CN108215243A - 纤维增强树脂成型品及其制造方法 - Google Patents

纤维增强树脂成型品及其制造方法 Download PDF

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Publication number
CN108215243A
CN108215243A CN201711348678.9A CN201711348678A CN108215243A CN 108215243 A CN108215243 A CN 108215243A CN 201711348678 A CN201711348678 A CN 201711348678A CN 108215243 A CN108215243 A CN 108215243A
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CN
China
Prior art keywords
fiber
molded product
base material
reinforced resin
resin molded
Prior art date
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Pending
Application number
CN201711348678.9A
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English (en)
Inventor
生井泽正树
宇田诚
田中宏幸
岩楯仁志
藤井拓也
新川智
小池郁
加川和宏
东弘英
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Honda Motor Co Ltd
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Honda Motor Co Ltd
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Publication date
Application filed by Honda Motor Co Ltd filed Critical Honda Motor Co Ltd
Publication of CN108215243A publication Critical patent/CN108215243A/zh
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    • 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
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
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    • 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
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    • B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
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  • Chemical Kinetics & Catalysis (AREA)
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Abstract

本发明提供一种纤维增强成型品及其制造方法。将通过将第一连续纤维(16)和第二连续纤维(20)以在彼此之间配置无纺布(18)的方式进行层积而形成的纤维基材(12)配置于上模(140)和下模(120)之间。使上模(140)和下模(120)接近而在彼此之间形成容量大于模腔(160)的封闭空间(170)，将液态的基体树脂(14)供给至封闭空间(170)。使上模(140)和下模(120)进一步接近而以使压力负荷被施加给纤维基材(12)的方式形成模腔(160)，使浸渍纤维基材(12)的液态的基体树脂(14)在模腔(160)内固化。其结果，能够得到纤维增强树脂成型品(10)。

Description

纤维增强树脂成型品及其制造方法
技术领域
