JP5074251B2 - Method for forming annular hollow member - Google Patents
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- JP5074251B2 JP5074251B2 JP2008072645A JP2008072645A JP5074251B2 JP 5074251 B2 JP5074251 B2 JP 5074251B2 JP 2008072645 A JP2008072645 A JP 2008072645A JP 2008072645 A JP2008072645 A JP 2008072645A JP 5074251 B2 JP5074251 B2 JP 5074251B2
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- Steering Controls (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Description
本発明は、プリプレグを用いたプレス成形において、環状中空部材を成形する方法に関する。 The present invention relates to a method for forming an annular hollow member in press molding using a prepreg.
繊維強化プラスチック（ＦＲＰ）は、不飽和ポリエステル樹脂、エポキシ樹脂、ポリイミド樹脂等の熱硬化性樹脂や、ポリエチレン、ポリプロピレン、ポリアミド、ポリフェニレンスルフィド（ＰＰＳ）、ポリエーテルエーテルケシン（ＰＥＥＫ）等の熱可塑性樹脂のマトリックス樹脂と、炭素繊維、ガラス繊維、アラミド繊維等の強化繊維からなるものであり、軽量で且つ強度特性に優れるため、近年、航空宇宙産業から一般産業分野に至るまで、幅広い分野において利用されている。 Fiber reinforced plastics (FRP) are thermosetting resins such as unsaturated polyester resins, epoxy resins, and polyimide resins, and thermoplastics such as polyethylene, polypropylene, polyamide, polyphenylene sulfide (PPS), and polyether ether kesin (PEEK). It is made of resin matrix resin and reinforcing fibers such as carbon fiber, glass fiber, and aramid fiber, and it is lightweight and has excellent strength properties, so it has been used in a wide range of fields from the aerospace industry to general industrial fields in recent years. Has been.
従来、例えば、自動車等のハンドルは、金属製の芯材とそれを被覆する合成樹脂等の外被から構成されている（例えば、特許文献１と２）。しかしながら、かかる形態のハンドルは、当然のことながら重たいものであり、また、金属製の芯材と合成樹脂の接着性に問題がある場合がある。従って、前記のごとく軽量で且つ強度特性に優れたＦＲＰを用いて、ＦＲＰのみのハンドルを製作することも試みられている。
そして、自動車等のハンドルの様なＦＲＰの環状中空部材は、プリプレグを用いたプレス成形によって製作されるのが普通である。かかる成形においては、先ず（ａ）棒マンドレルにポリプロピレン等のフィルムを巻き付け、（ｂ）その上からプリプレグを巻き付け積層し、（ｃ）プレプレグの積層後、棒マンドレルを抜いてパイプ状の積層体のみとし、（ｄ）このパイプ状の積層体を円形の金型にセットして成形加工する方法が取られてきた。しかしこの方法では、棒状でパイプ状の積層体を円形に曲げるため、円形の内側にしわが発生し、その結果、成形品の品位が劣るだけでなく成形品ごとに品位が異なるという問題があった。 An FRP annular hollow member such as a handle for an automobile or the like is usually manufactured by press molding using a prepreg. In such molding, first, (a) a film of polypropylene or the like is wound around a rod mandrel, (b) a prepreg is wound and laminated thereon, (c) after the prepreg is laminated, the rod mandrel is pulled out and only a pipe-shaped laminate is obtained. (D) This pipe-shaped laminate has been set in a circular mold and molded. However, in this method, since the rod-like and pipe-like laminate is bent into a circle, wrinkles are generated inside the circle. As a result, not only the quality of the molded product is inferior, but also the quality of each molded product is different. .
本発明の課題は、品位の優れた自動車等のハンドルの様なＦＲＰの環状中空部材を、プレス成形により成形する方法を提供することにある。 The subject of this invention is providing the method of shape | molding the annular | circular hollow member of FRP like a handle | steering_wheel of the motor vehicle etc. which was excellent in quality by press molding.
