JP3414782B2 - Manufacturing method of composite member - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a hollow composite member made of resin and fibers.

[0002]

2. Description of the Related Art It is known that a composite member made of synthetic resin which is reinforced with fibers is lightweight and has a large specific strength as represented by, for example, fiber reinforced plastic (FRP). In the well-known filament winding method used for manufacturing FRP, a predetermined amount of a fiber bundle impregnated with a matrix resin is wound around a mandrel, and then the resin is cured. Further, there is also known a pultrusion (pull molding method) for obtaining a tubular product having a desired cross-sectional shape by pulling out a resin containing fibers from a mold.

[0003]

When the above-mentioned filament winding method is used, not only is it laborious and expensive to manufacture, but also the length of the mandrel is limited, so that it is possible to manufacture an elongated composite member. Can not. In addition, since the hollow member that can be manufactured by the filament winding method is limited to a circular shape or a shape close to a circular shape (such as an elliptical shape), it is difficult to manufacture a composite member having a rectangular cross section such as an air duct. is there.

On the other hand, in the case of pull-through, it is difficult to manufacture a thin-walled product in order to carry out drawing. In addition, the composite member manufactured by drawing,
Since it is difficult to include fibers along the circumferential direction of the member, the strength in the radial direction is low even though the wall thickness is large, and it is not suitable for applications where internal pressure or external pressure is applied.

Therefore, an object of the present invention is that it can be applied to a cross section other than a circular shape without any problems and can be manufactured at low cost, and it has sufficient strength even when it is used in applications where internal pressure, external pressure and longitudinal load are applied. An object of the present invention is to provide a method for producing a hollow composite member that can be exhibited and has few restrictions on setting the thickness and the wall thickness.

[0006]

SUMMARY OF THE INVENTION The present invention was developed in order to achieve the above object, Ru cured comprising the steps of weaving a base material consisting of cylindrical fabric, the and the resin is impregnated with a resin to the substrate step A method of manufacturing a composite member having: a shuttle that rotates around a weaving ring and an outer diameter of the shuttle that is located at the center of the weaving ring and that can be changed in the step of weaving the base material. A cylindrical loom having a variable plug and a control member that is movably inserted in the variable plug and that changes the outer diameter of the variable plug according to the vertical position is used, and the shuttle of the shuttle is synchronized with the rotation of the shuttle. While weaving the warp threads alternately up and down and changing the outer diameter of the variable plug, a weft thread is wound between the warp threads vertically distributed on the outer peripheral surface of the variable plug while being wound in the circumferential direction of the variable plug. In curing the longitudinally weaving the substrate diameter of a cylindrical fabric that changes continuously, and the resin is impregnated with a resin to the substrate by writing
, After impregnated with the resin to the substrate, characterized by forming a hollow composite member radial to the longitudinal direction is changed by curing the resin while applying a pressure to the substrate It is a manufacturing method of a composite member. In the present invention, after impregnating the above base material with the above resin, this base material is inserted into a molding die in which the inner peripheral length of the cross section changes in the longitudinal direction, and the above resin is cured in a state where internal pressure is applied. By doing so, a composite member corresponding to the shape of the inner surface of the mold may be formed.

By using the above-mentioned cylindrical loom, a considerably long base material can be efficiently continuously produced. The base material is passed through a resin tank to contain the resin, then inserted into a mold, and molded into a desired cross-sectional shape by an internal pressure molding method under an appropriate temperature condition. If an internal pressure tube is inserted into the above-mentioned base material, preferable results may be obtained in applying the internal pressure.

[0008]

In the composite member obtained by hardening the above-mentioned base material with the resin, the resin is reinforced by the fibers of the base material embedded in the resin, and the fibers are arranged in the longitudinal direction and the circumferential direction. Of course, sufficient strength is exerted against the internal pressure and the external pressure applied in the radial direction. Further, a cross section other than a cylinder can be formed depending on the shape of the inner surface of the mold.

Therefore, for example, it is suitable for applications such as construction-related materials and structural materials for various kinds of equipment as well as pipes under pressure. When a thermoplastic resin is used as the matrix resin, it can be joined to other members if it is made deformable by heating the required parts of this composite member to the softening temperature of the resin during on-site construction. You can also do it.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. The hollow composite member 10 shown in FIG. 2 is obtained by impregnating a cylindrical base material 11 with a matrix resin 12 and curing the matrix resin 12. Base material 11 is warp yarn 15
And a weft thread 16 and the like, which is an aggregate of fibers, in which the resin 12 is reinforced. As the warp yarn 15 and the weft yarn 16, those having high tensile strength such as glass fiber, carbon fiber, and aramid fiber are suitable. Resin 1
For 2, a thermosetting resin such as epoxy or a thermoplastic resin (PEEK, for example) is used.

In the embodiment shown in FIG. 1, a cylindrical loom 2
The base material 11 is manufactured by
The internal pressure tube 21 is inserted through the inside of the base material, and the base material 11 is passed through the resin tank 22, so that the base material 11 is impregnated with the resin 12 before curing. The base material 1
When it is difficult to infiltrate the thermoplastic resin into 1 due to various conditions such as temperature, the thermoplastic resin is made into a thread shape, and when it is woven by the cylindrical loom 20, it is woven together with other threads and then heated. Alternatively, fibers made of a thermoplastic resin may be melted.

The substrate 11 that has passed through the resin tank 22 is dried in a drying stage 25 to have an appropriate viscosity and hardness, and becomes a so-called prepreg state, and a release device 26 is sandwiched between them by a winding device 27. It is wound up. It is preferable that the inner pressure tube 21 has such a surface state that the inner surface does not stick to it even if it is flatly crushed, and that the resin 12 does not seep out to the inner surface side when the base material 11 is passed through the resin tank 22. Moreover, a material that can ensure airtightness is used so that air does not leak outside when internal pressure is applied.

The wall thickness of the internal pressure tube 21 does not matter,
A thin material having flexibility that allows it to expand to some extent when internal pressure is applied is preferable. The material of the tube 21 is desired to have good adhesiveness with the resin 12 in order to integrate with the resin 12, but a material different from the resin 12 or a material common to the resin 12 may be used. By inserting the tube 21 into the base material 11, even if the base material 11 impregnated with the resin 12 is wound in a flatly crushed state, it is possible to prevent the inner surface of the base material 11 from sticking to each other. In the internal pressure molding method that is performed, the base material 11 can be expanded into a tubular shape.

The base material 11 impregnated with the above-mentioned resin 12 is inserted into a molding die 30 (only a part of which is shown) as shown in FIG. 3 as an example, and the inside of the base material 11, that is, the internal pressure tube. By applying internal pressure from the inside of 21 to press the base material 11 against the inner surface 31 of the mold 30, the base material 11 is molded into a predetermined shape. When a thermosetting resin is used for the resin 12, the mold 30 is heated to a temperature suitable for curing the resin 12,
By curing the resin 12 while applying internal pressure,
The columnar hollow composite member 10 is obtained. When a thermoplastic resin is used as the resin 12, the resin in a softened state by heating is hardened by cooling.

If the above-mentioned internal pressure molding method is applied, a mold 30a having a rectangular cross section as shown in FIG. 4 or a mold having a triangular or polygonal inner surface is used in addition to the cylinder, depending on the sectional shape of the mold 30. By using it, a hollow composite member having a circular cross section can be obtained.

When a thermoplastic resin is used for the composite member 10, after the composite member 10 is manufactured, a desired portion can be heated to make it deformable if necessary. Therefore, it is easy to connect the joint component 35 as illustrated in FIG. 5 or connect the composite member 10 to another structural material when performing the construction on the site using the composite member 10. In the example of FIG. 5, the joint component 3 is heated to a temperature at which the resin of the composite member 10 softens.
The joint component 35 can be attached by inserting 5 into the open end 36 of the composite member 10 and cooling.

A cylindrical loom 20 for weaving the base material 11 is constructed as shown in FIGS. 6 to 9. The cylindrical loom 20 will be described below. As shown in FIG. 7, a weaving ring 41 is provided on the machine frame 40, and a variable plug 42 is provided at the center of the weaving ring 41. The variable plug 42 is formed into a shape that is approximately a cylinder by combining a plurality of divided pieces 42a that are divided in the circumferential direction. The split pieces 42a are displaceable relative to each other in the radial direction of the variable plug 42, and by moving the tapered variable plug control member 45 inserted in the center of the variable plug 42 in the vertical direction, the cylindrical loom 20 is in operation. In addition, the radius of the variable plug 42 can be continuously changed.