本发明涉及一种具有纤维基材和基体树脂(Matrix resin)的纤维增强树脂成型品及其制造方法。
背景技术
作为纤维基材和基体树脂的复合材料的纤维增强树脂作为轻量且高强度、高刚性的原材料众所周知，近来，其成型品(纤维增强树脂成型品，下面也称为“FRP成型品”)作为汽车车身和航空器的结构部件逐渐地被采用。
例如，在日本发明专利公开公报特开2013-023184号中提出了一种FRP成型品，该FRP成型品为所谓的三明治结构，即，为了提高弯曲强度、弯曲刚性等弯曲特性而使用了通过由增强纤维织物构成的一组表层材料夹持芯材而构成的纤维基材。FRP成型品可以通过RTM(Resin Transfer Molding，树脂传递模塑)成型法来得到。在该RTM成型法中，使用能够形成与所期望的FRP成型品的形状相对应的模腔(products cavity/mold cavity)的成型模具，使液态的基体树脂浸渍(impregnate)在该模腔内成型的纤维基材，并使之固化。据此，能够得到FRP成型品。
发明内容
如上所述，在通过RTM成型法得到所述三明治结构的FRP成型品时，如果表层材料的纤维体积含量低的话，当在模腔内芯材被推压到表层材料时等，有如下担忧：在该表层材料的纤维上出现蛇行的部位、密度不均匀的部位。这些部位容易成为使表层材料产生弯折等的起点。因此，为了充分地提高FRP成型品的弯曲特性，需要增大表层材料的纤维体积含量，以避免在表层材料上产生所述部位。
但是，越增大表层材料的纤维体积含量，越难以使液态的基体树脂浸渍纤维基材。如果在纤维基材上产生未浸渍有基体树脂的未浸渍部位的话，有FRP成型品的强度降低的担忧。因此，为了避免产生未浸渍部位，而增加用于使基体树脂浸渍纤维基材的时间的话，则会使FRP成型品的生产效率大幅度地下降。
本发明的主要目的在于，提供一种不降低生产效率就能够提高弯曲特性的纤维增强树脂成型品。
本发明的另一目的在于，提供一种上述的纤维增强树脂成型品的制造方法。
根据本发明的一技术方案，提供一种具有纤维基材和基体树脂的纤维增强树脂成型品的制造方法，该纤维增强树脂成型品的制造方法具有：将通过将第一连续纤维和第二连续纤维以在彼此之间配置无纺布的方式进行层积而形成的所述纤维基材配置于上模和下模之间的工序；使所述上模和所述下模接近而在彼此之间形成容量大于模腔的封闭空间，将液态的所述基体树脂供给至该封闭空间的工序；和使所述上模和所述下模进一步接近而以使压力负荷被施加给所述纤维基材的方式形成所述模腔，使浸渍所述纤维基材的液态的所述基体树脂在所述模腔内固化的工序。
当如上述那样将压力负荷施加给纤维基材时，无纺布在第一连续纤维和第二连续纤维之间克服其弹力而被压缩。据此，第一连续纤维和第二连续纤维(下面也将这些统称为表层材料)通过来自上模和下模的压力负荷和来自无纺布的回弹力而被压缩，因此，使其表观体积含量增大。
即，在该制造方法中，使液态的基体树脂浸渍如下状态的纤维基材，即，该纤维基材为配置于封闭空间且因没有被施加压力负荷而使得表观纤维体积含量较小的状态。据此，能够良好地使基体树脂浸渍纤维基材，因此，能够抑制未浸渍部位的形成，从而能够有效率地得到表现出色的强度的纤维增强树脂成型品。
另外，通过将纤维基材配置于模腔内并且对其施加压力负荷，而能够使浸渍了液态的基体树脂后的表层材料的表观纤维体积含量增大。在该状态下，能够得到通过使纤维基材中的液态的基体树脂固化而使表层材料的纤维体积含量增大的纤维增强树脂成型品。即，能够得到具有出色的弯曲强度、弯曲刚性等弯曲特性的纤维增强树脂成型品。
综上所述，根据本发明所涉及的纤维增强树脂成型品的制造方法，能够同时实现纤维增强树脂成型品的生产效率的提高和弯曲特性的提高。
在上述的纤维增强树脂成型品的制造方法中，优选当将所述第一连续纤维、所述无纺布和所述第二连续纤维各自的在被施加所述压力负荷之前的厚度设为t1’、t2’、t3’且将所述第一连续纤维、所述无纺布和所述第二连续纤维各自的在被施加所述压力负荷时的厚度设为t1、t2、t3时，以下关系式成立：t2/t1＜t2’/t1’和t2/t3＜t2’/t3’。
在这种情况下，与在被施加压力负荷时的纤维基材中无纺布的厚度相对于第一连续纤维的厚度的比率相比，在被施加压力负荷前的纤维基材中无纺布的厚度相对于第一连续纤维的厚度的比率大。同样，与在被施加压力负荷时的纤维基材中无纺布的厚度相对于第二连续纤维的厚度的比率相比，在被施加压力负荷前的纤维基材中的无纺布的厚度相对于第二连续纤维的厚度的比率大。
即，无纺布伴随着压力负荷的施加而变化的厚度被设定成大于第一连续纤维和第二连续纤维各自伴随着压力负荷的施加而变化的厚度。据此，在压力负荷被施加给纤维基材时，能够有效地将来自无纺布的回弹力施加给表层材料，从而使表层材料的体积含量增大。其结果，能够更良好地得到如下作用效果：能够有效率地得到具有出色的弯曲特性的纤维增强树脂成型品。
