WO2007013543A1 - Method for lamination molding of fiber reinforced plastic and lamination molding apparatus - Google Patents

Abstract

An energy radiation curing resin is used as a matrix resin in a fiber reinforced plastic tape. An energy radiation is applied by an energy radiation irradiation device linked to a movable lamination head. The time necessary for varying the site irradiated with the energy radiation to any desired illuminance is not more than one sec, and the above tape is lamination molded while curing the energy radiation curing resin.

Description

 Specification

 Laminated molding method and laminated molding apparatus for fiber reinforced plastic

 Technical field

 The present invention relates to a lamination molding method and a lamination molding apparatus.

 Background art

 [0002] Fiber reinforced plastic (CFRP) products using carbon fibers and the like used for aircrafts and rockets are generally laminated by hand. Since manual manufacturing increases the manufacturing cost, an automatic laminate molding method (equipment) called the Fiber Placement method has been developed from the standpoints of reducing manufacturing cost and high-efficiency molding of large products. .

 [0003] In such an apparatus, a fiber-reinforced plastic tape is heated by a gas heater and pressed by a pressure roller to control the position, and is attached to the mold surface to produce a molded product having a complicated shape. When the tape is pasted, the desired fiber-reinforced plastic product is obtained by heating with a gas heater while applying pressure with an autoclave.

 [0004] However, in the automatic lamination molding apparatus (AFP apparatus) that performs the conventional fiber placement method, heating is required for bonding, and heating including the entire mold is essential for curing, and the heating process takes time. In addition, handling was lacking. Therefore, it has been desired to reduce the burden on the manufacturing process and cost.

 Patent Document 1: JP 2004-66593 A

 Disclosure of the invention

 Problems to be solved by the invention

[0005] The present invention has been made in view of the above circumstances, and does not require a heating operation, so that a laminated molded body having a small manufacturing and cost burden and excellent curability can be obtained. An object of the present invention is to provide a lamination molding method and a lamination molding apparatus.

 Means for solving the problem

[0006] In order to achieve the above object, the present invention is a lamination molding method in which a fiber-reinforced plastic tape is continuously supplied to a mold surface by a movable lamination head having a pressure roller. In addition, in the lamination molding method by the fiber placement method for laminating the tape, the matrix resin of the fiber reinforced plastic tape is an energy ray curing resin, and the energy is irradiated by an energy ray irradiation device interlocked with the movable lamination head. Irradiate the line

The time required to change the irradiance of the energy ray to any illuminance is within 1 second, and the tape is laminated while the energy ray-cured resin is cured. The time required for the above variable is preferably within 0.1 seconds, and more preferably within 0.01 seconds.

Here, it is preferable to use an LED as a light source of the energy beam irradiation device.

 Further, it is preferable to control the irradiation width of the energy ray at the bonded portion so that the width of the fiber reinforced plastic tape is within ± 10%. In addition, it is preferable that the light amount of the energy ray is controlled by the current value of the energy ray. In addition, it is preferable that the amount of the energy beam at the bonding site is controlled in accordance with the tape bonding operation. Moreover, it is preferable to control the light quantity of the energy beam according to the irradiation time of the energy beam. At this time, the light amount of the energy beam can be controlled by the irradiation slit width of the energy beam.

 [0008] In another aspect, the present invention is a fiber reinforced plastic laminate molding apparatus, comprising a movable laminate head for continuously supplying a fiber reinforced plastic tape to a mold surface, and the movable laminate head. In a lamination molding apparatus that includes a pressure roller for laminating the tape and performs lamination molding by a fiber placement method, the apparatus comprises an energy beam irradiation device that operates in conjunction with the movable lamination head, and the energy line irradiation device It is possible to irradiate energy rays, and it takes less than 1 second to change the irradiance to any illuminance at the site irradiated with energy rays. It is characterized by being laminated while curing the resin. The time required for the above variable is preferably within 0.1 seconds, and more preferably within 0.01 seconds.

[0009] In addition, it is preferable that an LED is provided as a light source of the energy beam irradiation apparatus. Further, the irradiation width of the energy beam at the bonded site is the fiber reinforced braid. It is preferable that the width of the stick tape can be controlled within ± 10%. Further, it is preferable that the light amount of the energy beam at the bonding site can be controlled in accordance with the tape bonding operation. In addition, it is preferable to control the light amount of the energy line by the current value of the energy line. In addition, it is preferable to control the amount of energy of the energy line by the irradiation time of the energy beam. At this time, it is preferable to control the light amount of the energy ray by the irradiation slit width of the energy ray.

