JPS6087018A - Compression molding stock of fiber reinforced plastic - Google Patents

Abstract

PURPOSE:To obtain compression molding stock with excellent moldability and strength of molded part by a structure wherein a high density layer is arranged on the outer periphery of a continuous section of circular prism, angular prism, circular cylinder or the like formed of tack-free material consisting in impregnating fibers with thermosetting resin. CONSTITUTION:Compression molding stock 2 of fiber reinforced plastic consists of a circular prism short fiber containing part 2a, the interior of which is made of matrix of thermosetting plastic and which is formed in semisolid state, and a long fiber layer 2b, which is impregnated with the resin having the quality samd as that of said plastic matrix and arranged on the outer periphery of the short fiber containing part 2a. The long fibers are wound onto the outer periphery of the part 2a with a certain angle, which is controlled at a proper angle so that the long fibers in the surface layer of a molded part is formed in a manner with sagging as small as possible due to the relationship between the amount of axial compression and the amount of peripheral swelling-out during the compression molding.

Description

[Detailed Description of the Invention] Fiber-reinforced plastics are widely used because they have excellent specific strength and other physical properties, and various molding methods are adopted depending on the target product.

Among these, bulk molded products with complex shapes are mainly produced by injection molding, but since the fiber content is usually limited to 60% or less, the strength and other physical properties of the molded product are also restricted. Another drawback is that long fibers cannot be effectively utilized in molded products.

In order to eliminate such drawbacks, the inventors of the present invention
We proposed a method for molding fiber-reinforced plastic in which uncured fiber-reinforced plastic material is placed in a closed mold and pressure-molded, and the mold temperature is controlled to complete the curing reaction of the plastic.

The present invention was proposed with the aim of providing a material suitable for such a method of molding fiber-reinforced plastics, and includes cylinders, square columns, and cylinders molded from a tack-free material in which fibers are impregnated with resin. The invention is characterized in that a high fiber density layer is provided at a required portion such as the outer periphery of the continuous cross-sectional body.

The fiber-reinforced plastic material for compression molding according to the present invention is constructed by pre-molding fibers impregnated with resin into a tack-free state (so-called B stage) into a continuous cross-sectional body such as a cylinder or a prismatic-cylindrical shape. Therefore, there are other molding methods, such as sheet molding, bulk molding, etc. Compared to methods using the sound or layup method, there are fewer air bubbles mixed into the material, the physical properties such as strength are improved, and there is less variation in quality.

When compression molding is performed using the above material, the flow distance is short, so it is possible to smoothly flow and deform it with a smaller force than in the normal compression molding method, and therefore molded products with complex shapes can be formed. It is possible to mold with high precision, it is possible to mold with a high fiber content, the occurrence of paris is reduced, and vJ
Separate yield is good. Moreover, since Hamura with fewer pores can be used, the pores in the molded article are also reduced, and a molded article with excellent physical properties can be obtained.

Furthermore, in the present invention, a high fiber density layer is provided at required parts where strength is required, such as the outer circumference and inner circumferential surface of the continuous cross-sectional body such as a cylinder, a prism, or a cylinder molded from a thermosetting resin. The present invention has many advantages, such as improved strength and rigidity, stronger physical properties such as wear resistance, and improved physical properties of molded products.

The present invention will be described below with reference to the illustrated embodiments.

g! shown in Figures 1 and 2! The cylindrical short fiber-containing part (2) made of reinforced plastic for compression molding is semi-hardened with a plastic matrix inside.
α) and a long fiber layer (21) whose outer periphery is impregnated with a resin of the same quality as this plastic matrix. At this time, the long fibers are wound around the outer periphery at a certain angle, and this wrapping angle is determined by the relationship between the amount of axial compression during compression molding and the amount of expansion in the circumferential direction, so that the long fibers are long on the surface layer of the molded product after molding. The fibers are adjusted to an appropriate angle so that they are molded with as little slack as possible.

Figures 6 and 4 show other embodiments of the material, in which the resin-impregnated long fiber layer disposed on the outer peripheral surface of the material (3) is formed of two layers of (3h)C30). , the winding angles are in opposite directions. In addition, the material shown in Figure 26 (8
) is a cylindrical braided product (8α) of long fibers impregnated with resin on the outer periphery.
) is arranged.

Figures 5 and 6 show other embodiments of the flooring material, in which strips (4α) made by cutting woven fabric, non-woven fabric mats, paper products, etc. into tape shapes and impregnating them with resin are used as a matrix of plastics. A cylindrical short fiber-containing part (2a
) is wound around the outer periphery to form a pile (4).

Figure 7 is a diagram corresponding to Figure 6, and there are two layers of resin-impregnated strips (4α) C4b) wrapped around the outer periphery of the cylindrical short fiber-containing part (2 cL). I've been asked.

