JP6859448B2 - Manufacturing method of fiber reinforced resin member, fuel tank and fiber reinforced resin member - Google Patents

Description

The present invention relates to a method for manufacturing a fiber reinforced resin member, a fuel tank, and a fiber reinforced resin member.

As a method for manufacturing a fiber-reinforced plastics (FRP) member, the one described in Patent Document 1 is known. The manufacturing method of Patent Document 1 is that a fiber sheet and a resin sheet are laminated to form a laminated body, and then molded using a molding die.

Japanese Unexamined Patent Publication No. 7-047596

However, in the conventional manufacturing method, there is a problem that the exposed fibers are fluffed due to the fibers being exposed at the ends of the fiber reinforced resin member. If the worker touches the fluffy part, it may be torn, which makes it difficult to handle the fiber reinforced resin member. In addition, the fibers may fray from the fluffy portion, or substances may enter between the fibers and the resin, which may cause deterioration of the product.

The present invention has been created to solve such a problem, and provides a method for manufacturing a fiber-reinforced resin member capable of suppressing the occurrence of fiber fluff, a fuel tank, and a fiber-reinforced resin member. Make it an issue.

In order to solve the above problems, the present invention comprises a preparatory step of preparing a laminated body in which fiber sheets are laminated so as to be sandwiched between resin sheets that are larger in size than the fiber sheets and do not contain fibers, and the fiber sheets are exposed. It has a main molding step of pressure molding the laminated body so as not to prevent the laminate, and after the main molding step, a mounting hole is formed in a portion where the fiber sheet extends, while the end portion of the fiber sheet is formed. It is characterized in that an unnecessary portion is cut in the region of the unreinforced portion at the outer position.

According to such a configuration, since the fibers are not exposed to the outside of the fiber reinforced resin member, the occurrence of fluffing of the fibers can be suppressed.

Further, in the main molding step, it is preferable to pinch the resin sheet with a molding die at a position outside the end portion of the fiber sheet.

According to such a configuration, the work of separately cutting the end portion can be omitted, so that the work man-hours can be reduced.

Further, the laminate is composed of a plurality of the fiber sheets and a plurality of the resin sheets arranged between the plurality of fiber sheets and in the outermost layer, and in the preparation step, the laminated body is arranged in the outermost layer. It is characterized in that the size of only the resin sheet is made larger than that of the fiber sheet.

According to such a configuration, since only the outermost resin sheet is enlarged, the material cost can be reduced.

Further, the present invention has a tank body, a pair of fiber reinforced resin members that sandwich the outside of the tank body, and a fastening portion that fastens both ends of the pair of fiber reinforced resin members. The member is composed of a fiber-reinforced layer and a matrix resin layer containing no fibers laminated on top of each other, and an unreinforced portion is formed at an end portion without the fiber-reinforced layer interposed therebetween. A mounting hole for use is formed in a portion where the fiber reinforced layer extends, and an unnecessary portion is cut in the region of the unreinforced portion.

According to such a configuration, the fiber is not exposed because the end portion of the fiber reinforced resin member is covered with the unreinforced portion. As a result, the work of assembling the carbon-based reinforced resin member to the tank body can be easily performed.

Further, the present invention is formed by laminating a fiber-reinforced layer and a matrix resin layer containing no fiber, and an unreinforced portion in which the fiber-reinforced layer is not interposed is formed at an end portion. A mounting hole is formed in a portion where the fiber reinforcing layer extends, and an unnecessary portion is cut in the region of the unreinforced portion.

According to such a configuration, since the fibers are not exposed to the outside of the fiber reinforced resin member, the occurrence of fluffing of the fibers can be suppressed.

According to the method for producing a fiber-reinforced resin member, the fuel tank and the fiber-reinforced resin member of the present invention, the occurrence of fluffing of fibers can be suppressed.

