reinforcing fiber laminate is included after shaping, the reinforcing fiber laminate is once removed from the male mold in a later step and placed on another mold. Although it is possible to suppress the return (so-called spring back) of the reinforcing fiber laminate when changing, etc., if this demolding operation is not required, the subsequent heat forming step can be performed without cooling. .

  Examples of the reinforcing fiber laminate used in the present invention include a dry base material provided with a resin material on at least one surface or a prepreg. When using a dry substrate, an FRP molded body can be obtained by performing a resin injection and a heating step after the above shaping step, and when using a prepreg, by performing a heating step using an autoclave. it can.

  Examples of the reinforcing fibers constituting the reinforcing fiber laminate used in the present invention include carbon fibers, glass fibers, and aramid fibers. Among these, carbon fibers are particularly preferably used because they are excellent in specific strength and inelastic modulus and are also excellent in water absorption resistance. Examples of the form of the reinforcing fibers include woven fabrics, knitted fabrics, braided fabrics, non-woven fabrics, and reinforcing fiber sheets aligned in one direction.

  The resin material applied to the dry base material preferably contains a thermoplastic resin as a main component for the purpose of functioning as a binder between the shaped reinforcing fiber laminates. The thermoplastic resin is preferably at least one selected from, for example, polyamide resin, polysulfone resin, polyether sulfone resin, polyetherimide resin, polyphenylene ether resin, polyimide resin, polyamideimide resin, and phenoxy resin. Of these, polyamide resin, polyetherimide resin, polyphenylene ether resin, and polyether sulfone resin are particularly preferably used. In addition, examples of the form of the resin material include fibers, films, particles, and the like. Among these, particles are preferable.

  The “matrix resin” impregnated in the prepreg may be a thermosetting resin or a thermoplastic resin. In the case of a thermosetting resin, examples of the main material include an epoxy resin, an unsaturated polyester resin, a vinyl ester resin, a phenol resin, a polyurethane resin, and a silicon resin, and these may be one kind. Alternatively, two or more types can be mixed and used. When these thermosetting resins are employed as the matrix resin, it is possible to add an appropriate curing agent or reaction accelerator to the thermosetting resin.

  In the case of a thermoplastic resin, the main materials are polyethylene resin, polypropylene resin, polyvinyl chloride resin, ABS resin, polystyrene resin, AS resin, polyamide resin, polyacetal resin, polycarbonate resin, thermoplastic polyester resin, PPS resin, A fluororesin, a polyetherimide resin, a polyetherketone resin, a polyimide resin, and the like can be exemplified. These may be used alone or in combination of two or more. These thermoplastic resins may be used alone, as a mixture, or as a copolymer. In the case of a mixture, a compatibilizer can be used in combination. Further, brominated flame retardants, silicon-based flame retardants, red phosphorus, and the like can be added as flame retardants.

  The matrix resin used for the prepreg and the matrix resin injected into the laminate obtained by laminating a plurality of dry base materials may be the same and are not particularly distinguished.

  Next, an embodiment of the present invention will be described with reference to FIGS.

  FIG. 1 is a schematic cross-sectional view for explaining an embodiment of the method for producing a fiberized plastic molded body of the present invention, and FIG. 2 is a plan view of the configuration of FIG. 1 viewed from the vertical direction.

  First, in FIGS. 1 and 2, the reinforcing fiber laminate 1 and the rigid sheet 2 are arranged on the upper surface of the male mold 5. FIG. 1 shows a form in which the reinforcing fiber laminate 1 is arranged directly on the upper surface of the male mold 5 and the rigid sheet 2 is arranged on the upper surface, but the reinforcing fiber is used for the purpose of facilitating demolding after shaping. A release film or a release cloth (not shown) can be disposed above and below the laminate 1.

  Next, the male rubber 5, the reinforcing fiber laminate 1 and the rigid sheet 2 are covered with the shaping rubber 3, and the shaping rubber 3 is brought into close contact with the sealing material 6 mounted on the tool plate 4. A closed space is formed by the rubber 3, the tool plate 4 and the sealing material 6.

  Next, the fiberized plastic molded body of the present invention can be manufactured by discharging the air in the sealed space formed by the shaping rubber 3, the tool plate 4 and the sealing material 6 from the suction port 7. it can.

  FIG. 3 is a perspective view for illustrating the male mold used in the present invention.

  In FIG. 3, the male mold 5 is a male mold having a typical shape having two male side surface mountain-shaped portions 11 on the side surface and one male side valley-shaped portion 12 sandwiched between them. The present invention is not limited to this shape, and can be applied to a male mold having a plurality of valley-shaped portions on the side surface.