The winding directions are, for example, opposite to each other.

The material (5) shown in Figure 8 is a cylindrical short fiber containing part (20
For example, (5α) is a long fiber layer impregnated with a resin or a high fiber density layer obtained by cutting a woven fabric, a nonwoven fabric mat, a paper product, etc. into a tape shape and impregnating it with a resin.

It is arranged in two layers as shown in (5b). In FIG. 9, a high fiber density layer (6α) C6h) impregnated with resin is provided on the outer periphery of a cylindrical short fiber-containing portion (20α).

The material (7) shown in Figure 10 is a prismatic short fiber containing part (2) formed into a semi-hardened plastic matrix.
1α), long fibers i(7α) impregnated with resin are arranged on the outer periphery of the fibers 1α).

Here, the fibers of long and short fibers, woven fabrics cut into tape shapes, non-woven mats, paper products, etc. include vertical cords, inorganic fibers such as glass, metals, ceramics, organic fibers such as aramid fibers, and various whiskers. etc. are used, and the arrangement and number of layers of long fibers and tapes are selected depending on moldability and purpose of use.

On the other hand, thermosetting resins such as epoxy resins, unsaturated polyester resins, polyimide resins, vinyl ester mfk, and phenol resins can be used as the plastic matrix.

At the material stage, the matrix plastic is placed in a semi-cured B stage depending on its type, or in a state in which it retains fluidity suitable for molding by adding a thickener. Furthermore, stabilizers, curing accelerators, mold release agents, colorants, fillers, etc. may be added as necessary.

In the above explanation, the core material is explained as consisting of a short fiber-containing part formed in a semi-hardened plastic matrix, but this may also be a resin itself that does not contain short fibers (・.

Figures 11 and 12 show the spur gear (1) shown in Figure 16.
The molding process is shown in which M (401 is an upper and lower mold, and a molding gap 6 (It) is provided between both molds. Also, a ring) C0 is an upper and lower punch.

Then, as shown in Fig. 11, the upper mold (to) and the lower mold (to)
Place the material (2; shown in FIG. 1 above) between the
In this state, force is applied to both molds C30) (4i to close the molds, and the upper punch 60) and lower punch ffO+ pressurize the material (2) to compress the same material (2) as shown in Figure 12. It is deformed and the empty ring is filled with fiber-reinforced plastic to form it into the shape of a spur gear (1).

On the other hand, the mold 0Q is controlled at a predetermined temperature depending on the material and shape of the cable trunk (2), especially the material of the matrix and the shape of the molded product, and held for a predetermined time to complete the hardening of the plastic, and then molded. Open the mold and take out the molded product.

Fig. 14 is an explanatory diagram showing the fiber arrangement on the surface of the spur gear (1) using the cable trunk (2), and (2b) shows long fibers, but in reality, the long fibers around the outer periphery of the material are arranged in a predetermined manner. It is molded in a densely arranged state.

FIG. 15 shows the surface of a spur gear (9) formed in the same manner as the fiber (3) shown in FIG.
3b) are disposed in a cross-shaped manner on the surface layer. Further, this molded product can be similarly obtained from the cable trunk (8) shown in FIG. 26.

In addition, in this molding process, the material (4) shown in Fig. 5, which is wrapped with tape-shaped woven fabric, non-woven fabric mat, paper product, etc., may also be used instead of the material (2). can.

Figures 16 and 17 show a molding method for forming a shaft hole in the boss portion of a spur gear. is placed between the upper and lower molds (13) (14), and a tubular upper and lower punch α5
1 (16), the material (5) is compressed, and the shaft hole forming shaft aη is passed through the hollow part of the lower punch (L6) and inserted into the hollow part of the upper punch aω, and the shaft hole is formed by the coaxial αη. , a gear with a shaft hole (one is molded).

Note that α barrel in the figure is a molding gap formed between the upper and lower molds (1:(l(14)).

Figure 18 shows a gear with a shaft hole (the shaft hole in the wing is made of a spline), and a high fiber density layer is also formed on the spline part by using the grout (6) shown in Figure 9 to increase the strength and strength. This is an example of improved wear resistance.

Figure 19 shows a fiber-reinforced plastic spur gear (26) with a metal sheath shaft (c) integrally molded, and Figure 20 shows a fiber-reinforced plastic bevel gear (26) with a metal bushing (c) having a keyway. Fig. 21 shows a fiber-reinforced plastic cam (c) equipped with a metal bushing Q7) having a keyway, and although not shown in these cases, the shaft hole forming shaft ( It is sufficient to consider that the tip portion at 1 is integrated with the fiber-reinforced plastic moon as a nest.