本発明の請求項１に記載された発明は、繊維強化材とマトリックス樹脂とからなるプリプレグを用いて環状中空部材を成形するに際し、（１）該環状中空部材用のマンドレルを被覆するための、環状中空部材の上面部分用と下面部分用の２種類のドーナツ形状のプリプレグであって、それぞれの外円周及び内円周に沿って歯車形状のラップ部を設けたものを作製し、（２）該２種類のプリプレグを用いて、お互いのラップ部が互い違いになるようにして前記マンドレルを上下から被覆し、（３）得られた被覆物を上下分割型の環状金型にセットして賦形加工を行い賦形体とし、次いで、（４）前記金型の上型を取り外し、得られた賦形体を金型の下型にセットしたままの状態で、前記マンドレルを賦形体から引き抜いて取り除き、その後、（５）賦形体を成形用環状金型に再配置して成型加工を行うことを特徴とする環状中空部材の成形方法である。 In the invention described in claim 1 of the present invention, when forming an annular hollow member using a prepreg comprising a fiber reinforcing material and a matrix resin, (1) for coating the mandrel for the annular hollow member, Two types of donut-shaped prepregs for the upper surface portion and the lower surface portion of the annular hollow member, in which gear-shaped wrap portions are provided along the outer circumference and the inner circumference, are produced. ) Using the two types of prepregs, the mandrel is covered from above and below so that the lap portions are staggered. (3) The obtained coating is set in a vertically divided annular mold and applied. Forming is performed to form a shaped body, and then (4) removing the upper mold of the mold and removing the mandrel from the shaped body with the obtained shaped body still set in the lower mold of the mold. ,afterwards,( ) Is a method of forming an annular hollow member characterized by rearranging to molding a shaped object in the molding annular die.
そして、請求項２に記載された発明は、環状中空部材が、円形のハンドルであることを特徴とする請求項１記載の環状中空部材の成形方法である。この場合に、環状部材用のマンドレルは、通常、円形で輪状のものである。マンドレルの材質は、柔軟性があり変形自在のものである限り、金属製でも良いが、好ましくは、ゴムやポリメチルペンテンポリマー（ＰＭＰ）等の合成樹脂製のものである。
The invention described in
本発明においては、プリプレグの形状を、あらかじめ目的の成形品の形状にすること、且つ、歯車形状のラップ部を持たして、上下２枚のプリプレグが、歯車形状のラップ部で互い違いにオーバーラップして、環状中空部材を形成するように構成されている。従って、本発明によれば、プレス成形によって、しわ等の表面欠陥のないＦＲＰの環状中空部材、例えば、自動車等のハンドルを、生産効率良く成形することができる。表面の平滑性や品位も従来の方法によるものよりも優れたものが得られる。 In the present invention, the shape of the prepreg is set to the shape of the desired molded product in advance, and the gear-shaped wrap portion is alternately overlapped by the gear-shaped wrap portion having a gear-shaped wrap portion. And it is comprised so that an annular hollow member may be formed. Therefore, according to the present invention, an FRP annular hollow member having no surface defects such as wrinkles, for example, a handle of an automobile or the like, can be formed with high production efficiency by press molding. Surface smoothness and quality superior to those obtained by conventional methods can be obtained.
本発明は、繊維強化材とマトリックス樹脂とからなるプリプレグを用いて環状中空部材を成形す
る方法に関するものであるが、以下、本発明のステップごとに図を用いて説明する。
The present invention relates to a method of forming an annular hollow member using a prepreg composed of a fiber reinforcing material and a matrix resin. Hereinafter, each step of the present invention will be described with reference to the drawings.
