JPH09201880A - Manufacture of fiber-reinforced plastic having insert - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture an FRP molded product in which shrin by setting is inhibited to produce hardly sink, appearance is beautiful, and strength is excellent by a method wherein a preform fiber-board of a width larger than a height of an insert is so set that its width direction corresponds to a height direction of the insert. SOLUTION: A preform fiberboard 16 having a width of about 1.2 times a height of an insert 23 is set in a space of a male mold preform 14, a female mold preform 15, and an insert 23 so that its width direction becomes a height direction. A resin composition in which about 100 pts.wt. of polyset 7020AP and about 60 pts.wt. of sun light 300 are mixed, is mixed in Permec N18 at a tip of an injection gun 20, and injected into a mold. Resin composition for molding FRP is set at ordinary temperature under this state to obtain FRP molded product. Oceasrence of sink of the FRP molded product is inhibited thus, and the FRP molded product which is free from molded defects is manufactured.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a fiber reinforced plastic having an insert.

[0002]

2. Description of the Related Art Fiber reinforced plastics (hereinafter referred to as FRP), which is a composite of resins such as unsaturated polyester resin using fibers as a reinforcing material, are widely used for housing materials, boats, industrial crosspieces, electric parts, automobile parts, etc. It is an essential material for modern life. Some FRP molding methods use a preform. The preform is obtained by preliminarily molding the reinforcing material fibers into the shape of a molded product. As a molding method using a preform, there are a matched metal die method, a resin injection method, a vacuum assisted resin injection method, a cold press method, a back method and the like.

When manufacturing an FRP molded product having an insert, a reinforcing material (preform) and an insert arranged in the shape of the mold are set in a space formed by a male mold and a female mold, and a resin is molded in the mold. Inject and cure.
In this case, there may be a space between the preform and the insert. In such a case, if you inject and cure the resin while leaving the space as it is, a part of the preform that is not impregnated with the resin will be created, so set the plate-shaped reinforcing fiber (glass fiber board) in this space. ing. And when the space is large, glass fiberboards are laid down side by side and stacked. The glass fiber board set in the space between the preform and the insert is manufactured in the same manner as the prepreg foam.

[0004]

However, if the glass fiberboards are laid sideways on top of each other and set so that they cannot be stacked more than the height of the insert, the space between the insert and the glass fiberboard is set. Sinking occurred severely and there was a problem in appearance. If the glass fiber board is laid sideways and stacked over the height of the insert, when setting the preform, the glass fiber board on the upper side shifts sideways and covers the insert, impairing the appearance after molding. Further, since the glass fiber board is manufactured by the same method as the preform, the fibers are oriented in the plane direction, and it is difficult to be compressed in the thickness direction. For this reason, it is difficult to compress after setting in the space. In order to solve such a problem, a method of reducing the shrinkage of the resin is generally taken, but FRP is used.
There is a problem that the strength of the molded product is reduced. The present invention provides a method for producing an FRP using a fiber-reinforced preform, which can suppress the occurrence of sink marks in the FRP molded article, which is a problem of the above-mentioned conventional techniques, and can produce an FRP molded article having no molding defect. Is.

[0005]

The present invention provides an insert 2
3, male preform 14 and female preform 15
The preformed fiber board 16 having a width larger than the height of the insert 23 is vertically inserted into the space formed by (1) so that the width direction is the height direction of the insert 23, and the molding resin is injected and cured. It is a method for producing a fiber-reinforced plastic having a characteristic insert (see FIG. 1). When the preform fiber board 16 is inserted upright so that the width direction is the height direction of the insert 23, when the male preform 14 is set, the preform fiber board 16 is pushed at a right angle to the orientation plane of the fibers. It will be. Preform fiberboard 16 against compression in the direction perpendicular to the orientation plane
Is easily deformed in the direction perpendicular to the compression, and the insert 23
Then, the space formed by the male preform 14 and the female preform 15 is deformed and packed to reduce the gap. As a result, the amount of resin required to fill the space formed by the insert 23 and the male preform 14 and the female preform 15 is small, and sink marks are less likely to occur.