在上述的纤维增强树脂成型品的制造方法中，优选以下关系式成立：t2’/t1’＝3～20；t2’/t3’＝3～20；t2/t1＝2～10；t2/t3＝2～10。在这种情况下，能够更良好地同时实现纤维增强树脂成型品的弯曲特性的提高和生产效率的提高。这样得到的纤维增强树脂成型品尤其能够作为汽车车身结构部件来适当地使用。
在上述的纤维增强树脂成型品的制造方法中，优选通过针刺法(needle punch)将层积的所述第一连续纤维、所述无纺布和所述第二连续纤维一体化而形成所述纤维基材。在这种情况下，能够使沿厚度方向取向的纤维配置于表层材料和无纺布的层间，因此，能够通过锚定效应(anchor effect)等而使表层材料和无纺布不容易剥离。另外，沿厚度方向取向的纤维形成液态的基体树脂的流路，由此，液态的基体树脂容易浸渍纤维基材，能够抑制产生未浸渍部位。
其结果，即使纤维增强树脂成型品被施加了弯曲负荷，也能够抑制表层材料和无纺布剥离，因此，能够更有效地提高弯曲强度。另外，能够良好地使基体树脂浸渍纤维基材，因此，能够更有效地提高纤维增强树脂成型品的生产效率和强度。
根据本发明的另一技术方案，提供一种具有纤维基材和基体树脂的纤维增强树脂成型品，在该纤维增强树脂成型品中，所述纤维基材具有第一连续纤维、第二连续纤维和配置于所述第一连续纤维和所述第二连续纤维之间的无纺布，当所述第一连续纤维的厚度和纤维体积含量分别为t1和Vf1，所述无纺布的厚度和纤维体积含量分别为t2和Vf2，所述第二连续纤维的厚度和纤维体积含量分别为t3和Vf3时，以下关系式成立：Vf1＞Vf2；t1＜t2；Vf3＞Vf2；t3＜t2。
如上所述，本发明所涉及的纤维增强树脂成型品具有纤维体积含量大于无纺布且厚度小于无纺布的表层材料，据此，能够以比仅具有连续纤维的普通的纤维增强树脂成型品少的纤维的使用量呈现同等的弯曲特性。
在上述的纤维增强树脂成型品中，优选所述无纺布的厚度方向的中心侧的纤维体积含量小于厚度方向的两端侧的纤维体积含量。在这种情况下，由于纤维基材的厚度方向的表层侧的纤维体积含量大于厚度方向的中心侧的纤维体积含量，因此，能够更有效地提高纤维增强树脂成型品的弯曲刚性。
根据与附图配合的下面的优选的实施方式的说明，上述的目的、特征和优点将会更清楚。
附图说明
图1是本发明的实施方式所涉及的纤维增强树脂成型品的主要部位的概略纵截面图。
图2是用于得到图1的纤维增强树脂成型品的成型装置处于开模状态时的主要部位的概略纵截面图。
图3是表示从图2变为闭模状态时的中途的状态的主要部位的概略纵截面图。
图4是表示从图3更接近闭模状态的状态的主要部位的概略纵截面图。
图5为图4的主要部位的放大图。
图6是表示从图4更接近闭模状态的状态的主要部位的概略纵截面图。
图7是表示图6之后的闭模状态的主要部位的概略纵截面图。
图8为图7的主要部位的放大图。
图9是表示在图7之后，进行开模，将纤维增强树脂成型品脱模的状态的主要部位的概略纵截面图。
具体实施方式
下面，对于本发明所涉及的纤维增强树脂成型品(FRP成型品)，根据其与其制造方法的关系以优选的实施方式为例，参照附图详细地进行说明。
图1是本实施方式所涉及的纤维增强树脂成型品10的主要部位的概略纵截面图。纤维增强树脂成型品10具有纤维基材12和与该纤维基材12进行复合化的基体树脂14(参照图4)。纤维基材12是将第一连续纤维16、无纺布18和第二连续纤维20按照此顺序进行层积，并如后述那样通过针刺法(Needle Punch)来形成为一体。因此，在第一连续纤维16及第二连续纤维20(下面，也将这些统称为表层材料16、20)与无纺布18的层间配置有沿纤维基材12的厚度方向取向的纤维。
第一连续纤维16是例如将使增强纤维沿一方向取向的片状的UD材料16a、16b以彼此的增强纤维的取向方向不同的方式进行层积而构成。此外，构成第一连续纤维16的UD材料并不局限于2张，也可以仅为1张、或3张以上。另外，UD材料16a、16b也可以以增强纤维的取向方向相同的方式层积。作为增强纤维的优选的材料，列举有碳纤维、玻璃纤维、树脂纤维等。
无纺布18以在厚度方向上具有弹性的方式由增强纤维形成为片状。作为增强纤维的优选的材料，可以举出与构成第一连续纤维16的增强纤维相同的材料。另外，无纺布18被调节成厚度方向的中心侧的纤维体积含量小于厚度方向的两端侧的纤维体积含量。
第二连续纤维20可以被设为与第一连续纤维16相同的各种结构。在本实施方式中，第二连续纤维20将使增强纤维沿一方向取向的片状的UD材料20a、20b以彼此的增强纤维的取向方向不同的方式进行层积而构成。
