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

Manufacturing method of fiber reinforced resin molded product Download PDF

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JP7049616B2
JP7049616B2 JP2019162348A JP2019162348A JP7049616B2 JP 7049616 B2 JP7049616 B2 JP 7049616B2 JP 2019162348 A JP2019162348 A JP 2019162348A JP 2019162348 A JP2019162348 A JP 2019162348A JP 7049616 B2 JP7049616 B2 JP 7049616B2
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reinforced resin
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molded product
dimensional model
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JP2021037733A (en
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勝利 滝澤
倫靖 鳥山
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/10—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies
    • B29C43/12—Isostatic pressing, i.e. using non-rigid pressure-exerting members against rigid parts or dies using bags surrounding the moulding material or using membranes contacting the moulding material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
    • B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
    • B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C64/00—Additive manufacturing, i.e. manufacturing of three-dimensional [3D] objects by additive deposition, additive agglomeration or additive layering, e.g. by 3D printing, stereolithography or selective laser sintering
    • B29C64/10—Processes of additive manufacturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C69/00—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore
    • B29C69/02—Combinations of shaping techniques not provided for in a single one of main groups B29C39/00 - B29C67/00, e.g. associations of moulding and joining techniques; Apparatus therefore of moulding techniques only
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/44—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using isostatic pressure, e.g. pressure difference-moulding, vacuum bag-moulding, autoclave-moulding or expanding rubber-moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B33—ADDITIVE MANUFACTURING TECHNOLOGY
    • B33Y—ADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
    • B33Y10/00—Processes of additive manufacturing

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Composite Materials (AREA)
  • Physics & Mathematics (AREA)
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Description

本発明は、繊維強化樹脂成形品の製造方法に関する。 The present invention relates to a method for producing a fiber-reinforced resin molded product.

樹脂原料に炭素繊維やグラスファイバーなどの繊維を混合することで、樹脂成型品の強度が強化される。繊維強化された樹脂成形品は、例えばプレス成型法、オートクレーブ法によって製造されている。 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.

プレス成型法（ＲＴＭ法）においては、シート状繊維品を、製造する樹脂成形品の形状に対応する雌雄一対の金型の間に配置し、キャビティに樹脂成分を注入して硬化することで繊維強化樹脂成形品を得る。 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.

オートクレーブ法においては、プリプレグを、製造する成形品に対応する金型の上に配置し、金型とプリプレグを気密性の袋に入れ、その袋ごとオートクレーブに入れて加圧しかつ袋内を減圧することで金型とプリプレグを密着させながら加熱し、プリプレグ中の熱硬化性樹脂を硬化させて繊維強化樹脂成形品を得る。 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.

また、プレス成型法やオートクレーブ法を改善したものとして、特許文献１には、熱プレス機やオートクレーブなどの装置が不要となる、繊維強化樹脂成形品の製造方法が開示されている。この方法では、繊維強化樹脂基材を型の内面に配置し、繊維強化樹脂基材型のコア空間部に熱膨張性カプセルを含む粉体混合物を充填し、繊維強化樹脂基材型を密閉した後、繊維強化樹脂基材と型の内面との間の空気を排気し、次いで加熱している。 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.

特許第６４０５４３３号公報Japanese Patent No. 6405433

しかしながら、これらの方法は、前述のとおり、いずれも高価な金型を必要とするため、安価な製品の製造には不向きであり、加工工程に手間を要するといった問題があった。 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.

本発明は、上記の問題に鑑みてなされたものであって、本発明の目的は、繊維強化樹脂成形品を容易に製造することができる方法、それによって得られる繊維強化樹脂成形品を提供することにある。 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.