 The invention's effect

 [0010] According to the present invention, there is provided a laminate molding method and a laminate molding apparatus that do not require a heating operation, can obtain a laminate molded body that has a small manufacturing and cost burden and is excellent in hardening properties. Provided.

 Brief Description of Drawings

 FIG. 1 is a conceptual diagram for explaining an embodiment of a laminate molding system to which a laminate molding method and apparatus according to the present invention is applied.

 FIG. 2 is a conceptual diagram illustrating an LED module employed in the embodiment of FIG.

 BEST MODE FOR CARRYING OUT THE INVENTION

[0012] Hereinafter, the laminate molding method and laminate molding apparatus according to the present invention will be described in more detail with reference to embodiments thereof.

 FIG. 1 is a conceptual diagram illustrating an embodiment of a lamination molding system including a lamination molding apparatus according to the present invention. In this embodiment, CF (carbon fiber) is used as a fiber reinforced plastic tape, and a material in which UV (ultraviolet ray) cured resin is impregnated as a matrix resin (prepreda and towpreda! Is adopted.

 The layer forming apparatus system according to the present embodiment includes a control processor (computer) 100 and a control interface 102. The control processor 100 is configured to be able to control the movable laminated head (not shown) having the pressure roller 104 and the energy line irradiation device 106 via the control interface 102.

Furthermore, the energy beam irradiation device 106 includes an LED power supply device 108 as a main component, An LED module 110 is provided. In other words, an ultraviolet LED (light emitting diode) is used as the light source. The energy beam irradiation device 106 is configured such that at least the LED module 110 can be interlocked with the movable laminated head. Here, interlocking means that the fiber reinforced plastic tape is stuck together by the caloric pressure roller 104 and is at least moved along with the movable laminated head.

 The layer forming apparatus system further includes a speed sensor 112, a material temperature sensor 114, and a UV illuminance sensor 116.

 The material temperature sensor 114 and the UV illuminance sensor 116 are installed in the vicinity of the bonding site 119 of the fiber reinforced plastic tapes 118a and 118b.

 As the mechanical configuration of the movable laminated head for operating the pressure roller 104, a conventional one can be adopted, and the description thereof is omitted here.

FIG. 2 explains the configuration of the LED module 110. In the LED module 110 according to the present embodiment, the three units 120 and the condenser lens 122 are supported by the light shielding fence 124. Each unit 120 includes a light emitting portion 126 having 21 light emitting element forces in the central portion when viewed from the front [FIG. 2 (b)]. In the present embodiment, the three units 120 have a width of 25 mm, the distance from the light emitting surface of the LED to the focal point is about 50 to 100 mm, and the focal width is about 5 to: LOmm. The condenser lens 122 is configured so that the position can be adjusted back and forth.

 In the present embodiment, the pressure roller of the movable laminated head is similar to the conventional laminated molding apparatus.

By 104, the fiber reinforced plastic tape 118a is pressed onto the surface of the mold while controlling the position. In the figure, it is attached to the fiber reinforced plastic tape 118b, but the first tape is attached to the mold. In this respect, it is the same as the conventional laminated forming apparatus (method).

In the present embodiment, when performing the pasting operation in this way, the pasting operation is performed by curing the energy ray curable resin constituting the matrix resin of the fiber reinforced plastic tape. At that time, the application site 119 is irradiated with energy rays (ultraviolet rays). As a result, only the layer of the energy ray curable resin on the side of the application site 119 of the fiber reinforced plastic tape is cured. Therefore, figure In terms of 1, the uncured layer (upper surface) of the fiber reinforced plastic tape 118a and the uncured layer (lower surface) of the fiber reinforced plastic tape 118b are integrated with almost uncured force and strongly bonded.

 [0018] On the other hand, the time required for changing the ultraviolet ray irradiated by the LED module 110 to an arbitrary illuminance of the irradiated portion is within one second. This time is preferably within 0.1 seconds, and more preferably within 0.01 seconds.

 The light emission amount is maintained by a current instruction from the control processor 100 via the control interface 102 to the LED power supply device 108. Since the movement of the movable laminated head is also controlled by the control processor 100, the light emission amount is maintained in accordance with the moving speed of the pressure roller 104.

 [0020] For example, when the speed 10 sensor 112 detects that the pressure roller 104 moves on a mold surface having a certain curvature, the information is transmitted to the control processor 100 via the control interface 102. . Then, in accordance with the curvature, the current from the LED power supply 108 changes so that the amount of light necessary for bonding the materials is kept constant.