It is a perspective view which shows the fuel tank which concerns on 1st Embodiment of this invention. It is sectional drawing which shows the circumference of the fiber reinforced resin member of 1st Embodiment. It is a perspective view which shows the fiber reinforced resin member. It is a side view which shows the fiber reinforced resin member. It is an enlarged sectional view of the main part of the part A of FIG. It is an enlarged sectional view of the main part of the part B of FIG. It is a perspective view which shows the preparation process of the manufacturing method of the fiber reinforced resin member which concerns on 1st Embodiment. It is sectional drawing which shows the arrangement process and the molding process of the manufacturing method of the fiber reinforced resin member which concerns on 1st Embodiment. It is a perspective view which shows the preparation process of the manufacturing method of the fiber reinforced resin member of 2nd Embodiment. It is a schematic plan view which shows the fiber-reinforced resin member completed by the manufacturing method of the fiber-reinforced resin member of the 2nd Embodiment.

Hereinafter, a case where the method for manufacturing a fiber reinforced resin member according to an embodiment of the present invention is applied to a method for manufacturing a fuel tank will be described. In the following description, when referring to "front and back", "left and right", and "up and down", the direction shown in FIG. 1 is used as a reference. It should be noted that each direction is set for convenience in explaining the fuel tank T, and is not intended to limit the direction when the fuel tank T is mounted on the vehicle.

[First Embodiment]
As shown in FIGS. 1 and 2, the fuel tank T is mounted on a means of transportation such as an automobile, a motorcycle, and a ship, and includes a tank body 1 and a plurality of fiber reinforced resin members 21 (8 in the present embodiment). It is mainly composed of one) and.

The tank body 1 is a hollow container made of resin for storing fuel such as gasoline, and has a multi-layer structure including, for example, a barrier layer. The tank body 1 is mainly made of a thermoplastic resin such as polyethylene or high-density polyethylene. The tank body 1 is molded by, for example, blow molding.

The tank body 1 is composed of a lower wall 11, an upper wall 12, a first side wall 13, a second side wall 14, a third side wall 15, and a fourth side wall 16. The lower wall 11, upper wall 12, third side wall 15 and fourth side wall 16 of the tank body 1 are formed with recesses 3 that are continuous over the entire circumference. In this embodiment, four recesses 3 are arranged side by side in parallel in the front-rear direction with a gap. As shown in FIG. 2, the recess 3 has a bottom portion and a pair of side walls rising from the bottom portion, and is formed so as to open to the outside. The recess 3 is formed with a constant cross section over the entire circumference. The number of recesses 3 is not limited.

The fiber reinforced resin member 21 is a member that reinforces the tank body 1, and is arranged side by side in parallel in the front-rear direction with a gap on the outer surface of the tank body 1. The fiber reinforced resin member 21 is a fiber reinforced plastic (FRP: Fiber-Reinforced Plastics) formed by impregnating a fiber sheet (carbon fiber sheet, glass fiber sheet, etc.) with a resin. As shown in FIGS. 3 and 4, the fiber-reinforced resin member 21 is a thin band-shaped member, and has a band portion 21a covering one half circumference side along the outer surface of the tank body 1 (see FIG. 1) and a band portion. It is composed of extending portions 21b and 21b extending outward from both ends of 21a. The shape of the band portion 21a is formed so as to correspond to the shape of the outer surface of the tank body 1. Mounting holes 21c for fastening portions 22 (for example, bolts and nuts) are formed in both extending portions 21b.

The fiber-reinforced resin member 21 is fastened by the fastening portion 22 with the upper and lower sides as a set in a state of being arranged in the recess 3 formed in the tank body 1. That is, the outside of the tank body 1 is sandwiched between the pair of fiber reinforced resin members 21. The fiber reinforced resin member 21 arranged on the lower side is continuously arranged over the third side wall 15, the lower wall 11, and the fourth side wall 16. Further, the fiber reinforced resin member 21 arranged on the upper side is continuously arranged over the third side wall 15, the upper wall 12, and the fourth side wall 16. The arrangement position of the fiber reinforced resin member 21 may be appropriately set according to the shape and application of the tank body 1.

FIG. 5 is an enlarged cross-sectional view of a main part of the portion A in FIG. FIG. 5 schematically shows a cross section of the band portion 21a of the fiber reinforced resin member 21.
The fiber-reinforced resin member 21 is composed of, for example, three fiber-reinforced layers 31 and four matrix resin layers 32, and the layers are alternately laminated. The thickness of the layers and the number of layers are schematically shown, and do not limit the present invention.