前記目的を達成するため、本発明の第一の観点に係る繊維強化樹脂成形品の製造方法は、
立体造形物の少なくとも一部を、強化用繊維とマトリクス樹脂とを含有するシート状の繊維強化樹脂基材で被覆して積層体を得る被覆工程と、
排気口を備える軟質気密容器の内部に、前記積層体と粉体とを、前記軟質気密容器の内側面と前記積層体との間に前記粉体が存在し、かつ前記積層体と前記粉体との間に離形材を配置するように充填して封止する封止工程と、
封止した前記軟質気密容器を排気することで前記立体造形物と前記繊維強化樹脂基材とが密着した状態で前記軟質気密容器内を加熱して前記繊維強化樹脂基材を前記立体造形物と結着させる結着工程と、
前記軟質気密容器から前記立体造形物と結着した前記繊維強化樹脂基材との複合体を取り出すとともに前記粉体を取り除くことで繊維強化樹脂成形品を得る取出工程と、を含む。 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.

前記粉体は、複数種の粉体からなる混合物である、と好ましい。 The powder is preferably a mixture of a plurality of types of powder.

前記封止工程において、前記軟質気密容器内に、熱膨脹材を更に充填すると好ましい。 In the sealing step, it is preferable to further fill the soft airtight container with a heat-expanding material.

前記強化用繊維は、炭素繊維である、と好ましい。 The reinforcing fiber is preferably carbon fiber.

前記立体造形物は、３Ｄプリンタで造形した立体造形物である、と好ましい。 It is preferable that the three-dimensional model is a three-dimensional model modeled by a 3D printer.

本発明の繊維強化樹脂成形品の製造方法によれば、容易に高強度な繊維強化樹脂成形品が得られる。 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.

第一の実施形態に係る繊維強化樹脂成形品の製造方法の流れ図。The flow chart of the manufacturing method of the fiber reinforced resin molded article which concerns on 1st Embodiment. 第一の実施形態に係る被覆工程を示す概略図。The schematic diagram which shows the coating process which concerns on 1st Embodiment. 第一の実施形態に係る積層体を示す概略図。The schematic diagram which shows the laminated body which concerns on 1st Embodiment. 第一の実施形態に係る封止工程を示す概略図。The schematic which shows the sealing process which concerns on 1st Embodiment. 第一の実施形態に係る結着工程の排気を示す概略図。The schematic diagram which shows the exhaust of the binding process which concerns on 1st Embodiment. 第一の実施形態に係る結着工程を示す概略図。The schematic diagram which shows the binding process which concerns on 1st Embodiment. 第一の実施形態に係る取出工程を示す概略図。The schematic diagram which shows the taking-out process which concerns on 1st Embodiment. 実施例に係る立体造形物及び繊維強化樹脂成形品の写真。Photographs of a three-dimensional model and a fiber-reinforced resin molded product according to an embodiment. 実施例に係る被覆工程及び封止工程を示す概略図。The schematic diagram which shows the coating process and the sealing process which concerns on Example. 実施例に係る封止工程を示す概略図。The schematic which shows the sealing process which concerns on Example. 実施例に係る封止工程を示す概略図。The schematic which shows the sealing process which concerns on Example.

本発明の一実施形態に係る繊維強化樹脂成形品の製造方法について、図を参照しながら説明するが、本発明はこれに限定されない。 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.

本製造方法は、図１に示すように、被覆工程Ｓ１と、封止工程Ｓ２と、結着工程Ｓ３と、取出工程Ｓ４と、を少なくとも含む。以下各工程について詳細に説明する。 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.

（被覆工程Ｓ１）
被覆工程Ｓ１では、図２に示すように、立体造形物１の少なくとも一部を、強化用繊維２とマトリクス樹脂３とを含有するシート状の繊維強化樹脂基材４で被覆して、図３に示すような積層体５を得る。 (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.

立体造形物１は、繊維強化樹脂成形品の形状の元になるものであり、被覆工程Ｓ１、封止工程Ｓ２及び結着工程Ｓ３で変形しない程度の強度があれば組成や形状は特に限定されない。組成としては、樹脂、セラミック、紙、金属、木質材などが挙げられる。立体造形物１の形状は、図２に示すような空洞部分があるものであってもよいが、後述する、封止工程Ｓ２において空洞部分に粉体を充填する出入り口を有する形状であることが好ましい。立体造形物１に空洞部分があると得られる繊維強化樹脂成形品の軽量化の点で好ましい。 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.