  4A to 4C are perspective views for illustrating the shape of the reinforcing fiber laminate in the shaping step. Next, the shape of the reinforcing fiber laminate in the shaping step will be described with reference to FIGS. 4 and 3.

  As shown in FIG. 1, when the air in the sealed space formed by the shaping rubber 3, the tool plate 4, and the sealing material 6 is discharged from the suction port 7, the reinforcing fiber laminate 1 is shown in FIG. As shown in a) to (c) (and FIG. 3), from the male upper surface 8 of the male mold 5, the male shoulder 9 and the male side surface 10 are pressed by the shaping rubber 3 in this order. The shape of the male mold 5 is finally formed. FIG. 4 (b) shows the shape of the reinforcing fiber laminate 1 during the shaping process, but the function of the rigid sheet 2 arranged in accordance with the male side surface mountain-shaped portion 11 of the male mold 5. It has shown that it is preferentially shaped from the part corresponding to the male side valley-shaped part 12 of the male mold 5. Due to this effect, after forming the portion corresponding to the male side valley-shaped portion 12 of the male mold 5, the reinforcing fiber laminate 1 is free from defects such as wrinkles and bridging, and a molded product with good dimensional accuracy is obtained. can get.

  Finally, when a dry substrate is used as the reinforcing fiber laminate 1, a resin injection and a thermoforming process are performed. When a prepreg is used, an FRP molded body is obtained by performing a thermoforming process using an autoclave. Can be obtained.

  Next, the manufacturing method of the fiber reinforced plastic molding of this invention is demonstrated in detail based on an Example.

[Example 1]
(Laminate placement process)
First, as shown in FIG. 1, a male mold 5 (material: polyurethane, dimensions: maximum width 300 mm, minimum width 250 mm, length 600 mm, height 250 mm, corner radius 5 mm) was placed on the surface of the tool plate 4. Next, a release film (“Toyoflon” (registered trademark) manufactured by Toray, dimensions (length 600 mm, width 600 mm, thickness 0.05 mm)) on the male mold 5, and a substrate (Toray Ltd. "Torayca" (registered trademark), cross: carbon fiber T800S, basis weight 200 g / ^{m 2)} 48 sheets quasi-isotropic laminate reinforcing fibers laminated body 1 (dimensions: length 550 mm, width 500 mm), and a releasing cloth ( B4444 manufactured by Richmond, length 600 mm, width 600 mm, and thickness 0.05 mm) were sequentially arranged.

(Rigid sheet placement process)
As shown in FIG. 2, the rigid sheet 2 (“Lumirror” (registered trademark) manufactured by Toray, dimensions: length 150 mm, width 600 mm, thickness 0.35 mm) is applied to the male side surface mountain-shaped portion 11 of the male type 5. Two places were arranged so as to be along.

(Shaping rubber placement process)
A shaping rubber 3 (SH950T manufactured by Kureha Elastomer Co., Ltd.) was disposed on the reinforcing fiber laminate 1 and the rigid sheet 2, and a sealed space was formed by the shaping rubber 3, the tool plate 4 and the sealing material 6.

(Shaping process)
The air in the sealed space was discharged from the air inlet 7 provided on the tool plate 4 using a vacuum pump, and the reinforcing fiber laminate 1 was brought into close contact with the male mold 5. Thereafter, these series of components were placed in a heating furnace and held at a temperature of 80 ° C. for 2 hours, and then cooled to 30 ° C. or lower, and then demolded. The shaped reinforcing fiber laminate did not show quality defects such as wrinkles and bridges. By injecting a liquid epoxy resin into the reinforced fiber laminate thus obtained and performing heat curing, a fiber reinforced plastic molded article having excellent dimensional accuracy, surface quality and mechanical strength could be obtained.

[Example 2]
In the rigid sheet arranging step described in the first embodiment, after the rigid sheet a (dimensions: length 600 mm, width 600 mm) is arranged, the rigid sheet b (dimensions) is provided at a position along the male side mountain-shaped portion 11 of the male mold 5. : 150 mm in length and 600 mm in width) Except that two places were arranged, shaping was performed in the same manner as in Example 1. The shaped reinforcing fiber laminate did not show quality defects such as wrinkles and bridges. By injecting a liquid epoxy resin into the reinforced fiber laminate thus obtained and performing heat curing, a fiber reinforced plastic molded article having excellent dimensional accuracy, surface quality and mechanical strength could be obtained.

[Comparative Example 1]
The shaping was performed in the same manner as in Example 1 except that the rigid sheet arranging step described in Example 1 was omitted. In the inner corner portion of the shaped reinforcing fiber laminate, wrinkles due to bridging occurred between the mountain-shaped portion and the mountain-shaped portion of the mold. A liquid epoxy resin was injected into the reinforced fiber laminate thus obtained and heat-cured. Compared with the fiber-reinforced plastic molded body obtained in Example 1, the dimensional accuracy, surface quality, and mechanical strength were higher. An inferior fiber reinforced plastic molding was obtained.

