Preform for molding fiber-reinforced resin beam, process for producing the same, apparatus for producing the same, and process for producing fiber-reinforced resin beam

Abstract

A preform for the molding of a fiber-reinforced resin beam, the preform comprising: a reinforcing-fiber beam which has been formed from a reinforcing-fiber base made up of many reinforcing fibers and has a cross-sectional shape comprising at least one linear part and at least one curved part connected to the linear part; and a release sheet bonded and united through an adhesive resin to at least part of a surface of the reinforcing-fiber base along the lengthwise direction for the base. A process for producing a preform comprises: a step in which a continuous flat reinforcing-fiber base having a release sheet bonded and united to a surface thereof is shaped so that the cross-sectional shape of the base comes to have a curved part to thereby produce a preshaped object; and a preshaped-object uniting step in which the preshaped object is bonded and united to another preshaped object.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a divisional application of U.S. patent application Ser. No. 12 / 524,241, filed Jul. 23, 2009, which is a U.S. National Phase Application of PCT International Application No. PCT / JP2008 / 050864, filed Jan. 23, 2008, which claims priority to Japanese Patent Application No. 2007-016230, filed Jan. 26, 2007, which applications are incorporated by reference herein in their entirety for all purposes.FIELD OF THE INVENTION[0002]The present invention relates to a preform for molding a fiber-reinforced resin beam, a process for producing the same, an apparatus for producing the same, and a process for producing a fiber-reinforced resin beam. The preform of the invention for molding a fiber-reinforced resin beam is preferably used when a fiber-reinforced resin beam is produced using a matrix resin by a resin transfer molding method.BACKGROUND OF THE INVENTION[0003]A fiber reinforced resin molded object comprising reinforcing fibe...

AI Technical Summary

Benefits of technology

This patent describes a method for making fiber-reinforced resin beams used in applications like cars and aircraft. By using a pre-made sheet that has been bonded to a dry reinforcing fiber base using an adhesive resin, the work of arranging the release sheet in the mold is reduced, and a better quality beam can be made. Additionally, the method prevents fuzz during trimming of the reinforcing fiber. Overall, this method simplifies the process of making high-quality fiber-reinforced resin beams.

Problems solved by technology

However, in the autoclave molding method in which the prepreg sheet is used, there has been a problem that a complicated three-dimensionally shaped molded object is difficult to be molded.

And, since materials cost is too high and molding time is too long, there has been a problem that production cost of the molded object becomes high.

However, by only simply placing a necessary number of the reinforcing fiber cloths in the mold by laying on the other in turn, it is difficult to produce a composite material in which reinforcing fiber cloth has no significant wrinkles and the reinforcing fibers distribute nearly uniformly, and in addition, having a high fiber volume fraction Vf (volume percentage occupied by reinforcing fiber in total volume of molded object).

However, this work for preparing the preform and quality of the preform bring about a great influence to production cost and quality of the composite material.

However, since the release material is, generally, a cloth such as of polyamide or polyester fiber, and media material is, generally, a net-like material (mesh) formed by such as polyamide, by only simply placing these materials at a desired position on a surface of the preform, these are difficult to be fixed at the position.

In particular, in order to arrange and fix the release material to a surface of the preform of complicated shape having a bent portion or branch portion in cross-sectional shape, there has been a problem that considerable work is required, and cost merit of the resin transfer molding method is counteracted.

For that purpose, in most cases, the release material is formed with a material of which thickness is small, not having good adhesive properties, and in addition, which is slippery.

In addition, since the release material is, as the above-mentioned, generally, a woven fabric such as of polyamide or polyester fiber, is poor in stretchability, there was a problem that, unless it is tightly arranged along the shape of preform, when the mold is pushed against the preform, a wrinkle is generated in the release material or a tension of the release material at position of bent portion of the preform is generated, and the mold cannot be pushed against a predetermined position, and the matrix resin is collected in the gap generated between the release material and the preform to form a resin rich portion, and quality of resin molded object formed is deteriorated.

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