立体造形物１は、その製造方法によっては限定されないが、例えば、３Ｄプリンタで造形することが好ましい。３Ｄプリンタで造形することで、空洞部分を有するような立体形状や二連リング形状のように従来の金型では成形することが困難な複雑な形状も成形することができる。また、少量生産にも好適である。 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.

繊維強化樹脂基材４は、強化用繊維２とマトリクス樹脂３とを含有するシート状の材料である。 The fiber-reinforced resin base material 4 is a sheet-like material containing the reinforcing fibers 2 and the matrix resin 3.

強化用繊維２は、繊維強化樹脂基材４中で一方向に並んでいても、平織、綾織、朱子織などの織物状で存在していても、無秩序に分散していてもよい。 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.

強化用繊維２としては、結着工程Ｓ３の加熱温度で劣化しない繊維であれば特に限定されず、炭素繊維、カーボンナノチューブ、グラフェンシート、セルロースナノファイバー、ガラス繊維、鉱物繊維などが挙げられる。中でも、得られる繊維強化樹脂成形品の強度の点で、炭素繊維が好ましい。強化用繊維２のサイズは特に限定されないが、例えば繊維長が数百ｎｍ以上数ｍｍ以下の繊維を用いることができる。 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.

強化用繊維２は、一種単独で又は複数種を組み合わせて用いることができる。 The reinforcing fiber 2 can be used alone or in combination of a plurality of types.

マトリクス樹脂３は、被覆工程Ｓ１においては柔軟性を有し、結着工程Ｓ３で結着できる樹脂であれば特に限定されないが、例えばエポキシ樹脂、不飽和ポリエステル、フェノール樹脂などの熱硬化性樹脂の半硬化樹脂や、ポリ塩化ビニリデン系樹脂、アクリル系樹脂、ＡＮ系共重合体系樹脂などの熱可塑性樹脂が挙げられる。 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.

マトリクス樹脂３は、繊維強化樹脂基材４中において、繊維と繊維の間、繊維の周囲にマトリクス（母材）として存在する。 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.

繊維強化樹脂基材４としては、強化用繊維２にマトリクス樹脂３を含浸させてシート状にした、プリプレグとして市販されているものを用いることができる。プリプレグは、強化用繊維に熱硬化性樹脂を含浸させ、加熱又は乾燥して半硬化状態にした樹脂のシート、または、強化用繊維に溶融した熱可塑性樹脂を含浸させ、その熱可塑性樹脂を固化したシートである。例えば、炭素繊維強化プラスチック（Carbon Fiber Reinforced Plastic：ＣＦＲＰ）の熱硬化性樹脂プリプレグとして東レ株式会社のトレカ（登録商標）やＣＦＲＰの熱可塑性樹脂プリプレグとして日鉄ケミカル＆マテリアル株式会社のＴＥＰｒｅｇ（登録商標）等の各種プリプレグを用いることができる。繊維強化樹脂基材４の厚みは特に限定されないが、例えば０．０７ｍｍ以上０．２ｍｍ以下である。 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.

繊維強化樹脂基材４の積層数は適宜選択することができ、単層であっても複層であってもよい。 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.

繊維強化樹脂基材４は、予め超音波カッターなどで切断して、立体造形物１の形状や凹凸に合わせたものを用いることができる。 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.

立体造形物１を繊維強化樹脂基材４で被覆する際に、立体造形物１が空筒部分を形成しており外側面と内側面を有している場合には、必要とされる強度により、外側面と内側面のいずれか一方又は両面を被覆することができる。 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.

立体造形物１と繊維強化樹脂基材４とが直接接触した状態で被覆を行うと、後述する結着工程Ｓ３で、立体造形物１と繊維強化樹脂基材４を結着することができる。また、部分的に立体造形物１と繊維強化樹脂基材４の間に離形層を設けたり、繊維強化樹脂基材４にしわを寄せて被覆したりすすることで、部分的に立体造形物１と硬化した繊維強化樹脂基材４の間に空間を生じさせて、結着させないこともできる。非結着部分は、繊維強化樹脂成形品１４の可動部とすることが可能である。 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.

（封止工程Ｓ２）
封止工程Ｓ２では、図４に示すように、排気口６を備える軟質気密容器７の内部に、積層体５と粉体８とを、軟質気密容器７の内側面と前記積層体５との間に粉体８が存在するように充填して封止する。 (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.

軟質気密容器７は、積層体５と粉体８を収納できる大きさであり、軟質気密容器７の外側と内側で圧力を伝達できる柔軟性を備える材質であれば特に限定されない。例えば、図４に示すような耐熱性ビニール袋や、チューブの一端を閉じたチューブ容器などを用いることができる。袋の口は、積層体５と粉体８の出入り口になるとともに、管を挟んで閉じることで排気口６として機能する。このように積層体５等の出入り口を排気口６として共用することができるが、積層体５等の出入り口と異なる部分に別途排気口６を設けることもできる。 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.

粉体８は、流動性と熱伝導性があれば、大きさ、形状、材質は特に限定されない。粉体８としては、例えば、平均粒径１～２００μｍの有機粉体又は無機粉体を用いることができる。粉体８は、一種単独で用いることができ、又、粒径、形状などの異なる複数種の粉体８を用いることできる。粉体８として粒径の異なる複数種の粉体からなる混合物を用いると、軟質気密容器７中での充填性に優れ、かつ脱気の際に同伴する粉体８を減らすことができるので好ましい。 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. ..

封止工程Ｓ２において、粉体８に加えて他の部材を充填することができる。他の部材としては、チョップドファイバーや、熱膨脹材などが挙げられる。 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.

チョップドファイバーを用いる場合には、繊維径が１～２０μｍ、長さ０．５～５ｍｍにカットしたチョップドファイバーが好ましい。 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.

熱膨脹材としては、熱膨張性マイクロカプセルが挙げられる。熱膨脹材を用いると、硬化工程Ｓ３の際に熱膨脹材が熱で膨脹し、軟質気密容器７の中の圧力を高めて繊維強化樹脂基材４の立体造形物１の形状への追随性を向上させることができる。熱膨脹材は、粉体８と均一に混合して用いることができる。また、粉体８を再利用する観点で、熱膨脹材を伸縮性のある包装フィルムなどで包装してスティック形状にして、粉体８と共に軟質気密容器７内に配置することが好ましい。 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.

積層体５と粉体８との間には、薄い紙などの離形材を配置することができる。離形材を配置することで取出工程Ｓ４における粉体８の除去が容易になる。離形材としては、フッ素樹脂フィルムやシリコーンフィルムなどのフィルム類が用いられる。 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.

軟質気密容器７に積層体５と粉体８とを、軟質気密容器７の内側面と積層体５との間に粉体８が存在するように充填して封止する方法としては、例えば、軟質気密容器７に積層体５を入れて、積層体５の空筒部分と積層体５の周囲に粉体８を充填し、積層体５と粉体８の出入り口（排気口６）に管を挟み込んで封止する（図４参照）。 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).

（結着工程Ｓ３）
結着工程Ｓ３では、図５に示すように、封止した軟質気密容器７を排気することで立体造形物１と繊維強化樹脂基材４とが密着した状態で軟質気密容器７内を加熱して繊維強化樹脂基材４を立体造形物１と結着させる。 (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.

封止した軟質気密容器７の排気口６からガス９（空気）を排気すると、外気圧１０で軟質気密容器７が収縮し、その外気圧１０が軟質気密容器７及び粉体８を通して立体造形物１と繊維強化樹脂基材４とを密着させる。粉体８が存在することで、立体造形物１の凸部分が軟質気密容器７に直接接触することを防ぐとともに、外気圧１０を繊維強化樹脂基材４の凹部分を含む全面に均等に伝えて立体造形物１と繊維強化樹脂基材４との間の隙間を埋めて密着させる。粉体８は、圧及び熱を伝えるとともに、排気の際にはガス流路として機能する。 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.

排気は、減圧ポンプ１１などで排気口６から直接行うことができるが、図５に示すように減圧ポンプ１１と排気口６の間に、同伴した粉体８を捕捉するトラップ１２を設けることが好ましい。 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.