 [0021] In the present embodiment, it is also possible to hold the fiber-reinforced plastic tape in a wound state before being cured and to heat it before and after heating it at the bonding site 119 or just before it. As a result, the viscosity of the energy ray curable resin can be adjusted to prevent the oozing of the resin. The material temperature sensor 114 detects the temperature of the material at the bonding site 119 or the like, and makes it possible to appropriately control such a cooling and heating device.

 [0022] In addition, based on information from the UV illuminance sensor 116, it is possible to monitor whether or not the irradiation amount at the bonded portion 119 is appropriate through the control interface 102, and the amount of light emitted from the LED module 110. Can be maintained appropriately. In addition, the irradiation width of the above-mentioned energy ray at the bonding site 119 should be covered within ± 10% of the width of the fiber reinforced plastic tape.

[0023] It should be noted that, in addition to the case of the laminate molding method according to the present embodiment, in the present invention, the laminate molded body that has been bonded can be removed immediately. After-curing by heating can be performed in the demolded state. This curing does not involve molds and is much easier to handle than heating with conventional molds. [0024] In the present embodiment, an LED module using an ultraviolet LED is employed, and the light emission amount can be optimally maintained in real time with better response characteristics compared to employing a UV lamp. Therefore, a stable pasting operation can be executed, and the quality of the laminated molded body is stabilized. In addition, the heating operation is not required and the manufacturing and cost burden can be reduced as compared with the conventional lamination molding method (apparatus) by the heating operation.

 As a light source used in the energy beam irradiation apparatus, a mercury lamp, a metal halide lamp, an electrodeless lamp (for example, a fusion UV lamp), an LED, or the like can be used as a lamp as long as the purpose of the present invention is met.

 In addition, in order to irradiate the bonded area in close proximity, it is possible to guide the UV light to the adjacent area of the bonded surface using a glass fiber.

 In the present invention, in order to use light from the light source more effectively, the light is preferably condensed. As the light collecting method, in addition to the lens condensing as in the embodiment of FIG. 1, various condensing methods such as a concave mirror, a reflecting plate, and a condensing plate can be used alone or in combination. is there.

 [0025] In the present embodiment, CF is used as the material of the reinforcing fiber used in the fiber-reinforced plastic tape. However, for example, glass fiber (GF), aramid fiber, or the like may be used. it can. However, CF (carbon fiber) is advantageous from the standpoint of leaving an uncured layer in the present invention having a high light-shielding property. The resin content is preferably 30 wt% to 55 wt%, and more preferably 35 wt% to 40 wt%.

 [0026] Energy ray-cured resin used in fiber-reinforced plastic tape is UV

 (UV) Not only cured resin but also other energy ray cured resin!

 As the UV curable resin, a radical polymerizable resin composition, a cationic polymerizable resin composition, or a mixed resin composition thereof can be employed.

 [0027] Furthermore, a chain-curing type rosin composition can also be employed. “Chain-curing type resin composition” refers to a resin that begins to cure with energy rays such as UV (ultraviolet rays) and cures with chain curing using its own curing reaction heat. It is a composition.

That is, in the case of a chain-curing type resin composition, when the energy ray is irradiated any time, curing occurs at the irradiated site, and then the chain heats due to this curing heat generation. to this Therefore, it can be cured regardless of the presence of energy rays and the shielding material, so it shows the behavior of hardening immediately to the deep part where the energy rays do not reach. For example, CFRP with a thickness of 1 cm can be cured in 3 minutes.

[0028] Such a chain-curing type resin composition includes a weight of a cationic photopolymerization initiator component described in JP-A-11-193322 and a cationic photopolymerization initiator. A rosin composition containing a specific ratio can be employed. For example, this resin composition can cure CFRP having a plate thickness of 1 cm in 3 minutes.

 Even when such a chain-curing type of resin composition is used, if the Vf (volume content) of CF is 41% or more, even if one side of the fiber reinforced plastic tape / prepreg is irradiated with ultraviolet rays, Can be set to not cure.

 Employing such a chain-curing type resin composition has the advantage that the above-mentioned after-curing process can be completed in a short time due to the presence of the cationic photothermal polymerization initiator system component.

 In addition, a sensitizer and a proliferation agent can be transferred to the energy beam curable resin.

 Further, in the present invention, glass fiber can be used as a means for guiding light to the pasting site.

 [0029] In addition, the amount of light in the energy beam irradiation apparatus can be executed by controlling the irradiation slit width in addition to controlling the irradiation time.

 As described in the above embodiment, the fiber-reinforced plastic tape can be cooled and held and heated at the application site.