[0006]

BEST MODE FOR CARRYING OUT THE INVENTION The insert 23 and the preform fiber board 16 inserted in the space formed by the male preform 14 and the female preform 15 have a width (average width) larger than the height of the insert 23. 1 to 1.3 times)
is required. Insert 23 and male preform 1
It is desirable to pack as many fibers as possible into the space formed by 4 and the female preform 15. Therefore, it is desirable to use a preform fiber board having a large width, but if the width is too large, the preform fiber board 16 falls on the upper surface of the insert 23, and the appearance of the FRP molded product deteriorates. The upper limit of the width varies depending on the height of the insert 23 and the strength of the waist of the preform fiber board 16, so it is necessary to preliminarily determine the optimum dimension by experiments or the like. Further, the thickness and the dimension of the insert 23 in the longitudinal direction are also selected so that the preform fiber board 16 can be set as densely as possible. In particular, the preform fiber board 16 is used in combination with a thin one as necessary so that no side surface void is formed.

The type of the reinforcing material used in the present invention is not particularly limited, and for example, glass fiber, carbon fiber, aramid fiber and the like are used. For these fibers, the long fibers 8 are cut by the cutter 6 on the preform molding screen die 1.
The short fiber 9 is cut by the above method, or the long fiber is not cut and is piled as it is, or at the same time, or after being piled, the aqueous emulsion adhesive 12 is sprayed or sprinkled, and dried to form a preform. (See FIG. 2). The insert 23 and the preform fiber board 16 inserted and set in the space formed by the male preform 14 and the female preform 15 are manufactured in the same manner. The preform fiber board 16 can be used in any of a mat shape such as a chopped strand mat and a continuous mat, and a cloth shape such as a glass cloth and a roving cloth. However, with the insert 23,
Independence is required when setting in the space formed by the male preform 14 and the female preform 15. A cloth-like material such as a glass cloth or a roving cloth having no self-supporting property is used by spraying or spraying the aqueous emulsion adhesive 12 and drying it to impart self-supporting property.

The preform molding screen die 1 has a small hole, and the reinforcing material deposited by the decompression device 3 which sucks and exhausts from one side of the screen die 1 is suction-held on the screen die 1. The screen die 1 has a predetermined shape to be molded, and the opening ratio of small holes is usually about 50%. As the material of the screen type, punching metal,
FRP or the like is preferably used.

In such a structure, first, the decompression device 3
To suck the screen mold 1. Screen type 1
The reduced pressure of (1) holds the aqueous emulsion adhesive 12 supplied from the reinforcing material 8 or 9 and the spray gun 7 on the inner surface of the screen mold. The amount of exhaust air during suction is proportional to the surface area of the mold, so it is appropriately monitored by the pressure gauge 5 and adjusted by the adjustment damper 4 so as to maintain an appropriate depressurized state. Thermosetting resin emulsion 10 and curing agent A1 diluted with water
It mainly comprises a spray gun 7 for spraying an aqueous emulsion adhesive 12 in which 1 is mixed onto the screen mold 1.

Next, the reinforcing material 8 is supplied to the upper surface of the screen die 1 in the depressurized state via the cutter 6. When glass roving or the like is used as the reinforcing material 8, it is cut into an appropriate length by the cutter 6 and supplied as a glass chop. In the glass chop, since the inner surface of the screen mold 1 is in a vacuum suction state, the screen mold 1
It is held on the upper surface. The glass roving or the like may be cut to an appropriate length, or may be continuously supplied without being cut.

As the aqueous emulsion adhesive 12, for example, a thermoplastic resin emulsion such as vinyl acetate resin or acrylic resin, or a thermosetting resin emulsion such as unsaturated polyester resin, vinyl ester resin or epoxy resin is used. When using a thermosetting emulsion, a curing agent is usually used together. When the thermosetting resin emulsion is used, the curing agent is supplied from the tank 11, mixed with the thermosetting resin emulsion by the spray gun 7, and supplied onto the screen mold 1.

The reinforcing fiber 9 and the aqueous emulsion adhesive 12 may be supplied simultaneously, and the glass chop 9
The aqueous emulsion adhesive 12 may be supplied on the above. For supplying the aqueous emulsion adhesive 12 and the glass chop 9 by spraying, the spray-up machine used in the spray-up method can be used as it is. After spraying or spraying the aqueous emulsion adhesive, it is usually dried at a temperature of 160 to 200 ° C.

In the resin injection method, the male preform 14, the female preform 15, the preform fiber board 16 and the insert 23 thus obtained are set in the RI mold 21, and the molding resin composition is prepared. 17 and the curing agent 18 are mixed and injected by the injection gun 20 (see FIG. 1). Male preform 14 and female preform 1
The periphery of 5 is pinched by pinch-off 22.

The method of supplying the molding resin composition into the mold is not limited to the resin injection molding method, and other molding methods such as the matched metal die method and the vacuum assist resin injection method can be used. After the injection, the resin composition for molding is cured at room temperature to obtain an FRP molded product. The R1 mold 21 may be heated to shorten the curing time.

The molding resin composition is not particularly limited, and an unsaturated polyester resin composition or the like is used, and other molding conditions are not particularly limited.

[0016]

The present invention will be described below in more detail with reference to examples.

Preparation of male preform 14, female preform 15 and preform fiber board 16. [Equipment specifications] Screen type for male preform: Width 800 mm, length 800 mm, depth 30 mm, with a recess, and material F
A female mold made of RP and having a porosity of 50% and a surface area of 2.0 m ² was used. Screen type for female preform: 600 mm in width, 600 m in length, and 27 mm in height with a convex portion, and material FR
A female mold made of P, having a porosity of 50% and a surface area of 2.0 m ² was used. Screen type for preform fiberboard: width 1000 mm,
A flat plate type having a length of 1000 mm, made of FRP, having a porosity of 50% and a surface area of 1.0 m ² was used. Decompression device (exhaust fan): Exhaust capacity 200 m ³ / min Aqueous emulsion adhesive and glass fiber supply device: Togiken Co., Ltd. spray-up machine Drying equipment: 180-200 ° C hot air circulation dryer

[Materials used] Reinforcing material: Nitto Boseki Co., Ltd. glass roving (RS-
240F-114AJ) Aqueous emulsion adhesive:
Unsaturated polyester resin emulsion (using Vinizole EP10Y manufactured by Daido Kasei Co., Ltd.) Curing agent: benzoyl peroxide (using Vinizol 9000 manufactured by Daido Kasei Co., Ltd.)

First, on the surface of the screen die 1, a fluorine-based release agent (Frecoat FRP: High Sol Aerospace and Industrial Division (HYSOL AER
ROSPACE & INDUSTRIAL PROD
A product name of UCTS DIVISION) was applied and a mold release treatment was performed. Next, the decompression device 3 was operated, and the decompression adjusting damper 4 was adjusted so that the atmospheric pressure became 2450 Pa.
Next, a glass chop obtained by cutting the glass roving 8 into 50 mm by the cutter 6 was adjusted by a spray-up machine in which the discharge capacity was adjusted to 3 kg / min, and the aqueous emulsion adhesive was also adjusted so that the blowing rate was 3 kg / min. A spray gun (spray-up machine) 7 was used to spray the screen mold 1 at the same time. The mixing ratio of the curing agent A in the aqueous emulsion adhesive 12 was set to 0.5% by weight. After the glass chop 9 and the aqueous emulsion adhesive 12 were sprayed until the spray amount of the glass chop became 4 kg, the glass chop was cured and dried with hot air at 200 ° C. for 3 minutes.

Preparation of FRP molded product [Specifications of equipment] Mold: FRP type for RI Injection machine: Venus HIS (manufactured by Venus) [Materials used] 1) Resin: unsaturated polyester resin (manufactured by Hitachi Chemical Co., Ltd., product Name Polyset 7010AP is used) 2) Resin (low shrinkage agent): (Hitachi Chemical Co., Ltd., trade name Polyset 646 used) 3) Filler: Calcium carbonate (trade name of Takehara Chemical Industry Co., Ltd.) Sunlight 300 is used.) 4) Curing agent: methyl ethyl ketone peroxide (using NOF Corporation's trade name Permec N)

EXAMPLE In the space between the male preform 14, the female preform 15 and the insert 23, a preform fiber board 16 having a width 1.2 times the height of the insert 23 is placed in the height direction. And set it so that Polyset 7020AP
Of 100 parts by weight and 60 parts by weight of Sunlight 300 were mixed, and a resin composition containing Permec N18 was injected at the tip of the injection gun 20.
And then poured into the mold. In this state, the FRP molding resin composition was cured at room temperature to obtain an FRP molded product.

Comparative Example 1 An FRP molded product was obtained in the same manner as in Example except that the preform fiber board 16 was set so that the width direction was horizontal.

Comparative Example 2 An FRP molded product was obtained in the same manner as in the example, except that the width of the preform fiber board 16 was 1.4 times the height of the insert 23. In this molded product, the glass fiber plate was broken and overlapped on the insert, and the portion was convex.

Comparative Example 3 The composition of the molding resin was changed to 70 parts by weight of Polyset 7010AP, 64630 parts by weight of Polyset, and 60 parts by weight of Sunlight 300. Set so that the width direction is horizontal)
An FRP molded product was obtained.

The appearance and bending strength of the molded products obtained in the examples and the comparative examples 1, 2 and 3 were examined. Table 1 shows the results. The thickness of each FRP molded product was 30 mm. The volume shrinkage of the resin used in Examples, Comparative Examples 1 and 2 was 7.5%, and the volume shrinkage of the resin used in Comparative Example 3 was 2.5%.

[0026]

[Table 1] ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━ Item Example Comparative Example 1 Comparative Example 2 Comparative Example 3 ─── ──────────────────────────── Molding appearance (mm) 0.03 0.2 0.03 0.01 Bending strength (MPa) ) 200 190 192 135 Bending elastic modulus (GPa) 11.2 10.5 10.8 5.8 Note) The molding appearance is a value obtained by measuring the sink mark size with a surface roughness meter. ━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━━

It can be seen from Table 1 that the molded articles of the examples have almost no sink marks and excellent bending strength. On the other hand, the molded product of Comparative Example 1 has a large sink mark, the molded product of Comparative Example 2 has a problem in appearance, and the molded product of Comparative Example 3 has a problem in bending strength.

[0028]

According to the present invention, a preform fiber board having a width 1.0 to 1.3 times the height of the insert is provided in the space formed by the male preform, the female preform and the insert. By setting so that the width direction is the height direction of the insert, it is possible to manufacture a FRP molded product which is suppressed in curing shrinkage and has a beautiful appearance with almost no sink mark and excellent strength.

[Brief description of drawings]

FIG. 1 is a cross-sectional view for explaining a set state of a preform according to an embodiment of the present invention.

FIG. 2 is a schematic explanatory view showing an example of a preform manufacturing apparatus.

[Explanation of symbols]

 14 Male preform 15 Female preform 16 Preform fiberboard 23 Insert

Claims (1)

[Claims] 1. A preform fiber board having a width larger than the height of the insert is erected in a space formed by the insert, the male preform and the female preform so that the width direction is the height direction of the insert. A method for producing a fiber-reinforced plastic having an insert, characterized in that the resin for molding is injected, and a molding resin is injected and cured.