The fiber reinforced layer 31 is a layer formed by impregnating a fiber sheet 41 (see FIG. 7) with a matrix resin (matrix resin sheet 42 (see FIG. 7)) and curing the fiber sheet 41.
The matrix resin layer 32 is a layer formed by curing the matrix resin (matrix resin sheet 42). The matrix resin layer 32 is formed on both sides of the fiber reinforced layer 31 (that is, between the fiber reinforced layers 31 and the outermost layer (surface) of the fiber reinforced resin member 21).

FIG. 6 is an enlarged cross-sectional view of a main part of the portion B of FIG. FIG. 6 schematically shows a cross section of the extending portion 21b of the fiber reinforced resin member 21.
The fiber reinforced layer 31 does not reach the end of the extending portion 21b, and a plurality of matrix resins (matrix resin sheet 42 (see FIG. 7)) are integrated at the end of the extending portion 21b. A hardened unreinforced portion 33 is formed. Although not shown, unreinforced portions 33 are also formed on both sides of the fiber reinforcing layer 31 in the width direction. Therefore, the fiber reinforced resin member 21 in the present embodiment is covered with the matrix resin so that the fiber reinforced layer 31 is not exposed to the outside. The mounting hole 21c (see FIG. 3) is preferably formed not in the region of the unreinforced portion 33 but in the portion where the fiber reinforcing layer 31 extends.

Next, a method of manufacturing a fuel tank will be described. The fuel tank manufacturing method mainly includes a tank body molding step, a fiber reinforced resin member molding step, and a fiber reinforced resin member mounting step.

The tank body molding step is a step of blow molding the tank body 1 (see FIG. 1) with a molding die for the tank body. In the main body molding step, a tubular or sheet-shaped parison is discharged from the die between the one mold and the other mold. The parison is, for example, a thermoplastic resin composed of a plurality of layers including a barrier layer inside. The mold for the tank body is preheated to a predetermined temperature so that the parison is plastically deformed. Then, the parison is transferred to the molding surface of the molding mold for the tank body by supplying air to the inside while molding the one mold and the other mold. The parison may be sucked by using the one-sided mold and the evacuation means provided on the other-side mold, and the parison may be transferred to the molding mold for the tank body. After a predetermined time has passed, the tank body 1 is completed by removing the mold and removing excess burrs.

Next, the fiber reinforced resin member molding process will be described. The fiber reinforced resin member molding step is a step of manufacturing the fiber reinforced resin member 21. The fiber-reinforced resin member molding step mainly includes a preparation step, a placement step, and a main molding step.

As shown in FIG. 7, the preparatory step is a step of superimposing the plurality of fiber sheets 41 and the plurality of matrix resin sheets 42 in order to form the laminated body 40. In the preparatory step, the matrix resin sheet 42 is arranged on both sides of the fiber sheet 41. As a result, the matrix resin sheet 42 is arranged between the fiber sheets 41 or in the outermost layer (surface) of the laminated body 40.

The fiber sheet 41 is a thin sheet made of carbon fiber, glass fiber, resin fiber or the like. The type of the fiber sheet 41 is not particularly limited, and may be, for example, a cloth material in which fibers are woven, a felt material in which finely cut short fibers are molded, or the like. The shape and size of the fiber sheet 41 are not particularly limited, but it is preferable that the fiber sheet 41 is preformed according to the shape of the finished product. The fiber sheet 41 here has an elongated strip shape in accordance with the fiber reinforced resin member 21 (see FIG. 3).

The matrix resin sheet 42 is a thin film made of a thermoplastic resin (high-density polyethylene, polyethylene, polyamide (nylon), etc.) or a thermosetting resin (phenol resin, epoxy resin, etc.). The matrix resin sheet 42 is preferably in a shape and size that can cover the fiber sheet 41, and is, for example, the same shape as the fiber sheet 41 and larger in size than the fiber sheet 41. The matrix resin sheet 42 here has an elongated strip shape similar to the fiber sheet 41, and is larger in size than the fiber sheet 41. In addition, only the size of the matrix resin sheet 42 arranged on the outermost layer (surface) of the laminated body 40 may be set to a size capable of covering the fiber sheet 41.

As shown in FIG. 8, the arranging step is a step of arranging the laminated body 40 in the molding die K. As the molding mold K, a first mold K1 arranged on the lower side and a second mold K2 arranged on the upper side are used. Both the first type K1 and the second type K2 are provided with the temperature control means M inside. In the arranging step, the laminated body 40 is arranged between the first type K1 and the second type K2.

As shown in FIG. 8, this molding step is a step of molding the fiber reinforced resin member 21 (see FIG. 3) by the molding die K, and the first die K1 and the second die K2 are die-clamped and press-molded. .. In this molding step, the temperature of the molding die K may be appropriately set to a temperature at which the laminated body 40 can be molded. Then, after the mold is removed, unnecessary parts are cut by laser processing, water jet processing, or the like to complete the fiber reinforced resin member 21 (see FIG. 3). Here, it is the region of the unreinforced portion 33 (see FIG. 6) that cuts the unnecessary portion, so that the fiber reinforcing layer 31 is not cut (that is, the outside of the fiber reinforcing layer 31 is cut). Further, the position outside the end portion of the fiber sheet 41, that is, the region of the unreinforced portion 33 may be pinched (sandwiched) by the molding die K to cut an unnecessary portion.

The pre-molding step may be performed before the main molding step. For example, the temperature of the molding die K is different between the pre-molding step and the main molding step, and an unnecessary portion may be cut after the pre-molding step is performed, and then the main molding step may be performed. In that case, after cutting after the pre-molding step, a new matrix resin sheet 42 may be placed on the outermost layer (surface), and then the main molding step may be performed.
Further, by adjusting the size of the matrix resin sheet 42 so that an unnecessary portion is not generated after the main molding step, it is possible to omit the work of cutting the unnecessary portion.

Next, the fiber reinforced resin member mounting process will be described. The fiber reinforced resin member attaching step is a step of attaching the fiber reinforced resin member 21 (see FIG. 3) to the tank body 1 (see FIG. 1). In the fiber reinforced resin member attaching step, the fiber reinforced resin member 21 is arranged in the recesses 3 formed in the lower wall 11 and the upper wall 12 of the tank body 1. Then, the fiber-reinforced resin members 21 arranged above and below are fastened as a set using the fastening portion 22. As a result, the fuel tank T shown in FIG. 1 is completed. A cushion member (not shown) may be arranged between the tank body 1 and the fiber reinforced resin member 21.

According to the method for manufacturing the fiber reinforced resin member according to the first embodiment described above, as shown in FIG. 6, the fiber reinforced resin member 31 does not reach the end of the fiber reinforced resin member 21, and the fiber reinforced resin member An unreinforced portion 33 is formed at the end portion of 21. As a result, the fiber reinforced layer 31 is not exposed to the outside of the fiber reinforced resin member 21, so that the occurrence of fluffing of the fibers can be suppressed. Therefore, the fiber-reinforced resin member 21 can be easily handled, and the fiber-reinforced resin member 21 can be easily assembled in the fiber-reinforced resin member attaching step. Further, it is possible to prevent the fibers of the fiber reinforced layer 31 from fraying and to prevent substances from entering between the fibers and the resin and deteriorating.

Further, in an example of the present embodiment, since the outside of the fiber sheet 41 is pinched by the molding die K, the work of separately cutting the end portion can be omitted, so that the work man-hours can be reduced.

Further, in an example of the present embodiment, the laminate 40 is composed of a plurality of fiber sheets 41 and a plurality of matrix resin sheets 42 arranged between the fiber sheets 41 and in the outermost layer. Then, in the preparatory step, only the size of the matrix resin sheet 42 arranged in the outermost layer is made larger than that of the fiber sheet 41. Therefore, the material cost can be reduced.

[Second Embodiment]
In the second embodiment, a case where a thin plate-shaped fiber reinforced resin member is attached to an outer surface (for example, an upper surface) of a rectangular parallelepiped tank body (not shown) will be described.
The fiber-reinforced resin member molding step according to the second embodiment mainly includes a preparation step, an arrangement step, and a main molding step, as in the first embodiment.

As shown in FIG. 9, the preparatory step is a step of stacking a plurality of fiber sheets 141 and a plurality of matrix resin sheets 142 in order to form a laminated body 140. In the preparatory step, the matrix resin sheet 142 is arranged on both sides of the fiber sheet 141. As a result, the matrix resin sheet 42 is arranged between the fiber sheets 41 or in the outermost layer (surface) of the laminated body 140.