在此，在为了构成纤维增强树脂成型品10而与基体树脂14复合化的纤维基材12中，表层材料16、20和无纺布18在沿厚度方向被压缩的状态下被维持。在将这种纤维增强树脂成型品10中的第一连续纤维16的厚度(UD材料16a、16b的合计厚度)设为t1，将第一连续纤维16的纤维体积含量设为Vf1，将无纺布18的厚度设为t2，将无纺布18的纤维体积含量设为Vf2，将第二连续纤维20的厚度(UD材料20a、20b的合计厚度)设为t3，将第二连续纤维20的纤维体积含量设为Vf3的情况下，它们之间以下关系式成立。Vf1＞Vf2；t1＜t2；Vf3＞Vf2；t3＜t2。
图2是用于得到纤维增强树脂成型品10的成型装置100的主要部位的概略纵截面图。该成型装置100具有作为成型模具的、下模120和上模140，在这些下模120和上模140之间能够形成与纤维增强树脂成型品10相对应的形状的模腔160(参照图7)和容量大于该模腔160的封闭空间170(参照图4和图6)。此外，图2表示成型装置100处于开模状态时的情况。
下模120为被定位固定的固定型，且为形成有向铅垂下方凹陷的腔形成用凹部180的所谓的凹型。在此，在下模120的上端面的边缘部形成有向上模140突出的突部200，该突部200以围绕所述腔形成用凹部180的方式突出形成。
在突部200的外侧面环绕形成有第一槽220。第一密封部件240被插入到该第一槽220。第一密封部件240的大部分从第一槽220露出。
另一方面，上模140为在未图示的升降机构的作用下能够相对于下模120下降(接近)或上升(离开)的可动型。另外，上模140为具有在进行闭模时进入所述腔形成用凹部180的腔形成用凸部260的、所谓的凸型。伴随着腔形成用凸部260进入腔形成用凹部180，形成有封闭空间170和模腔160。
上模140还具有柱状部280和基部300。所述腔形成用凸部260经由柱状部280与基部300连接。
在基部300的下端面的边缘部设置有围绕壁320，该围绕壁320向下模120延伸，在进行闭模时围绕所述突部200的外侧面侧。因此，在柱状部280和围绕壁320之间形成有相对凹陷的插入部340。即，插入部340由柱状部280的侧面、基部300的下端面和围绕壁320的内侧面形成。
在柱状部280的侧面、即在插入部340环绕形成有第二槽360，第二密封部件380被插入到该第二槽360。与第一密封部件240相同，第二密封部件380的大部分也从第二槽360露出。
如后所述，突部200进入到插入部340。伴随于此，第一密封部件240与围绕壁320的内侧面抵接，并且，第二密封部件380与突部200的内侧面抵接(参照图4)。其结果，在第一密封部件240和第二密封部件380之间形成有密封室400。
在基部300，以与密封室400连通的方式形成有排气用通路420。在该排气用通路420连接有排气管440，按照三通阀460和泵480的顺序从上游侧将两者安装于该排气管440。
在三通阀460还连接有朝空气敞开的敞开管500。即，三通阀460起到切换朝向泵480的流路和朝空气敞开的流路的作用。当切换为朝向泵480的流路时，由泵480来进行下模120和上模140的内部的排气。另一方面，当切换为朝空气敞开的流路时，下模120和上模140的内部朝空气敞开。此外，也可以不连接敞开管500，而将三通阀460的3个口中的1个朝空气敞开。
在上模140形成有流道540(runner)，该流道540从基部300经由柱状部280连接到腔形成用凸部260。该流道540为用于将从注入器560所导出的液态的基体树脂14(参照图4)供给至封闭空间170的供给通路。
接着，对使用成型装置100来制造本实施方式所涉及的纤维增强树脂成型品10的方法进行说明。
首先，将第一连续纤维16、无纺布18和第二连续纤维20按照此顺序进行层积，并通过沿厚度方向穿插针(未图示)的针刺加工来形成为一体，从而形成纤维基材12。在此的纤维基材12为与基体树脂14复合化之前的状态，换言之为表层材料16、20和无纺布18各自沿厚度方向被压缩之前的状态。即，当将压缩前(压力负荷施加前)的纤维基材12中的第一连续纤维16的厚度设为t1’，将无纺布18的厚度设为t2’，将第二连续纤维20的厚度设为t3’(参照图5)时，以下关系式成立：t1’＞t1；t2’＞t2；t3’＞t3。
接着，如图2所示，使成型装置100处于开模状态，将纤维基材12配置于腔形成用凹部180。此时，彼此相离的下模120和上模140之间朝空气敞开。另外，三通阀460为关闭状态。