先ず工程（１）では、環状中空部材用のマンドレルを被覆するための、環状中空部材の上面部分用と下面部分用の２種類のドーナツ形状のプリプレグであって、それぞれの外円周及び内円周に沿って歯車形状のラップ部を設けたものを作製する。本発明において用いられるマンドレルは、後述の様に、マンドレルは賦形体から引き抜いて取り除くことかできるものでなければならないから、柔軟性があり変形自在のものである必要がある。好ましくは、ゴムやポリメチルペンテンポリマー（ＰＭＰ）等の合成樹脂製のものである。 First, in step (1), two types of donut-shaped prepregs for the upper surface portion and the lower surface portion of the annular hollow member for covering the mandrel for the annular hollow member, each of which has an outer circumference and an inner circle, respectively. A product provided with a gear-shaped wrap portion along the circumference is produced. As will be described later, the mandrel used in the present invention must be capable of being pulled out from the shaped body and removed, and therefore must be flexible and deformable. Preferably, it is made of a synthetic resin such as rubber or polymethylpentene polymer (PMP).
プリプレグとは、繊維強化材に、熱硬化性樹脂や熱可塑性樹脂などのマトリックス樹脂を含浸させ、流動性や粘着性を除いて取り扱い性を良くした成形中間材である。本発明において用いられるプリプリグについては、後述するが特に制限はない。本発明においては、環状中空部材用のマンドレルを被覆するためのドーナツ形状のプリプレグであって、それぞれの外円周及び内円周に沿って歯車形状のラップ部を設けたものを、シート状のプリプレグから切抜いて作製する。図１は、かかるドーナツ形状のプリプレグの一例を示している。図１の１は環状のマンドレルを被覆する部分であり、２は外円周及に沿って設けられた歯車形状のラップ部であり、３は内円周に沿って設けられた歯車形状のラップ部である。かかるプリプレグを、環状中空部材の上面（表面）部分用と下面（裏面）部分用の２枚準備する。 A prepreg is a molded intermediate material in which a fiber reinforcing material is impregnated with a matrix resin such as a thermosetting resin or a thermoplastic resin to improve handling properties except for fluidity and adhesiveness. Although the prepreg used in the present invention will be described later, there is no particular limitation. In the present invention, a donut-shaped prepreg for covering a mandrel for an annular hollow member, which is provided with a gear-shaped wrap portion along each outer circumference and inner circumference, is a sheet-like shape. Cut out from the prepreg. FIG. 1 shows an example of such a donut-shaped prepreg. 1 is a portion covering an annular mandrel, 2 is a gear-shaped wrap portion provided along the outer circumference, and 3 is a gear-shaped wrap provided along the inner circumference. Part. Two prepregs are prepared for the upper surface (front surface) portion and the lower surface (back surface) portion of the annular hollow member.
次に工程（２）では、前記のようにして作製された２枚のプリプレグを用いて、お互いのラップ部が互い違いになるようにして前記マンドレルを上下（表裏）から被覆し、被覆物を作成する。２枚のプリプレグは、全く同じ種類で同一形状のものであっても良いが、種類の違うプリプレグであっても良く、また、環状マンドレルを完全に被覆でき、且つ、完全に環状中空部材を形成できるものである限り、上面部分用と下面部分用で大きさ（図１の１の部分の幅）が異なっていても良く、あるいはラップ部の歯車形状が異なっていても良い。図２は、ドーナツ形状のプリプレグの他の例を示している。 Next, in step (2), using the two prepregs produced as described above, the mandrel is covered from the top and bottom (front and back) so that the lap portions are staggered to create a covering. To do. The two prepregs may be of the same type and of the same shape, but may be of different types, and can completely cover the annular mandrel and form a completely annular hollow member. As long as it is possible, the size (width of the portion 1 in FIG. 1) may be different for the upper surface portion and the lower surface portion, or the gear shape of the wrap portion may be different. FIG. 2 shows another example of a donut-shaped prepreg.