[Comparative Example 2]
The shaping was performed in the same manner as in Example 2 except that the rigid sheet b described in Example 2 was not arranged. In the inner corner portion of the shaped reinforcing fiber laminate, wrinkles due to bridging occurred between the mountain-shaped portion and the mountain-shaped portion of the mold. A liquid epoxy resin was injected into the reinforced fiber laminate thus obtained and heat-cured. Compared with the fiber-reinforced plastic molded body obtained in Example 1, the dimensional accuracy, surface quality, and mechanical strength were higher. An inferior fiber reinforced plastic molding was obtained.

  The method for producing a fiber-reinforced plastic molded body according to the present invention includes molding of any FRP using a male mold having a valley shape on the side surface of the mold (for example, a stiffener or a girder as a mold material and a reinforcing member for automobiles, aircrafts and industrial applications) .), And is particularly suitable for forming a girder having a complicated shape.

DESCRIPTION OF SYMBOLS 1 Reinforced fiber laminate 2 Rigid sheet 3 Shaped rubber 4 Tool plate 5 Male 6 Seal material 7 Suction port 8 Male upper surface 9 Male shoulder 10 Male side 11 Male side mountain-shaped portion 12 Male side valley portion

Claims (10)

  A laminate arranging step of arranging a reinforcing fiber laminate on a male mold, a shaping rubber arranging step of arranging a shaping rubber from above the reinforcing fiber laminate, and between the shaping rubber and the male die A method for producing a fiber-reinforced plastic molded body comprising at least a shaping step of bringing the reinforcing fiber laminate into close contact with the male mold by depressurizing the sealed space, wherein a part of the surface of the reinforcing fiber laminate The manufacturing method of the fiber reinforced plastics molded object characterized by including the process of arrange | positioning a rigid sheet | seat in the.   A laminate arranging step of arranging a reinforcing fiber laminate on a male mold, a shaping rubber arranging step of arranging a shaping rubber from above the reinforcing fiber laminate, and between the shaping rubber and the male die Is a method for producing a fiber-reinforced plastic molded body comprising at least a shaping step of bringing the reinforcing fiber laminate into close contact with the male mold by depressurizing the hermetically sealed space, wherein at least one of the surfaces of the reinforcing fiber laminate A method for producing a fiber-reinforced plastic molded body comprising a step of disposing a rigid sheet processed body whose bending rigidity changes in an in-plane direction at a portion. A rigid sheet processed body whose bending rigidity changes in the in-plane direction,
A. Increase the thickness of the rigid sheet where you want to give rigidity.
B. Stack multiple sheets of rigid sheets where you want to add rigidity.
C. Change the material of the rigid sheet where you want to give rigidity to a material with a high Young's modulus.
D. Reduce the thickness of the rigid sheet at the site where rigidity is desired to be reduced; Cut out the rigid sheet where you want to weaken the rigidity.
The method for producing a fiber-reinforced plastic molded body according to claim 2, wherein the fiber-reinforced plastic molded body is produced by any one of the methods.   The method for producing a fiber-reinforced plastic molded body according to claim 2 or 3, wherein the rigid sheet processed body is a combination of a rigid sheet and another sheet material.   The method for producing a fiber-reinforced plastic molded article according to any one of claims 1, 3, and 4, wherein the rigid sheet has a Young's modulus of 3 GPa or more and a thickness of 0.1 to 0.5 mm.   The male mold is composed of an upper surface portion and a planar side surface portion substantially perpendicular to the upper surface portion, and has at least one valley shape on the side surface portion. A method for producing a fiber-reinforced plastic molding.   7. The fiber-reinforced plastic molded body according to claim 1, wherein the rigid sheet or the rigid sheet processed body has a bending rigidity distributed substantially parallel to the valley shape of the male side surface. Production method.   The method for producing a fiber-reinforced plastic molded body according to any one of claims 1 to 7, wherein the rigid sheet or the rigid sheet processed body is disposed so as not to hang over a valley-shaped portion on the male side surface.   The method for producing a fiber-reinforced plastic molded body according to any one of claims 1 to 8, wherein the rigid sheet or the rigid sheet processed body is disposed between the reinforcing fiber laminate and the shaped rubber.   The method for producing a fiber-reinforced plastic molded body according to any one of claims 1 to 9, wherein the reinforcing fiber laminate is composed of a dry base material or prepreg provided with a resin material on at least one side.

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