JP7049616B2 - Manufacturing method of fiber reinforced resin molded product - Google Patents

Description

The present invention relates to a method for producing a fiber-reinforced resin molded product.

By mixing fibers such as carbon fiber and glass fiber with the resin raw material, the strength of the resin molded product is enhanced. The fiber-reinforced resin molded product is manufactured by, for example, a press molding method or an autoclave method.

In the press molding method (RTM method), the sheet-shaped fiber product is placed between a pair of male and female dies corresponding to the shape of the resin molded product to be manufactured, and the resin component is injected into the cavity and cured to form the fiber. Obtain a reinforced resin molded product.

In the autoclave method, the prepreg is placed on the mold corresponding to the molded product to be manufactured, the mold and the prepreg are placed in an airtight bag, and the whole bag is placed in the autoclave to pressurize and depressurize the inside of the bag. As a result, the mold and the prepreg are heated while being in close contact with each other to cure the thermosetting resin in the prepreg to obtain a fiber-reinforced resin molded product.

Further, as an improvement of the press molding method and the autoclave method, Patent Document 1 discloses a method for manufacturing a fiber reinforced resin molded product, which eliminates the need for an apparatus such as a hot press machine or an autoclave. In this method, the fiber-reinforced resin base material is placed on the inner surface of the mold, the core space of the fiber-reinforced resin base material mold is filled with a powder mixture containing a heat-expandable capsule, and the fiber-reinforced resin base material mold is sealed. After that, the air between the fiber reinforced plastic base material and the inner surface of the mold is exhausted and then heated.

Japanese Patent No. 6405433

However, as described above, all of these methods require an expensive mold, and thus are unsuitable for manufacturing inexpensive products, and have a problem that the processing process requires time and effort.

The present invention has been made in view of the above problems, and an object of the present invention is to provide a method capable of easily producing a fiber-reinforced resin molded product, and a fiber-reinforced resin molded product obtained thereby. There is something in it.

In order to achieve the above object, the method for producing a fiber-reinforced resin molded product according to the first aspect of the present invention is:
A coating step of coating at least a part of the three-dimensional model with a sheet-shaped fiber-reinforced resin base material containing reinforcing fibers and a matrix resin to obtain a laminate, and a coating step.
The laminated body and the powder are present inside the soft airtight container provided with the exhaust port, and the powder is present between the inner side surface of the soft airtight container and the laminated body , and the laminated body and the powder are present. The sealing process of filling and sealing so that the release material is placed between and
By exhausting the sealed soft airtight container, the inside of the soft airtight container is heated in a state where the three-dimensional model and the fiber-reinforced resin base material are in close contact with each other, and the fiber-reinforced resin base material is used as the three-dimensional model. The binding process to bind and
It includes a step of taking out a composite of the fiber-reinforced resin base material bonded to the three-dimensional model from the soft airtight container and removing the powder to obtain a fiber-reinforced resin molded product.

The powder is preferably a mixture of a plurality of types of powder.

In the sealing step, it is preferable to further fill the soft airtight container with a heat-expanding material.

The reinforcing fiber is preferably carbon fiber.

It is preferable that the three-dimensional model is a three-dimensional model modeled by a 3D printer.

According to the method for producing a fiber-reinforced resin molded product of the present invention, a high-strength fiber-reinforced resin molded product can be easily obtained.

The flow chart of the manufacturing method of the fiber reinforced resin molded article which concerns on 1st Embodiment. The schematic diagram which shows the coating process which concerns on 1st Embodiment. The schematic diagram which shows the laminated body which concerns on 1st Embodiment. The schematic which shows the sealing process which concerns on 1st Embodiment. The schematic diagram which shows the exhaust of the binding process which concerns on 1st Embodiment. The schematic diagram which shows the binding process which concerns on 1st Embodiment. The schematic diagram which shows the taking-out process which concerns on 1st Embodiment. Photographs of a three-dimensional model and a fiber-reinforced resin molded product according to an embodiment. The schematic diagram which shows the coating process and the sealing process which concerns on Example. The schematic which shows the sealing process which concerns on Example. The schematic which shows the sealing process which concerns on Example.

A method for producing a fiber-reinforced resin molded product according to an embodiment of the present invention will be described with reference to the drawings, but the present invention is not limited thereto.

As shown in FIG. 1, the present manufacturing method includes at least a coating step S1, a sealing step S2, a binding step S3, and a taking-out step S4. Each process will be described in detail below.

(Coating step S1)
In the coating step S1, as shown in FIG. 2, at least a part of the three-dimensional model 1 is coated with a sheet-shaped fiber-reinforced resin base material 4 containing the reinforcing fibers 2 and the matrix resin 3, and FIG. The laminated body 5 as shown in is obtained.

The three-dimensional molded product 1 is the basis of the shape of the fiber-reinforced resin molded product, and the composition and shape are not particularly limited as long as it has enough strength not to be deformed in the coating step S1, the sealing step S2, and the binding step S3. .. Examples of the composition include resin, ceramic, paper, metal, and wood material. The shape of the three-dimensional model 1 may have a hollow portion as shown in FIG. 2, but it may have a shape having an entrance / exit for filling the hollow portion with powder in the sealing step S2, which will be described later. preferable. It is preferable in terms of weight reduction of the fiber-reinforced resin molded product obtained when the three-dimensional model 1 has a hollow portion.

The three-dimensional model 1 is not limited depending on the manufacturing method thereof, but is preferably modeled by, for example, a 3D printer. By modeling with a 3D printer, it is possible to form a complicated shape that is difficult to form with a conventional mold, such as a three-dimensional shape having a hollow portion or a double ring shape. It is also suitable for small-quantity production.

The fiber-reinforced resin base material 4 is a sheet-like material containing the reinforcing fibers 2 and the matrix resin 3.

The reinforcing fibers 2 may be arranged in one direction in the fiber-reinforced resin base material 4, may be present in the form of a woven fabric such as plain weave, twill weave, or satin weave, or may be randomly dispersed.

The reinforcing fiber 2 is not particularly limited as long as it is a fiber that does not deteriorate at the heating temperature of the binding step S3, and examples thereof include carbon fiber, carbon nanotube, graphene sheet, cellulose nanofiber, glass fiber, and mineral fiber. Of these, carbon fiber is preferable in terms of the strength of the obtained fiber-reinforced resin molded product. The size of the reinforcing fiber 2 is not particularly limited, but for example, a fiber having a fiber length of several hundred nm or more and several mm or less can be used.

The reinforcing fiber 2 can be used alone or in combination of a plurality of types.

The matrix resin 3 is not particularly limited as long as it is a resin that has flexibility in the coating step S1 and can be bound in the binding step S3, but is a thermocurable resin such as an epoxy resin, an unsaturated polyester, or a phenol resin. Examples thereof include thermoplastic resins such as semi-curable resins, polyvinylidene chloride resins, acrylic resins, and AN copolymer resins.

The matrix resin 3 exists as a matrix (base material) between the fibers and around the fibers in the fiber reinforced resin base material 4.

As the fiber-reinforced resin base material 4, a commercially available prepreg in which the reinforcing fiber 2 is impregnated with the matrix resin 3 to form a sheet can be used. The prepreg is made by impregnating a reinforcing fiber with a thermosetting resin and heating or drying it to make it semi-cured, or by impregnating the reinforcing fiber with a molten thermoplastic resin and solidifying the thermoplastic resin. It is a sheet that has been made. For example, Toray Co., Ltd.'s Treca (registered trademark) as a thermosetting resin prepreg for carbon fiber reinforced plastic (CFRP) and Nittetsu Chemical & Materials Co., Ltd.'s TEPreg (registered trademark) as a CFRP thermoplastic resin prepreg. ) And other various prepregs can be used. The thickness of the fiber-reinforced resin base material 4 is not particularly limited, but is, for example, 0.07 mm or more and 0.2 mm or less.

The number of layers of the fiber reinforced resin base material 4 can be appropriately selected, and may be a single layer or a plurality of layers.

The fiber-reinforced resin base material 4 can be cut in advance with an ultrasonic cutter or the like to match the shape and unevenness of the three-dimensional model 1.

When the three-dimensional model 1 is coated with the fiber reinforced resin base material 4, if the three-dimensional model 1 forms an empty cylinder portion and has an outer surface and an inner surface, the required strength is used. , Either one or both sides of the outer surface and the inner surface can be covered.

When the three-dimensional model 1 and the fiber-reinforced resin base material 4 are in direct contact with each other for coating, the three-dimensional model 1 and the fiber-reinforced resin base material 4 can be bonded in the binding step S3 described later. Further, by partially providing a release layer between the three-dimensional model 1 and the fiber-reinforced resin base material 4 or by wrinkling and covering the fiber-reinforced resin base material 4, the three-dimensional model is partially formed. It is also possible to create a space between 1 and the cured fiber reinforced resin base material 4 so as not to bind them. The non-bonded portion can be a movable portion of the fiber reinforced resin molded product 14.

(Sealing step S2)
In the sealing step S2, as shown in FIG. 4, the laminated body 5 and the powder 8 are placed inside the soft airtight container 7 provided with the exhaust port 6, and the inner side surface of the soft airtight container 7 and the laminated body 5 are provided. It is filled and sealed so that the powder 8 is present between them.

The soft airtight container 7 is of a size capable of accommodating the laminated body 5 and the powder 8, and is not particularly limited as long as it is a flexible material capable of transmitting pressure between the outside and the inside of the soft airtight container 7. For example, a heat-resistant plastic bag as shown in FIG. 4, a tube container in which one end of the tube is closed, or the like can be used. The mouth of the bag serves as an entrance / exit for the laminated body 5 and the powder 8, and also functions as an exhaust port 6 by closing the pipe by sandwiching the pipe. In this way, the entrance / exit of the laminated body 5 or the like can be shared as the exhaust port 6, but the exhaust port 6 can be separately provided at a portion different from the entrance / exit of the laminated body 5 or the like.

The size, shape, and material of the powder 8 are not particularly limited as long as they have fluidity and thermal conductivity. As the powder 8, for example, an organic powder or an inorganic powder having an average particle size of 1 to 200 μm can be used. The powder 8 can be used alone, or a plurality of types of powder 8 having different particle sizes, shapes, and the like can be used. It is preferable to use a mixture of a plurality of types of powders having different particle sizes as the powder 8 because the filling property in the soft airtight container 7 is excellent and the powder 8 accompanying during degassing can be reduced. ..

In the sealing step S2, other members can be filled in addition to the powder 8. Other members include chopped fibers and thermal expansion materials.

When chopped fiber is used, chopped fiber cut into a fiber diameter of 1 to 20 μm and a length of 0.5 to 5 mm is preferable.

Examples of the heat-expandable material include heat-expandable microcapsules. When the heat-expandable material is used, the heat-expandable material expands due to heat during the curing step S3, and the pressure in the soft airtight container 7 is increased to improve the followability of the fiber-reinforced resin base material 4 to the shape of the three-dimensional model 1. Can be made to. The thermal expansion material can be used by uniformly mixing with the powder 8. Further, from the viewpoint of reusing the powder 8, it is preferable to wrap the heat-expandable material in an elastic packaging film or the like to form a stick shape, and arrange the heat-expandable material together with the powder 8 in the soft airtight container 7.

A release material such as thin paper can be arranged between the laminate 5 and the powder 8. By arranging the release material, the powder 8 can be easily removed in the extraction step S4. As the release material, films such as a fluororesin film and a silicone film are used.

As a method of filling and sealing the laminated body 5 and the powder 8 in the soft airtight container 7 so that the powder 8 exists between the inner side surface of the soft airtight container 7 and the laminated body 5, for example, The laminated body 5 is put in a soft airtight container 7, the empty cylinder portion of the laminated body 5 and the powder 8 are filled around the laminated body 5, and a pipe is provided at the entrance / exit (exhaust port 6) of the laminated body 5 and the powder 8. It is sandwiched and sealed (see FIG. 4).

(Bundling step S3)
In the binding step S3, as shown in FIG. 5, the sealed soft airtight container 7 is exhausted to heat the inside of the soft airtight container 7 in a state where the three-dimensional model 1 and the fiber reinforced resin base material 4 are in close contact with each other. The fiber reinforced resin base material 4 is bound to the three-dimensional model 1.

When the gas 9 (air) is exhausted from the exhaust port 6 of the sealed soft airtight container 7, the soft airtight container 7 contracts at the outside air pressure 10, and the outside air pressure 10 passes through the soft airtight container 7 and the powder 8 to form a three-dimensional object. 1 and the fiber reinforced resin base material 4 are brought into close contact with each other. The presence of the powder 8 prevents the convex portion of the three-dimensional model 1 from coming into direct contact with the soft airtight container 7, and evenly transmits the external air pressure 10 to the entire surface including the concave portion of the fiber reinforced resin base material 4. The gap between the three-dimensional model 1 and the fiber-reinforced resin base material 4 is filled and brought into close contact with each other. The powder 8 transfers pressure and heat and functions as a gas flow path during exhaust.

Exhaust can be performed directly from the exhaust port 6 with a decompression pump 11 or the like, but as shown in FIG. 5, a trap 12 for capturing the accompanying powder 8 may be provided between the decompression pump 11 and the exhaust port 6. preferable.

As shown in FIG. 6, the heating in the soft airtight container 7 can be performed by putting the soft airtight container 7 in a state where the three-dimensional model 1 and the fiber reinforced resin base material 4 are in close contact with each other in the oven 13. Further, a heater may be arranged inside the soft airtight container 7 to heat the container.

The heating temperature is not particularly limited as long as it is the temperature at which the fiber-reinforced resin base material 4 is bound, and can be appropriately selected depending on the type of the matrix resin 3 to be used. For example, the temperature can be set to room temperature or higher and 200 ° C. or lower.

The above-mentioned exhaust is preferably performed even during heating. Gas may be generated when the fiber-reinforced resin base material 4 is bound, and by exhausting the gas, the three-dimensional model 1 and the fiber-reinforced resin base material 4 can be kept in close contact with each other.

By binding the fiber-reinforced resin base material 4, the composite body 14 is formed by integrating the three-dimensional model 1 of the laminate 5 and the fiber-reinforced resin base material 4.

(Extraction process S4)
In the take-out step S4, as shown in FIG. 7, the composite 14 of the three-dimensional model 1 and the fiber-reinforced resin base material 4 is taken out from the soft airtight container 7, and the powder 8 is removed to obtain the fiber-reinforced resin molded product 14. ..

The removed powder 8 and the soft airtight container 7 can be reused.

The fiber-reinforced resin base material 4 in the fiber-reinforced resin molded product 14 is firmly bonded to the three-dimensional model 1 due to the anchor effect of the surface unevenness of the three-dimensional model 1. Therefore, it is not necessary to remove the three-dimensional model 1 in the fiber-reinforced resin molded product 14, but it can also be removed by polishing or the like.

Since the fiber reinforced resin molded product 14 has the shape of the three-dimensional model 1 and has the strength of the fiber reinforced resin used as it is, it is possible to manufacture products of various shapes and sizes, and it is possible to manufacture custom-made medical tools and robots. It can be used for various purposes such as parts.

(Example)
Examples of the present invention will be described, but the present invention is not limited thereto. Here, a thermosetting resin is used as the matrix resin, and in the binding step, the three-dimensional model and the fiber reinforced resin base material are bound by curing the thermosetting resin.
Further, an example of molding one fiber reinforced resin molded product in one soft airtight container is shown, but the present invention is not limited to this, and even if a plurality of fiber reinforced resin molded products are molded in one soft airtight container. good.

A three-dimensional model 1 in the shape of an orthotic device shown in FIG. 8 (left) was modeled with a 3D printer. This prosthesis device can be fitted to a finger and can be bent at the notch portion 15.

Next, a sheet-shaped CFRP (Carbon Fiber Reinforced Plastic) prepreg was processed according to the shape of the three-dimensional model 1 to prepare a fiber reinforced resin base material 4. The fiber-reinforced resin base material 4 is processed into a tubular shape, and the fiber-reinforced resin base material 4 can be coated on the three-dimensional modeled object 1 by inserting the three-dimensional modeled object 1 (see FIG. 9).

The fiber-reinforced resin base material 4 is coated on the three-dimensional model 1 to form a laminate 5, then wrapped with a thin packaging material (release material 16), and the inside of the three-dimensional model 1 is filled with powder 8 and sealed. The package 17 was created (see FIG. 9). The powder 8 is an inorganic powder having an average particle size of 1 to 200 μm, and is a mixture with chopped fibers having a fiber diameter of 1 to 20 μm and a length of 0.5 to 5 mm.