次に工程（３）では、前記のごとくして得られた被覆物を上下分割型の環状金型にセットして賦形加工を行い賦形体とする。賦形加工の条件については特に制限はない。例えば、前記（２）で得られたドーナツ形状の被覆物を、上下分割型の下型にセットし、次いで上型をかぶせて上下型で締め込むことによって賦形体を得ることができる。 Next, in the step (3), the covering obtained as described above is set in an upper and lower divided annular mold and subjected to shaping to obtain a shaped body. There are no particular restrictions on the conditions for the shaping process. For example, the shaped body can be obtained by setting the donut-shaped covering obtained in (2) above on the lower mold of the upper and lower split mold, and then covering the upper mold and tightening with the upper and lower molds.
次に工程（４）では、賦形加工後、前記金型の上型を取り外し、得られた賦形体を金型の下型にセットしたままの状態で、前記マンドレルを賦形体から引き抜いて取り除く。本発明において用いられるマンドレルは、例えば、ゴムやＰＭＰ等の合成樹脂製で、柔軟性があり変形自在なものであるから、環状の賦形体に切れ目を入れ、その部分から引き抜いて取り除くことかできる。この際、賦形体は下型にセットされたままの状態であるので、賦形体が変形等することはない。マンドレルを引き抜き易くするためには、マンドレルに予めポリプロピレン等のフィルムを巻き付け被覆しておくのが好ましい。 Next, in the step (4), after the shaping process, the upper mold of the mold is removed, and the mandrel is pulled out and removed from the shaped article in a state where the obtained shaped article is set in the lower mold of the mold. . The mandrel used in the present invention is made of, for example, a synthetic resin such as rubber or PMP, and is flexible and deformable. Therefore, the mandrel can be cut into the annular shaped body and removed from the portion. . At this time, since the shaped body is still set in the lower mold, the shaped body is not deformed. In order to make it easy to pull out the mandrel, it is preferable to wind and coat a film of polypropylene or the like around the mandrel.
その後、工程（５）では、前記のごとくして得られた賦形体を成形用金型に配置（セット）して、成型加工を行う。成形加工は、プレス成形によって行われる。プレス成形とは、プレス機と金型を使用して加熱・加圧・圧縮によりＦＲＰを成形する方法であり、本発明においては、特に制限はなく、通常の絞りプレス成形等を利用できる。金型の材質については特に制限はない。なお、賦形用の金型と成形用金型は、同一のものであっても別々のものであっても良い。 Thereafter, in step (5), the shaped body obtained as described above is placed (set) in a molding die, and molding is performed. The molding process is performed by press molding. Press molding is a method of molding FRP by heating, pressurization, and compression using a press and a mold, and there is no particular limitation in the present invention, and ordinary drawing press molding or the like can be used. There are no particular restrictions on the material of the mold. The shaping mold and the molding mold may be the same or different.
本発明において用いられるプリプレグとしては、補強用のガラス繊維、炭素繊維、アラミド繊維等の繊維強化材の織物、不織布等のシート状物に、熱硬化性樹脂や熱可塑性樹脂等のマトリックス樹脂を含浸させて得られたプリプレグが挙げられる。繊維強化材やマトリックス樹脂に関しては特に制限はないが、繊維強化材として好ましいのは炭素繊維又はガラス繊維であり、その織物が好ましい。織物としては、例えば、平織、綾織、朱子織等の経糸と緯糸から構成されるものの他、繊維束を一方向に引き揃えシート状としたもの、これを直角方向にステッチ糸で縫合した一軸織物、一方向に引き揃えたシート状物を角度を変えて複数積層し、これを直角方向にステッチ糸で縫合した多軸織物等が挙げられる。繊維強化材とマトリックス樹脂の割合は、繊維強化材が全体の３０〜７０重量％であるものが好ましい。なお、本発明において一方向配列繊維プリプレグとは、繊維束を一方向に引き揃えシート状にしたものとマトリックス樹脂からなるプリプレグを意味する（一軸織物を含む）。 The prepreg used in the present invention is impregnated with a matrix resin such as a thermosetting resin or a thermoplastic resin into a sheet of material such as a woven fabric or a nonwoven fabric of a fiber reinforcing material such as glass fiber, carbon fiber or aramid fiber for reinforcement. The prepreg obtained by letting it be mentioned is mentioned. Although there is no restriction | limiting in particular regarding a fiber reinforcement and matrix resin, As a fiber reinforcement, a carbon fiber or glass fiber is preferable, and the textile fabric is preferable. Examples of the woven fabric include, for example, those composed of warp and weft such as plain weave, twill weave, satin weave, etc., fiber bundles that are aligned in one direction, and uniaxial fabrics that are stitched with stitch yarns in the perpendicular direction. A multi-axis woven fabric obtained by laminating a plurality of sheet-like materials arranged in one direction at different angles and stitching them with a stitch thread in a perpendicular direction. The ratio of the fiber reinforcing material to the matrix resin is preferably 30 to 70% by weight of the total fiber reinforcing material. In the present invention, the unidirectionally-arranged fiber prepreg means a prepreg made of a fiber bundle obtained by aligning fiber bundles in one direction and a matrix resin (including uniaxial woven fabric).