FIGS. 22 and 23 show the case of molding a flat molded product Ca 50) as shown in FIGS. 24 and 25, respectively, and the rectangular material shown in FIG.
7), compress the same material (7) with a continuous concave surface laterally using the upper and lower punches (C), and press the same material (7) into the molding gap (to) between the upper and lower molds 0 and 02. The molded article is molded by filling the molded article with water. In addition, in FIG. 23, a cross-sectional portion of the molded product is shown, which corresponds to the section AA in FIG. 24.

In this way, in the present invention, the # phase is formed into a continuous cross-sectional body such as a cylinder, a prism, or a cylinder before use, so compared to other forming methods, there are fewer air bubbles mixed in, and physical properties such as strength are improved. improved, and the variation in quality is reduced.

Furthermore, since force is applied near the portion to be deformed during compression molding, the force required for deformation is smaller than in normal compression molding methods, and therefore materials with a high fiber content can be molded.

In addition, since a high fiber density layer is placed in areas where strength is required, such as the outer periphery of the continuous cross-sectional body, strength and rigidity are improved, and physical properties such as abrasion resistance are strongly expressed, making it possible to improve the quality of molded products. Physical properties improve.

Although the molding example using a closed mold has been described above, similar effects can be obtained using a normal non-closed mold.

Although the present invention has been described above with reference to embodiments, the present invention is, of course, not limited to such embodiments, and can be modified in various ways without departing from the spirit of the present invention. .

[Brief explanation of drawings]

FIG. 1 is a perspective view of one embodiment of the fiber-reinforced plastic compression molding material according to the present invention, FIG. 2 is a vertical sectional view thereof, and FIG. 6 is a perspective view of another embodiment of the material according to the present invention. , FIG. 4 is a partially enlarged longitudinal view of the material, FIG. 5 is a perspective view showing the state of the manufacturing process of another embodiment of the material according to the present invention, and FIGS. 6 and 7 are partial longitudinal sections of the same material. A plan view, FIGS. 8 and 9 are longitudinal cross-sectional views showing other embodiments of the material according to the present invention, and FIG. 10 is a perspective view of still another embodiment of the material according to the present invention.
FIG. 11 and FIG. 12 are longitudinal cross-sectional views showing the steps of a method for hydroforming fiber-reinforced plastic using the above-mentioned material, respectively;
FIG. 16 is a perspective view of a molded product formed using the above material, FIGS. 14 and 15 are partially enlarged views thereof, and FIGS. 16 and 17 are views of a hydraulic molding method using the above material, respectively. FIGS. 18 to 20 are vertical cross-sectional views showing the steps of the example shown in FIG. FIGS. 22 and 26 show further illustrations of the hydroforming method using the above materials, respectively. FIGS. 24 and 25 are longitudinal cross-sectional views showing the steps of 10 examples, respectively. FIG. 24 and FIG. 25 are slope views of each molded product formed from the above-mentioned materials, and FIG. 26 is a slope view of still another example of the sorium according to the present invention. It is a diagram. (2) -- Material, (2h) ... Long fiber layer, (3J
-51, (3bX3c)... long fiber layer, (4)...
Material, (4α)<46)...Strip, (5)...Material, (5aX5A)--High fiber density layer, (6)--Cumulative moon, (5cL bar 6b)... High fiber density layer, (7)...
・Material, (7α)...long fiber layer, (8)-...material,
(8α)...Sub-agent for long fiber tubular braided products Patent attorney
Shigeru Okamoto, 6 extra-literary names, 10 illustrations, 11 illustrations, 13 illustrations, 12 illustrations, 14 illustrations, 19 illustrations, 21 wards procedural amendments (self-motivated), IMJ, 5th Peace, January 15th, Commissioner of the Patent Office, Kazu Wakasugi. Husband 1, Indication of the case 1982 Patent Kenbe No. 195194 2, Title of the invention Fiber reinforced plastic compression molding material 3, Relationship with the person making the amendment Case Patent applicant (820) Mitsubishi Heavy Industries, Ltd. 4 , Sub-Agent 5, - Subject of amendment Statement 6, Contents of amendment As shown in Attachment 7, Contents of amendment Correct with "Molding Compound". (2) Add "," next to "chill resin" on page 6, line 4. (3) "Hydrostatic molding method" in lines 4, 8, and 13 of page 11 will be corrected to "compression molding method."

Claims (1)

[Claims] A resin-impregnated high fiber density layer is placed on the outer periphery, inner periphery surface, etc. of a continuous cross-sectional body such as a cylinder, square column, cylinder, etc. molded from tack-free thermosetting resin. A material for compression molding of delicate reinforced plastic characterized by: