碳纖維複合材料成型品質探討與研究－以避震登山車車架為例

Analysis and Study of Carbon Fiber Composite Curing Quality-With Suspension MTB Frame.

陳建亨(Chris,Chen)

指導教授 ： 陳明德

國立中正大學/管理學院/企業管理學系/碩士(2012年)

摘要

碳纖維強化樹脂複合材料由於具有高剛性、高強度以及重量輕等優點，現已普遍應用於航太產業、汽車產業和運動器材產業。碳纖維強化樹脂應用於自行車車架之製造上，不同於一般金屬材料，因為碳纖維強化樹脂配合模具可以成型至任何可以想像的車架形狀。由於碳纖維強化樹脂材質的優越特性，使工程師們能夠很容易地設計出一台最佳力學結構的自行車車架，並且具備了高剛性、輕量化、耐疲勞以及騎乘舒適性等優點。
但由於外觀成型品質的不良，導致必須先施以補土製程才能對成型製品進行烤漆；而補土製程經由統計結果是車架所有生產製程之中成本最高、產能較低的製程，已嚴重侵蝕掉所屬產業的獲利與交期的競爭性。有鑑於此本論文將以實驗為主、理論為輔的方式，進行碳纖維登山自行車車架成型品質的探討與研究。
造成成型外觀品質不良的主要原因為樹脂流失率不穩定、模具溫差過大以及模具設計不良；首先將成型設備修改為以模溫控制開模時間與吹氣入壓時機，並搭配適合環氧樹脂系統的模壓成型條件來穩定樹脂流失率差異，實驗結果為樹脂流失率差異可從原先的7%控制到0.8%；接下來透過成型模具的重新設計來改善模具溫差過大與外觀缺膠現象；使模具溫差由原先的18.8℃降低至5.9℃，模具溫差縮小12.9℃。在外觀缺膠的改善亦具有顯著的成效，可由原先的25點外觀缺膠點數降低至5點，其改善成效可大幅度提升達80%；對於剩餘20%的外觀缺膠以及使用舊設計的成型模具；本論文亦提供了妥善與快速的解決對策。

關鍵字

熱壓成型 ； 碳纖維強化樹脂 ； 複合材料 ； 樹脂流失率 ； 氣泡

並列摘要

Because CFRP (Carbon Fiber Reinforced Plastics) composite possesses the advantages, such as high stiffness, high strength and lightweight, etc., CFRP has already been generally applied to aviation industry, automobile industry and sports Equipment industry. CFRP composite is used when produce the MTB bicycle frame, it is different from the general metal material, because CFRP can reach any form that you can imagine while applying to the mould. Because the superior characteristic of the carbon fiber material , making the engineer very apt to design a frame can reach the best mechanics structure , and the advantage the frame that make possesses high stiffness , lightweight , anti fatigue and riding comfortably etc.
Because the appearance quality of curing is not good, cause raw frame to finish Bondo (Putty) process first, can just spray paint to raw frame. Bondo (Putty) process has the highest cost and the least quantity of manufacturing capacity in all processes via counting. This will increase the production cost, and reducing produces competitiveness of delivery. In view of this, this thesis will regard experiment as the main research way, and assist through composite theory. Probe into and study curing quality about carbon fiber MTB bicycle frame.
Suppose at first that the resin flow out rate is unstable, the molds temperature difference is too big, cure molds design is not perfect, these three reasons are the main reasons that cause curing appearance not good. Make use of the modification of curing equipment, Control mould open time and offering opportunity of controlling the high-pressure air with the temperature of the mould. Must also match cure condition of the suitable epoxy resin system, could come to stabilize resin flow out rate. The resin flow out difference rate is from 7% original while changing into 0.8% through improving. And then through curing mould redesign, improving the difference of temperature of the mould too big and resin poor phenomenon of appearance. Curing mould redesign makes the difference of temperature of the same mould reduce from original 18.8 degrees Centigrade to 5.9 degrees Centigrade, difference of temperature of the mould has been reduced by 12.9 degrees centigrade altogether. Also there is obvious improvement in the poor resin of appearance; Reduce from original 25point to 5 point, it is up to 80 % to improve the effect. For remaining 20% of the poor resin of appearance, and is still using old curing molds, this thesis has also offered the appropriate and fast settlement countermeasure.

並列關鍵字

Hot Press Molding ； Carbon Fiber Reinforced Plastics ； Composite ； Resin Flow Out Rate ； Voids

參考文獻

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