A sector 50 is arranged around the variable plug 42, and a variable sector 51 is attached to the sector 50. As shown in FIG. 9, the variable sector 51 includes the support shaft 5
It is rotatable about 2. The tip 53 of the variable sector 51 is pressed against the variable plug 42 by a spring 54. The sector 50 is held at a predetermined position on the shuttle 55. The shuttle 55 rotates about the weaving ring 41 along the shuttle guide member 56 in the clockwise direction (arrow F direction) in the drawing. A bobbin 57 is provided on the shuttle 55, and the weft 1
6 is rolled up.

The warp yarns 15 are supplied from the outer peripheral portion of the cylindrical loom 20 toward the variable plug 42, and the shuttle 55 moves in the direction of arrow F.
As the yarn rotates, the warp yarns 15 are alternately distributed above or below the shuttle 55. That is, the warp yarn 15 is synchronized with the rotation of the shuttle 55.
Alternately go up and down shuttle 55,
The sector 50, the variable sector 51, and the shuttle 55 pass between the upper and lower warp threads 15. Although the warp yarn 15 is supplied over the entire circumference of the cylindrical loom 20, only a part of the warp yarn 15 is illustrated for convenience of the drawing.

The weft thread 16 wound around the bobbin 57 is guided to the tip portion 53 of the variable sector 51 via the sector 50. Then, as the variable sector 51 rotates around the variable plug 42, the weft thread 16 led out from the tip portion 53 of the variable sector 51 is woven between the warp threads 15 vertically distributed on the surface of the variable plug 42. Go on. Since the variable sector 51 is biased toward the variable plug 42 by the spring 54, the warp thread 15 and the weft thread 16 do not float up from the surface of the variable plug 42, and the cylindrical base material 11 is formed.
Is being woven.

Therefore, the radius of the base material 11 can be controlled by the radius of the variable plug 42. That is,
Since the thickness of the base material 11 corresponds to the outer diameter of the variable plug 42, the thickness of the base material 11 changes in the longitudinal direction by changing the outer diameter of the variable plug 42 by the variable plug control member 45. Can be woven. The woven base material 11 continuously emerges from the lower side of the cylindrical loom 20.

The cylindrical loom 20 is suitable for the production of the elongated hollow composite member 10 because it is durable and can efficiently weave a long material of several tens of meters or more, such as a fire hose. Moreover, since the cylindrical loom 20 can change the diameter of the base material 11 midway in the longitudinal direction of the base material 11 by operating the variable plug control member 45 during its operation, for example, as shown in FIG. It is also suitable for manufacturing the hollow composite member 10a whose diameter changes in the longitudinal direction.

Composite members 10 and 10 using the substrate 11
In the case of a, the cured resin is reinforced by the warp yarns 15 and the weft yarns 16, so that it can exhibit sufficient strength against internal pressure and also has sufficient strength in the longitudinal direction. Further, since it is easy to mold into a desired shape in accordance with the inner surface shape of the molding die, it is possible to easily manufacture a deformed cross section other than a circular shape. For example, it is also suitable for a member having a rectangular cross section and a cross section varying in the longitudinal direction, such as an air duct. This applies to both thermoplastic and thermosetting resins. In addition, if the composite members 10 and 10a are made by using the base material 11 of one layer, it is possible to obtain a composite member having a sufficiently thin wall thickness and toughness as compared with the pultrusion. Further, if the thickness of the base material 11 is increased by stacking the base material 11 in two or more layers, the strength increases according to the thickness, and a columnar hollow composite member having extremely high strength can be obtained.

The composite members 10 and 10a may be manufactured by using a cylindrical knit base material 60 having a knitting structure, a part of which is shown in FIG. The knit base material 60 is a series of yarns knitted in a lengthwise or transverse direction by a circular knitting machine or the like in a loop shape, and is highly stretchable. Therefore, in this case, by inserting the knit base material 60 impregnated with the resin into the mold 61 whose inner diameter changes in the longitudinal direction as shown in a part of FIG. 12, and applying the above-mentioned internal pressure molding method, It is possible to manufacture the composite member 10a whose diameter changes in the longitudinal direction as shown in FIG. 10, for example, depending on the shape of the inner surface.