マトリックス樹脂としては、熱硬化性や熱可塑性の樹脂を使用することができる。好ましいのは、熱硬化性樹脂であり、エポキシ樹脂、不飽和ポリエステル樹脂、フェノール樹脂、メラミン樹脂、ポリウレタン樹脂、シリコン樹脂、マレイミド樹脂、ビニルエステル樹脂、シアン酸エステル樹脂、マレイミド樹脂とシアン酸エステル樹脂を予備重合した樹脂等が挙げられる。これらの熱硬化性樹脂は、適宜量配合したものでも良い。これらの樹脂のうち、耐熱性、弾性率、耐薬品性に優れたエポキシ樹脂組成物、ビニルエステル樹脂組成物が特に好ましい。これらの熱硬化性樹脂には、硬化剤、硬化促進剤等が含まれていても良い。以下、実施例で本発明を詳述する。 As the matrix resin, a thermosetting or thermoplastic resin can be used. Preferable are thermosetting resins, epoxy resins, unsaturated polyester resins, phenol resins, melamine resins, polyurethane resins, silicone resins, maleimide resins, vinyl ester resins, cyanate ester resins, maleimide resins and cyanate ester resins. For example, a resin obtained by prepolymerization. These thermosetting resins may be blended in appropriate amounts. Of these resins, epoxy resin compositions and vinyl ester resin compositions excellent in heat resistance, elastic modulus, and chemical resistance are particularly preferable. These thermosetting resins may contain a curing agent, a curing accelerator and the like. Hereinafter, the present invention will be described in detail by way of examples.
以下、実施例により本発明を説明する。円形環状の自動車用ハンドルを成形する例を説明する。先ず、図１に示したように、外円周及び内円周に沿って歯車形状のラップ部を設けたドーナツ形状のプリプレグを、シート状の炭素繊維のプリプレグから切抜いた。炭素繊維のプリプレグとしては、炭素繊維ＨＴＡ３Ｋ（東邦テナックス社製、汎用グレードの炭素繊維、３０００フィラメント）を経糸緯糸とした平織物（東邦テナックス社製、Ｗ−３１０１）に、エポキシ樹脂を含浸させたものを用いた（樹脂含有率：４０％）。このプリプレグを５枚、積層パターンが（０／９０）、（±４５）、（３０／１２０）、（±４５）、（０／９０）となる様に重ねてシート状にしたものを用いた。環状のマンドレルとしては、ＰＭＰ製の直径３０ｍｍの棒を、直径３６９ｍｍの円形にしたものを用いた。
マンドレルの両端部は接着により、あるいは両端部に穴を開けてピンにて固定した。また、マンドレルにはＰＰフィルムを巻き付けた後、成形用ナイロンバックを巻き付け被覆した。
Hereinafter, the present invention will be described by way of examples. An example of forming a circular annular automobile handle will be described. First, as shown in FIG. 1, a donut-shaped prepreg provided with gear-shaped wrap portions along an outer circumference and an inner circumference was cut out from a sheet-like carbon fiber prepreg. As a carbon fiber prepreg, an epoxy resin was impregnated into a plain woven fabric (manufactured by Toho Tenax Co., Ltd., W-3101) having warp weft made of carbon fiber HTA3K (manufactured by Toho Tenax Co., Ltd., general-purpose grade carbon fiber, 3000 filaments). What was used (resin content: 40%). Five sheets of this prepreg were used, and the laminated patterns were (0/90), (± 45), (30/120), (± 45), and (0/90). . As the annular mandrel, a PMP rod having a diameter of 30 mm and having a circular shape with a diameter of 369 mm was used.