軟質気密容器７内の加熱は、図６に示すように、立体造形物１と繊維強化樹脂基材４とが密着した状態の軟質気密容器７をオーブン１３に入れて行うことができる。また、軟質気密容器７の内部にヒータを配置して加熱することもできる。 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.

加熱温度は、繊維強化樹脂基材４が結着する温度であれば特に限定されず、用いるマトリクス樹脂３の種類によって適宜選択できる。例えば、常温以上２００℃以下とすることができる。 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.

前述の排気は、加熱中にも行うことが好ましい。繊維強化樹脂基材４の結着の際にガスが発生することがあるが、そのガスを排気することで、立体造形物１と繊維強化樹脂基材４の密着を保つことができる。 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.

繊維強化樹脂基材４が結着することで、積層体５の立体造形物１と繊維強化樹脂基材４とが一体となった複合体１４となる。 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.

（取出工程Ｓ４）
取出工程Ｓ４では、図７に示すように、軟質気密容器７から立体造形物１と繊維強化樹脂基材４との複合体１４を取り出すとともに粉体８を取り除き、繊維強化樹脂成形品１４を得る。 (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. ..

取り除いた粉体８、軟質気密容器７は再利用することができる。 The removed powder 8 and the soft airtight container 7 can be reused.

繊維強化樹脂成形品１４中の繊維強化樹脂基材４は、立体造形物１の表面凹凸のアンカー効果などにより、立体造形物１と強固に結着している。従って、繊維強化樹脂成形品１４中の立体造形物１は取り除く必要はないが、研磨することなどで除去することも可能である。 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.

繊維強化樹脂成形品１４は、立体造形物１の形状で、用いる繊維強化樹脂の強度をそのまま備えるので、様々な形状、大きさのものを製造することができ、オーダーメイドの医療用具、ロボットの部品など、様々な用途に使用することができる。 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.

（実施例）
本発明の実施例を説明するが、本発明はこれに限定されない。なお、ここではマトリクス樹脂として熱硬化性樹脂を用い、結着工程では、熱硬化性樹脂を硬化することで立体造形物と繊維強化樹脂基材を結着している。
また、１つの軟質気密容器で１つの繊維強化樹脂成形品を成形する例を示すが、本発明はこれに限定されず、１つの軟質気密容器で複数の繊維強化樹脂成形品を成形してもよい。 (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.

３Ｄプリンタで図８（左）に示す義指装具の形状の立体造形物１を造形した。この義指装具は、指にはめることができると共に、切り欠き部分１５で屈曲可能である。 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.

次に、シート状のＣＦＲＰ（Carbon Fiber Reinforced Plastic）プリプレグを、立体造形物１の形状に合わせて加工して繊維強化樹脂基材４を準備した。繊維強化樹脂基材４は、筒状に加工してあり、立体造形物１を差し込むことで、立体造形物１に繊維強化樹脂基材４を被覆することができる（図９参照）。 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).

繊維強化樹脂基材４を立体造形物１に被覆して積層体５とした後、薄い包装材（離型材１６）で包装し、立体造形物１の内側に粉体８を充填して密封して梱包物１７を作成した（図９参照）。粉体８は、平均粒径１～２００μｍの無機粉体であり、繊維径が１～２０μｍ、長さ０．５～５ｍｍにカットしたチョップドファイバーとの混合物である。 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.

次に、梱包物１７の周囲に３つの熱膨脹材１８を均等に配置して、粉体８と共に、薄い包装材（離型材１９）で包装し梱包物２０を作成した（図１０参照）。熱膨脹材１８は、熱膨張性マイクロカプセルを伸縮性のある包装フィルムに充填してスティック状に包装したものである。 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.

次に、梱包物２０を軟質気密容器７に入れた。軟質気密容器７は気密性のある耐熱シートで、排気口６を備えている。梱包物２０の周囲に粉体８を充填し、排気口６にホース２１を通して閉じた（図１１参照）。そのホース２１をトラップ１２を介して減圧ポンプに接続してガスを排気し減圧した。減圧することで、立体造形物１と繊維強化樹脂基材４の隙間が無くなると共に、粉体８を介して、外気圧が均等に繊維強化樹脂基材４にかかり、立体造形物１と繊維強化樹脂基材４が互いに密着する。 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.