Next, the three heat-expanding materials 18 were evenly arranged around the package 17 and packaged with the powder 8 in a thin packaging material (separation material 19) to prepare the package 20 (see FIG. 10). The heat-expandable material 18 is obtained by filling a heat-expandable microcapsule in an elastic packaging film and packaging it in a stick shape.

Next, the package 20 was placed in a soft airtight container 7. The soft airtight container 7 is an airtight heat-resistant sheet and includes an exhaust port 6. The powder 8 was filled around the package 20 and closed by passing the hose 21 through the exhaust port 6 (see FIG. 11). The hose 21 was connected to a decompression pump via a trap 12 to exhaust gas and depressurize. By reducing the pressure, the gap between the three-dimensional model 1 and the fiber-reinforced resin base material 4 disappears, and the external air pressure is evenly applied to the fiber-reinforced resin base material 4 via the powder 8, so that the three-dimensional model 1 and the fiber-reinforced resin base material 4 are reinforced. The resin base materials 4 are in close contact with each other.

Next, the soft airtight container 7 was placed in an oven, and the soft airtight container 7 was heated while reducing the pressure to cure the fiber-reinforced resin base material 4.

Next, the composite of the three-dimensional model 1 and the fiber-reinforced resin base material 4 was taken out from the soft airtight container 7, and the powder 8 was removed to obtain a fiber-reinforced resin molded product 14. FIG. 8 shows a three-dimensional model 1 (left) and a fiber-reinforced resin molded product 14 (right). In addition, in the fiber-reinforced resin molded product 14 of FIG. 8, the portion corresponding to the cutout portion 15 of the three-dimensional model 1 of the fiber-reinforced resin base material 4 is cut out after binding. The cutout portion 22 of the fiber-reinforced resin molded product 14 showed flexibility like the three-dimensional model 1. The fiber-reinforced resin molded product 14 is lightweight but has the strength derived from the fiber-reinforced resin base material 4.

The present invention allows for various embodiments and modifications without departing from the broad spirit and scope of the invention. Further, the above-described embodiments are for explaining the present invention, and do not limit the scope of the present invention. That is, the scope of the present invention is shown not by the embodiment but by the scope of claims. Then, various modifications made within the scope of the claims and within the scope of the equivalent invention are considered to be within the scope of the present invention.

1 Three-dimensional model 2 Reinforcing fiber 3 Matrix resin 4 Fiber reinforced resin base material 5 Laminated body 6 Exhaust port 7 Soft airtight container 8 Powder 9 Gas 10 External pressure 11 Decompression pump 12 Trap 13 Oven 14 Composite (fiber reinforced resin molding) Product)
15 Notch part 16 Detachable material 17 Packaged material 18 Thermal expansion material 19 Demolded material 20 Packaged material 21 Hose 22 Notch part S1 Coating process S2 Sealing process S3 Binding process S4 Extraction process

Claims (5)

A coating step of coating at least a part of the three-dimensional model with a sheet-shaped fiber-reinforced resin base material containing reinforcing fibers and a matrix resin to obtain a laminate, and a coating step.
The laminated body and the powder are present inside the soft airtight container provided with the exhaust port, and the powder is present between the inner side surface of the soft airtight container and the laminated body , and the laminated body and the powder are present. The sealing process of filling and sealing so that the release material is placed between and
By exhausting the sealed soft airtight container, the inside of the soft airtight container is heated in a state where the three-dimensional model and the fiber-reinforced resin base material are in close contact with each other, and the fiber-reinforced resin base material is used as the three-dimensional model. The binding process to bind and
A step of taking out a composite of the fiber-reinforced resin base material bonded to the three-dimensional model from the soft airtight container and removing the powder to obtain a fiber-reinforced resin molded product.
A method for manufacturing a fiber-reinforced resin molded product, including. The method for producing a fiber-reinforced resin molded product according to claim 1, wherein the powder is a mixture composed of a plurality of types of powder. The method for producing a fiber-reinforced resin molded product according to claim 1 or 2, wherein in the sealing step, the soft airtight container is further filled with a heat-expanding material. The method for producing a fiber-reinforced resin molded product according to any one of claims 1 to 3, wherein the reinforcing fiber is carbon fiber. The method for manufacturing a fiber-reinforced resin molded product according to any one of claims 1 to 4, wherein the three-dimensional model is a three-dimensional model formed by a 3D printer.

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