A base material 70 composed of a blade (mesh tube) as shown in FIG . 13 may be used. The blade substrate 70 is
Since it contains a large number of fibers 71 (such as the above-mentioned organic fibers or inorganic fibers or metal wires) that intersect in an oblique direction with respect to the axis, it can be appropriately expanded and contracted before the resin is hardened, and the resin There After curing is to exhibit high strength in the radial direction and the longitudinal direction.

[0026]

According to the present invention, a long hollow composite member having high strength can be manufactured at low cost, and a thin to thick one can be selected as required, and A composite member whose diameter changes in the longitudinal direction can also be manufactured without problems. This composite member exerts a great effect in that not only the strength in the longitudinal direction but also sufficient strength can be exhibited even in a use environment where internal pressure or external pressure is applied.

[Brief description of drawings]

FIG. 1 is a schematic view of a part of an apparatus for manufacturing a hollow composite member showing an embodiment of the present invention.

FIG. 2 is a perspective view showing an example of a hollow composite member.

FIG. 3 is a perspective view showing an example of a molding die.

FIG. 4 is a perspective view showing a modified example of the mold.

FIG. 5 is a perspective view of a part of a hollow composite member including a joint part.

FIG. 6 is a perspective view of a cylindrical loom that produces a cylindrical base material.

FIG. 7 is a cross-sectional view showing a part of the cylindrical loom shown in FIG.

8 is a perspective view showing a part of the cylindrical loom shown in FIG.

FIG. 9 is a plan view showing a part of the cylindrical loom shown in FIG. 6.

FIG. 10 is a perspective view of a hollow composite member whose diameter changes in the longitudinal direction.

FIG. 11 is a front view showing a part of the knit base material in an enlarged manner.

FIG. 12 is a perspective view of a mold whose inner diameter changes in the longitudinal direction.

FIG. 13 is a perspective view showing a part of a blade base material.

[Explanation of symbols]

10, 10a ... Hollow composite member, 11 ... Base material, 12 ... Matrix resin, 15 ... Warp thread, 16 ... Weft thread, 20 ... Cylindrical loom, 21 ... Internal pressure tube, 22 ... Resin tank, 30 ... Molding mold, 35 … Joint parts, 42… Variable plugs, 4
2a ... Dividing piece, 45 ... Variable plug control member, 51 ... Variable sector, 60 ... Knit base material, 61 ... Mold for molding, 70 ...
Blade base material.

─────────────────────────────────────────────────── --- Continuation of the front page (56) References JP-A-63-98430 (JP, A) JP-A-51-34968 (JP, A) JP-B 48-20431 (JP, B1) JP-B 42- 15795 (JP, B1) JP-B-35-7482 (JP, B1) (58) Fields investigated (Int.Cl. ⁷ , DB name) B29C 70/00-70/88 D03D 3/02 D03D 25/00 D03D 41/00

Claims (2)

(57) [Claims] And 1. A process for weaving a base material consisting of cylindrical fabric, a method for producing a composite member and a step of Ru curing the is allowed and the resin of resin-impregnated base material, weaving the base In the process, a shuttle that rotates around the weaving ring, a variable plug that is located in the center of the above-mentioned wibbling ring and that can change the outer diameter, and a vertically movable position that is movably inserted into the variable plug. A cylindrical loom having a control member for changing the outer diameter of the variable plug in accordance with the above is used, and the warp yarns are alternately distributed above and below the shuttle in synchronization with the rotation of the shuttle and the outer diameter of the variable plug is changed. However, it is made of a tubular fabric whose diameter changes in the longitudinal direction by weaving a weft yarn between the warp yarns distributed above and below the outer peripheral surface of the variable plug while winding the weft yarn in the circumferential direction of the variable plug. Weaving the base continuously, curing the and the resin is impregnated with a resin to the substrate
In, after impregnated with the resin to the substrate, characterized by forming a hollow composite member radial to the longitudinal direction is changed by curing the resin while applying a pressure to the substrate Manufacturing method of composite member. 2. The base material is impregnated with the resin, and then the base material is inserted into a molding die in which the inner peripheral length of the cross section changes in the longitudinal direction, and the resin is cured under an internal pressure. The method for producing a composite member according to claim 1, wherein the composite member is molded according to the shape of the inner surface of the mold.