次に、軟質気密容器７をオーブンに入れ、軟質気密容器７を減圧しながら加熱して、繊維強化樹脂基材４を硬化させた。 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.

次に、軟質気密容器７から、立体造形物１と繊維強化樹脂基材４との複合体を取り出し粉体８を取り除き、繊維強化樹脂成形品１４を得た。図８には、立体造形物１（左）と、繊維強化樹脂成形品１４（右）が示されている。なお、図８の繊維強化樹脂成形品１４は、繊維強化樹脂基材４の立体造形物１の切り欠き部分１５に対応する部分を結着後に切り取ったものである。繊維強化樹脂成形品１４の切り欠き部分２２は、立体造形物１と同様に屈曲性を示した。繊維強化樹脂成形品１４は、軽量でありながら繊維強化樹脂基材４に由来する強度を備えていた。 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.

本発明は、本発明の広義の精神と範囲を逸脱することなく、様々な実施の形態及び変形が可能とされるものである。また、上述した実施の形態は、この発明を説明するためのものであり、本発明の範囲を限定するものではない。すなわち、本発明の範囲は、実施の形態ではなく、特許請求の範囲によって示される。そして、特許請求の範囲内及びそれと同等の発明の意義の範囲内で施される様々な変形が、この発明の範囲内とみなされる。 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 立体造形物
２ 強化用繊維
３ マトリクス樹脂
４ 繊維強化樹脂基材
５ 積層体
６ 排気口
７ 軟質気密容器
８ 粉体
９ ガス
１０ 外気圧
１１ 減圧ポンプ
１２ トラップ
１３ オーブン
１４ 複合体（繊維強化樹脂成形品）
１５ 切り欠き部分
１６ 離型材
１７ 梱包物
１８ 熱膨脹材
１９ 離型材
２０ 梱包物
２１ ホース
２２ 切り欠き部分
Ｓ１ 被覆工程
Ｓ２ 封止工程
Ｓ３ 結着工程
Ｓ４ 取出工程 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)

立体造形物の少なくとも一部を、強化用繊維とマトリクス樹脂とを含有するシート状の繊維強化樹脂基材で被覆して積層体を得る被覆工程と、
排気口を備える軟質気密容器の内部に、前記積層体と粉体とを、前記軟質気密容器の内側面と前記積層体との間に前記粉体が存在し、かつ前記積層体と前記粉体との間に離形材を配置するように充填して封止する封止工程と、
封止した前記軟質気密容器を排気することで前記立体造形物と前記繊維強化樹脂基材とが密着した状態で前記軟質気密容器内を加熱して前記繊維強化樹脂基材を前記立体造形物と結着させる結着工程と、
前記軟質気密容器から前記立体造形物と結着した前記繊維強化樹脂基材との複合体を取り出すとともに前記粉体を取り除くことで繊維強化樹脂成形品を得る取出工程と、
を含む、繊維強化樹脂成形品の製造方法。 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. 前記粉体は、複数種の粉体からなる混合物である、請求項１に記載の繊維強化樹脂成形品の製造方法。 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. 前記封止工程において、前記軟質気密容器内に、熱膨脹材を更に充填する、請求項１又は２に記載の繊維強化樹脂成形品の製造方法。 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. 前記強化用繊維は、炭素繊維である、請求項１～３のいずれか１項に記載の繊維強化樹脂成形品の製造方法。 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. 前記立体造形物は、３Ｄプリンタで造形した立体造形物である、請求項１～４のいずれか１項に記載の繊維強化樹脂成形品の製造方法。 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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JP2005288785A (en) 2004-03-31 2005-10-20 Toray Ind Inc Method for producing preform
JP2016531773A (en) 2013-08-05 2016-10-13 オルト−ノバ ゲーエムベーハー フュア オルトペディー−テフニークOrtho−Nova Gmbh Fur Orthopadie−Technik Method for producing composite molded body and composite molded body thereof
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