JPH074880B2 - Resin impregnated fiber base material and method for producing fiber reinforced plastic - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a resin-impregnated fiber base material and a method for producing a fiber-reinforced plastic, and more specifically, a resin having excellent mechanical properties and flame retardancy and little anisotropy. The present invention relates to an impregnated fiber base material and a method for producing a fiber-reinforced plastic using the same.

[Conventional technology]

Conventionally, as a molding method for fiber reinforced plastics (hereinafter abbreviated as FRP), there is known a pultrusion molding method in which a resin-impregnated fiber reinforced material is continuously drawn into a heating die hole and allowed to run in the axial direction of the die for curing. ing. This method is easy to automate by continuous molding, suitable for mass production, and the equipment cost and mold cost are relatively low.
Production is rapidly increasing. In particular, FRP, which has excellent electrical insulation properties, light weight, and mechanical properties, with flame resistance added, is used for electrical equipment such as insulating ladders, covers for third railroad trains, and various corrosion-resistant base materials and trailers for chemical plants. It is used in large quantities in transportation equipment such as side walls and bus trim parts.

As the fiber reinforcement used for FRP, continuous strand mats and rovings are used mainly because of their excellent workability and mechanical properties. However, since the fiber reinforced material is arranged in the drawing direction, the strength and elastic modulus of the molded product in the drawing direction are high, but the mechanical properties in the lateral direction perpendicular to the drawing direction are extremely low, showing a large anisotropy, It has a drawback that it cannot be used when strength or rigidity is required in a direction other than the direction.

In order to solve this drawback, woven cloth such as roving cloth is used as part of the fiber reinforcement to improve the mechanical properties in the transverse direction.Even with this method, the mechanical properties in the drawing direction and the transverse direction are the same. It was difficult to do.

Further, when imparting flame retardancy to FRP, a resin mixture containing an inorganic filler such as aluminum hydroxide is used, but since this mixture has a high viscosity, a woven fabric such as roving cloth is used as a fiber reinforcement material. However, when the resin mixture is used, the impregnating ability of the resin mixture into the fiber is poor, and the mechanical properties of the molded product are significantly deteriorated.

[Problems to be Solved by the Invention]

An object of the present invention is to solve the above-mentioned problems of the prior art and to produce a resin-impregnated fiber base material which is excellent in mechanical properties and flame retardancy and which produces a fiber-reinforced plastic with little anisotropy, and a fiber-reinforced plastic using the same. To provide a manufacturing method of.

[Means for Solving the Problems]

The present invention relates to a resin liquid in which at least one layer of a pair of laminated layers composed of a mat and a cloth and the mat layer are mat layers on both outermost layers, and the mat layers and the cloth layers are alternately positioned. The resin-impregnated base material and the resin-impregnated fiber base material obtained by laminating with the impregnating roller are continuously drawn into the heating die hole, and the resin is hardened and pulled out while running in the die axial direction. The present invention relates to a method for producing a fiber-reinforced plastic, which uses the resin-impregnated fiber base material.

Mats and cloths are used as the fiber reinforcement of the resin-impregnated fiber base material used in the present invention. A chopped strand mat, a continuous mat, or the like can be used as the mat, and a roving cloth or the like can be used as the cloth, but it is preferable to use a combination of the continuous mat and the roving cloth from the viewpoint of moldability. The type of fiber reinforcement is not particularly limited, but glass fiber is preferable from the viewpoint of cost.

Thermosetting resins such as unsaturated polyester resins and epoxy resins are used in the resin liquid used in the present invention, and unsaturated polyester resins are preferable from the viewpoint of moldability.

The above resin liquid contains 5 parts of inorganic filler per 100 parts by weight of resin.
It is preferable to use a mixture of 0 parts by weight or more, and more preferably 50 to 100 parts by weight from the viewpoint of the appearance and mechanical properties of the molded product. As an inorganic filler, calcium carbonate,
Aluminum hydroxide, clay, glass powder and the like are used, but when the molded product is required to have flame retardancy, it is preferable to use aluminum hydroxide.

A curing agent, a curing accelerator, a low-contraction agent, a coloring agent, a release agent, and the like are added to the resin liquid, and the mixture is used as a resin mixture.

In the present invention, the mat and the cloth as the fiber reinforcing material have the same mechanical properties in the drawing direction and the transverse direction of the molded product, and in order to obtain a molded product with less deformation such as warp,
Except for one layer mat, it is used as a mat and cloth pair,
Moreover, both surfaces of the outermost layer are mat layers, and the mat layers and the cloth layers are laminated so as to be alternately positioned. That is, at least one layer of a pair of laminated layers made of mat and cloth and the mat layer are drawn into the resin liquid in the above-described positional relationship, impregnated with the resin liquid by the impregnating roller, and laminated.

In the present invention, the mat and the cloth need to be laminated to form a pair of layers and drawn into the resin liquid.

When the cloth is drawn into the resin liquid alone without being laminated with the mat, the liquid adhering to the cloth surface is removed by the impregnating roller because the viscosity of the resin liquid is high, but the impregnation property into the cloth becomes very poor. In the present invention, since a pair of mats and cloths are drawn into the resin liquid and the mats are laminated adjacent to each other on both sides of the cloth, the matte having a high resin liquid retention rate is removed in the impregnation step. This resin liquid is transferred to and impregnated with the cloth, and the impregnation property of the resin into the cloth is improved.

The respective fiber reinforcing material layers drawn into the resin liquid are impregnated with the resin liquid by an impregnating roller to be laminated, and are continuously sent to a heating die hole to be cured to be a molded product. Since this molded product is obtained by stacking a plurality of the resin-impregnated fiber base materials described above, it has excellent mechanical properties and little anisotropy. The proportion of the mat and cloth in the molded product is preferably 25 to 40% by weight from the viewpoint of mechanical properties and moldability of the molded product.

FIG. 1 is a flow chart showing an example of an FRP manufacturing apparatus used in the manufacturing method of the present invention.

This apparatus comprises a resin tank 3 in which a resin liquid impregnating a plurality of fiber reinforcements (mat 1 and cloth 2) is stored, a guide plate 4 for guiding the fiber reinforcements installed in the resin tank 3, and An impregnating roller 5 which impregnates the fiber reinforcement with a resin liquid and removes an excess of the resin liquid and laminates it; a heating die 6 which impregnates the resin liquid and cures the laminated resin-impregnated fiber base material; and a curing by the heating die 6. It comprises a driving device 10 for adjusting the drawing speed of the cured molded body 7 and a cutter 8 for cutting the cured molded body 7 into an appropriate length. It is preferable to install a large number of the impregnating rollers 5 in order to improve the impregnation of the resin liquid into the fiber reinforcing material. The length of the heating die is usually 500-150 mm
The drawing speed of the cured molded body 7 is usually 0.2 to 1.5 mm.
It is said to be about a minute.

In the example shown in FIG. 1, in the constitution, as the fiber reinforcement, the upper layer of the mat 1 is a cloth 2a and a mat 1a, a cloth 2b and a mat 1b, a cloth 2c and a mat 1c, a cloth 2d and a mat 1d and a cloth 2e. 5 layers of the mat and the mat 1e are set in order respectively, and these respective layers (6 layers) are drawn into the guide plate 4 in the resin layer 3 and pass through the resin liquid, and then the resin is impregnated by the impregnation roller 5. The liquid is impregnated, excess resin liquid is removed, and the layers are laminated and drawn into the heating die 6 to be cured. The drawing speed of the cured molded body 7 is adjusted by the drive device 8, and the cured molded body 7 is cut by the cutter 9 to form a molded product.

〔Example〕

 Hereinafter, the present invention will be described in detail with reference to Examples.

Example 1 As a device shown in FIG. 1, a pultruding machine (model: MC8000) manufactured by British Plutrex Co. and a width of 200 mm and a thickness shown in FIG.
A heating die 6 having a drawing shape dimension of 8 mm and a length of 1000 mm was used. The heating die 6 is provided with heaters at four positions before and after the upper and lower surfaces, and the die temperature on the drawing side is 130
℃, the die temperature of the outlet was set to 150 ℃.

200 mm wide continuous mat # 8624
(Manufactured by Asahi Fiber Glass Co., Ltd.), using 200 mm wide roving cloth FEWR-570 (manufactured by Fuji Fiber Glass Co., Ltd.) as the cloth, in order from the top layer [mat and cloth layer / mat and cloth layer / mat and cloth layer / mat. Cross layer /
Mat and cloth layer / mat and cloth layer / mat layer]
The layers (six layers and the mat layer) were drawn into the guide plate 4 of the resin tank 3.