[0030] As another embodiment, it is possible to hold the reinforcing material fiber without impregnation and immerse it in an energy ray curable resin immediately before the irradiation with the energy ray to adjust the temperature. . It is also possible to spray energy ray-cured resin by spraying at this time. As a heating method for fiber reinforced plastic tape, when CF is used as reinforced fiber, it is also possible to conduct electricity to this CF. It is. At this time, it is possible to heat using a part-chromium wire.

 Industrial applicability

[0031] The laminate molded body obtained by the laminate molding method according to the present invention is an aircraft, a rocket or the like. It can be applied to products with curved surfaces such as wings and fuselage.

Claims

The scope of the claims  [1] A fiber reinforced plastic tape is continuously supplied to the surface of a mold by a movable lamination head equipped with a pressure roller, and the fiber is subjected to a lamination molding method by a fiber placement method in which the tape is laminated. The matrix resin of the reinforced plastic tape is an energy line curing resin, and the energy beam is irradiated by the energy beam irradiation device linked to the movable laminated head. A method for laminating a fiber-reinforced plastic, characterized in that the time required for the process is less than 1 second, and the tape is laminated and molded while curing the energy ray-cured resin.  [2] The fiber reinforced plastic tape is continuously supplied to the surface of the mold by a movable laminating head equipped with a pressure roller. The matrix resin of the fiber reinforced plastic tape is an energy line curing resin, the energy beam is irradiated by the energy beam irradiation device interlocked with the movable laminated head, and the LED is used as the light source of the energy beam irradiation device. The fiber reinforced plastic is characterized in that the time required to change the irradiance of the part irradiated with the light to within 1 second is less than one second, and the above tape is laminated and molded while curing the energy ray cured resin. Lamination molding method. [3] The fiber reinforcement according to claim 1 or 2, wherein an irradiation width of the energy beam at the bonded portion is controlled so as to be within ± 10% of the width of the fiber-reinforced plastic tape. Plastic laminate molding method. [4] The fiber-reinforced plastic according to any one of claims 1 to 3, wherein the amount of the energy rays at the bonding site is controlled in accordance with the tape bonding operation. Lamination molding method. [5] The method for forming a layer of fiber-reinforced plastic according to any one of [1] to [4], wherein the light quantity of the energy beam is controlled by a current value of the energy beam. [6] The laminated fiber-reinforced plastic according to any one of claims 1 to 5, wherein the light quantity of the energy beam is controlled by the irradiation time of the energy beam. Molding method.  [7] The fiber reinforced plastic laminate molding method according to any one of [1] to [6], wherein the light amount of the energy beam is controlled by the irradiation slit width of the energy beam.  [8] A movable laminating head for continuously supplying fiber reinforced plastic tape to the surface of the mold, the movable laminating head having a pressure roller for laminating and forming the tape, and according to the fiber placement method A lamination molding apparatus that performs lamination molding is equipped with an energy beam irradiation device that works in conjunction with the movable lamination head, and the energy beam irradiation device can irradiate the energy beam and irradiate the energy beam. The time required to change the illuminance to any desired area is less than 1 second, and lamination molding is performed while curing the energy ray curable resin that forms the matrix resin of the fiber reinforced plastic tape. An apparatus for laminating and forming fiber reinforced plastics. [9] A movable laminating head for continuously supplying fiber reinforced plastic tape to the surface of the mold, the movable laminating head having a pressure roller for laminating and forming the tape, and according to the fiber placement method The lamination molding apparatus for performing the lamination molding is equipped with an energy beam irradiation device that works in conjunction with the movable lamination head, and the energy beam irradiation device can irradiate the energy beam. An LED is used as the light source of the device, and the time required to change the irradiance of the part irradiated with energy rays to any illuminance is within 1 second. A fiber reinforced plastic laminate molding device characterized in that the laminate molding is carried out while fat is cured. [10] The irradiation width of the energy beam at the bonding site can be controlled to be within ± 10% of the width of the fiber reinforced plastic tape. Fiber reinforced plastic lamination molding equipment. [11] The fiber-reinforced plastic laminate according to any one of [8] to [9], wherein the light amount of the energy beam at the bonding site is controllable in accordance with the tape bonding operation. Molding equipment. [12] The amount of light of the energy line is controlled by the current value of the energy line. 12. The apparatus for laminating and forming fiber-reinforced plastics according to any one of claims 8 to 11.  [13] The fiber reinforced plastic laminate molding apparatus according to any one of [8] to [12], wherein the light quantity of the energy beam is controlled by the energy beam irradiation time. 14. The fiber reinforced plastic laminate molding apparatus according to any one of claims 8 to 13, wherein the light quantity of the energy beam is controlled by the width of the irradiation slit of the energy beam.