The fiber sheet 141 has a rectangular shape, and a notch 141a is formed in the central portion. The notch 141a corresponds to, for example, a pump module (not shown) included in a rectangular parallelepiped tank body (not shown). The matrix resin sheet 142 has a shape and size capable of covering the fiber sheet 141, and here, it has a rectangular shape.

Since the arrangement step and the main molding step are the same as those in the first embodiment, the description thereof will be omitted. FIG. 10 shows an outline of the fiber reinforced resin member 121 completed by the method for manufacturing the fiber reinforced resin member of the second embodiment. FIG. 10 schematically shows the plane surface of the fiber reinforced resin member 121.

The fiber-reinforced resin member 121 is composed of a fiber-reinforced layer 131 and a matrix resin layer 132 formed on both sides of the fiber-reinforced layer 131, and the layers are alternately laminated. The notch 132a formed in the matrix resin layer 132 is formed by being pinched (sandwiched) by the molding die K, for example, in the main molding step. In the preparation step, the matrix resin sheet 142 in which the notch is formed may be prepared in advance and laminated.

The fiber reinforced layer 131 does not reach the outer edge of the fiber reinforced resin member 121, and a plurality of matrix resins (matrix resin sheet 142 (see FIG. 9)) are integrally formed on the outer edge of the fiber reinforced resin member 121. A hardened unreinforced portion 133 is formed. The unreinforced portion 133 is formed over the entire circumference of the outer edge of the fiber reinforced layer 131. That is, the fiber reinforced layer 131 is not exposed to the outside by the unreinforced portion 133.

According to the method for manufacturing the fiber-reinforced resin member according to the second embodiment described above, the same effect as the method for manufacturing the fiber-reinforced resin member according to the first embodiment is obtained.

Although the embodiments of the present invention have been described above, the design can be appropriately changed within a range not contrary to the gist of the present invention.

1 Tank body 3 Recesses 21,121 Fiber reinforced resin member 31,131 Fiber reinforced layer 32,132 Matrix resin layer 33,133 Unreinforced part 40,140 Laminated body 41,141 Fiber sheet 42,142 Matrix resin sheet (resin sheet)
T fuel tank K molding mold

Claims (5)

A preparation step of preparing a laminate of fiber sheets were laminated so as to sandwich a resin sheet fibers rather large in size than the fiber sheet is not contained,
Have a, and the molding step of compression molding the laminate to the fiber sheet is not exposed,
After the main molding step, a mounting hole is formed in a portion where the fiber sheet extends, and an unnecessary portion is cut in a region of an unreinforced portion outside the end portion of the fiber sheet. A method for manufacturing a fiber reinforced resin member. The method for manufacturing a fiber-reinforced resin member according to claim 1, wherein in the main molding step, the resin sheet is pinched by a molding die at a position outside the end of the fiber sheet. The laminate is composed of a plurality of the fiber sheets and a plurality of the resin sheets arranged between the plurality of fiber sheets and in the outermost layer.
The method for manufacturing a fiber-reinforced resin member according to claim 1 or 2, wherein in the preparation step, the size of only the resin sheet arranged in the outermost layer is made larger than that of the fiber sheet. With the tank body
A pair of fiber reinforced resin members that sandwich the outside of the tank body,
It has a fastening portion for fastening both ends of the pair of fiber reinforced resin members, and has.
The fiber-reinforced resin member, together with a matrix resin layer fiber-reinforced layer and the fibers are not contained is formed by stacking, the fiber reinforced layer is formed is unreinforced portion that is not interposed end ,
A fuel tank characterized in that a mounting hole for the fastening portion is formed in a portion where the fiber reinforced layer extends, and an unnecessary portion is cut in a region of the unreinforced portion. A fiber-reinforced layer and a matrix resin layer containing no fibers are laminated and formed, and an unreinforced portion in which the fiber-reinforced layer does not intervene is formed at an end portion .
A fiber-reinforced resin member characterized in that a mounting hole is formed in a portion where the fiber-reinforced layer extends, and an unnecessary portion is cut in a region of the unreinforced portion.

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