The resin mixture shown in Table 1 is supplied to the resin tank 2 to drive it.
Run the pultrusion machine with a 10 pultrusion speed of 0.4 mm / min,
A molded product with a length of 2 m was produced. The characteristics of the obtained molded article (impregnating ability of a resin mixture with a cloth substrate, bending strength, bending elastic modulus, appearance and flame retardancy) were examined as follows,
The results are shown in Table 2.

(1) Impregnating ability of the cloth substrate: Visual observation.

(2) Bending strength: Measured according to JIS K 6911.

(3) Flexural modulus: Measured according to JIS K 6911.

(4) Appearance: Visual observation.

(5) Flame retardancy: Measured according to JIS A 1322.

Comparative Example 1 A guide plate obtained by laminating five layers of the fiber reinforcing material in Example 1 [mat and cloth and mat layer / cloth and mat and cloth layer / cloth and mat and cloth layer / mat and cloth and mat layer]. A molded product 9 was manufactured in the same manner as in Example 1 except that the molded product was pulled into No. 4, and the characteristics of the molded product were examined in the same manner as in Example 1. The results are shown in Table 2.

Comparative Example 2 In Example 1, the fiber reinforcing material was added to [mat and cloth layer /
Cross layer / cross layer / matte and cross layer / matte layer / cloth and matte layer / cross layer / cross layer / cloth and matte layer].
A molded product 9 was manufactured in the same manner as in 1. and the physical properties of the molded product were examined in the same manner as in Example 1. The results are shown in Table 2.

As is clear from Table 2, in Example 1 of the present invention, the impregnating property of the resin mixture into the cloth base material is good, and the anisotropy of the bending property in the drawing direction and the transverse direction perpendicular thereto is small, A molded product having a good appearance and excellent flame retardancy was obtained. On the other hand, in Comparative Example 1, the mat and the cloth and the mat or the cloth and the mat and the cloth are used as a pair, and the mat and the cloth are not used as a pair. Therefore, in Comparative Example 2, only the cloth is used without a pair, Impregnation into the cloth base material was poor, and voids were generated in the molded product, resulting in poor appearance and poor mechanical properties.

〔The invention's effect〕

According to the production method of the present invention, the mat layer and the cloth layer are alternately positioned as the fiber reinforcing material, and both surfaces of the outermost layer are the mat layers to improve the impregnation property of the cloth with the resin liquid. Therefore, it is possible to obtain a molded article having excellent mechanical properties and flame retardancy of the molding method and having little anisotropy.

[Brief description of drawings]

FIG. 1 is a flow chart showing an example of a fiber reinforced plastic manufacturing apparatus used in the manufacturing method of the present invention, and FIG.
It is a figure which shows the shape of the heating die used in the figure. 1, 1a, 1b, 1c, 1d, 1e ... Matt, 2a, 2b, 2c, 2d, 2e
... cloth, 3 ... resin tank, 4 ... guide plate, 5 ... impregnating roller,
6 ... Heating die, 7 ... Cured molding, 8 ... Driving device, 9 ...
cutter.

Claims (4)

[Claims] 1. A resin in which at least one of a pair of laminated layers of mat and cloth and the mat layer are mat layers on both sides of the outermost layer, and the mat layers and the cloth layers are alternately positioned. A resin-impregnated fiber base material obtained by impregnating a liquid and then laminating it with an impregnation roller. 2. A resin-impregnated fiber base material according to claim 1, wherein a thermosetting resin mixture containing 50 parts by weight or more of an inorganic filler is used as the resin liquid with respect to 100 parts by weight of the resin. 3. A method for producing a fiber-reinforced plastic in which a resin-impregnated fiber base material is continuously drawn into a heating die hole, and the resin is hardened and drawn while traveling in the die axial direction, wherein the resin-impregnated fiber base material is used. A method for producing a fiber-reinforced plastic, characterized by using the resin-impregnated fiber base material according to claim 1. 4. The method for producing a fiber-reinforced plastic according to claim 3, wherein a thermosetting resin mixture containing 50 parts by weight or more of an inorganic filler with respect to 100 parts by weight of the resin is used as the resin liquid.