Both ends of the mandrel were fixed by bonding or by making holes in both ends. Further, after a PP film was wound around the mandrel, a molding nylon bag was wrapped around the mandrel.
図１において、１は上記環状のマンドレルを被覆する部分であり、幅が４０〜５０ｍｍとし、２は外円周及に沿って設けられた歯車形状のラップ部であり、高さが１０〜２０ｍｍで、上辺の長さが５０〜１００ｍｍで、下辺の長さを４５〜９５ｍｍとなるようにした。３は内円周に沿って設けられた歯車形状のラップ部であり、高さが１０〜２０ｍｍで、上辺の長さが３０〜５０ｍｍで、下辺の長さを３５〜５５ｍｍとなるようにした。かかるドーナツ形状のプリプレグを、環状中空部材の上面（表面）部分用と下面（裏面）部分用の２枚準備した。
In FIG. 1, 1 is a portion covering the annular mandrel, the width is 40 to 50 mm, 2 is a gear-shaped wrap portion provided along the circumference of the outer circle, and the height is 10 to 20 mm. Therefore, the length of the upper side is 50 to 100 mm and the length of the lower side is 45 to 95 mm.
次に、上記２種類のプリプレグを用いて、お互いのラップ部が互い違いになるようにして前記マンドレルを上下から被覆した。そして、得られた被覆物を上下分割型の環状金型にセットし、型締めして、賦形体とした。 Next, the mandrel was covered from above and below using the above-described two kinds of prepregs so that the lap portions of each other were alternated. Then, the obtained covering was set in a vertically divided annular mold and clamped to obtain a shaped body.
その後、前記金型の上型を取り外し、得られた賦形体を金型の下型にセットしたままの状態で、環状の賦形体の一箇所（マンドレルの継ぎ目の箇所）に切れ目を入れ、その部分から前記マンドレルを引き抜いて取り除いた。そして、前記環状の成形用金型に配置して、面圧１０ｋｇ／ｃｍ２の圧力下、１１０℃で３０分間プレス成形を行った。その後、金型を冷却し脱型して得られたハンドル（環状中空部材）は、しわ等の表面欠陥のないものであった。 Thereafter, the upper mold of the mold is removed, and the obtained shaped body is set in the lower mold of the mold, and a cut is made at one place of the annular shaped body (the seam of the mandrel). The mandrel was pulled out of the part and removed. And it arrange | positioned to the said cyclic | annular shaping | molding metal mold | die, and press-molded for 30 minutes at 110 degreeC under the pressure of 10 kg / cm < 2 > of surface pressure. Thereafter, the handle (annular hollow member) obtained by cooling and removing the mold was free from surface defects such as wrinkles.
１ 環状のマンドレルを被覆する部分
２ 外円周に沿って設けられた歯車形状のラップ部
３ 内円周に沿って設けられた歯車形状のラップ部
DESCRIPTION OF SYMBOLS 1 The part which coat | covers a cyclic |
Claims (2)
The method for forming an annular hollow member according to claim 1, wherein the annular hollow member is a circular handle.
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