接着，驱动所述升降机构，使上模140向下模120下降。在该下降过程中，上模140的围绕壁320的内侧面与下模120的突部200的外侧面相向。如图3所示，当围绕壁320的内侧面与第一密封部件240接触时，通过该第一密封部件240，突部200和围绕壁320之间被密封。其结果，在下模120和上模140之间形成有与空气阻隔的空间520。
接着，驱动泵480并且操作三通阀460，来打开朝向泵480的流路。据此，排气管440变为与下模120和上模140之间的空间连通的状态，因此，空间520内的空气由泵480排出。其结果，空间520变为大致50～100kPa的负压。
此外，在进行空间520的排气的过程当中，也继续进行上模140的下降。因此，如图4所示，腔形成用凸部260进入到腔形成用凹部180，并且接近纤维基材12。另外，突部200接近插入部340，进而，突部200的内侧面和柱状部280的侧面相向。即，成型装置100更接近闭模状态。
当突部200的内侧面与第二密封部件380接触时，通过该第二密封部件380，突部200和柱状部280之间被密封。其结果，在下模120和上模140之间形成有容量大于模腔160(参照图7)的封闭空间170。在该封闭空间170内，上模140不接触纤维基材12，换言之，压力负荷不会被施加于纤维基材12。因此，如图5的主要部位放大图所示，纤维基材12的表层材料16、20和无纺布18各自保持沿厚度方向被压缩之前的状态不变。
在突部200和围绕壁320之间，维持由第一密封部件240密封的状态。因此，在第一密封部件240和第二密封部件380之间形成有密封室400。密封室400由第二密封部件380将其与封闭空间170隔离。
此时，使三通阀460处于关闭(closure)状态，并且切断(de-energized)泵480的动力源，使之停止排气。此外，根据第一密封部件240和第二密封部件380的安装位置和上模140的下降速度，预先计算出形成密封室400的时间，根据该计算结果设定排气的停止时间即可。
再者，由注入器560导出液态的基体树脂14。在此，作为液态的基体树脂14的优选的例子，列举有环氧树脂、聚氨酯树脂、聚酰胺树脂(ε-己内酰胺)等。在ε-己内酰胺树脂的情况下，可以同时供给催化剂和活性剂。作为催化剂，例如有钠等的碱金属及其氧化物、氢氧化物和氢化物、以及碱土类金属及其氧化物、氢氧化物和氢化物等，作为活性剂，例如有异氰酸酯(isocyanate)、酰基内酰胺(Acyl lactam)、异氰脲酸酯衍生物、酰卤、碳酰胺内酰胺等。
另外，在环氧树脂的情况下，可以同时供给由酸酐、脂肪族多胺、酰胺-胺(amide，amine)、聚酰胺、路易斯碱基、芳香族多胺等构成的固化剂。
以上这种液态的基体树脂14在经过流道540之后，从腔形成用凸部260的顶端被导出到封闭空间170。液态的基体树脂14通过由注入器560以规定压力射出而较为容易地在纤维基材12和腔形成用凸部260之间的间隙流动。当规定量的液态的基体树脂14被导出时，停止射出该液态的基体树脂14。
在停止该射出之前或之后、或者在停止射出的同时操作三通阀460，从而打开朝空气敞开的流路。即，敞开管500变为与密封室400连通的状态。据此，密封室400朝空气敞开，因此，其结果，密封室400变为大气压。
上模140进一步下降，如图6所示，使腔形成用凸部260进一步进入到腔形成用凹部180时，液态的基体树脂14被该腔形成用凸部260按压。此时，上模140也不与纤维基材12接触，使得封闭空间170内的纤维基材12不会被施加压力负荷。即，此时，如后所述，也不会对纤维基材12进行使其表观纤维体积含量增大的压缩。
这样，纤维基材12不会沿厚度方向被压缩、液态的基体树脂14被腔形成用凸部260(上模140)加压以及封闭空间170为负压的这三种情况相辅相成，而使液态的基体树脂14容易沿纤维基材12展开。据此，能够良好地使液态的基体树脂14浸渍纤维基材12。
接着，如图7所示，进一步使上模140下降，从而在下模120和上模140之间形成模腔160。据此，模腔160内的纤维基材12被施加压力负荷，使之沿厚度方向被压缩。即，在第一连续纤维16和第二连续纤维20之间，无纺布18克服其弹力而被压缩。其结果，通过来自上模140和下模120的压力负荷和来自无纺布18的回弹力来压缩表层材料16、20，而能够有效地使表观体积含量增大。
具体而言，如图8的主要部位放大图所示，第一连续纤维16的厚度减小而变为t1，该第一连续纤维16的表观纤维体积含量增大而变为Vf1。另外，无纺布18的厚度减小而变为t2，该无纺布18的表观纤维体积含量增大而变为Vf2。再者，第二连续纤维20的厚度减小而变为t3，该第二连续纤维20的表观纤维体积含量增大而变为Vf3。
优选被施加压力负荷之前的纤维基材12的厚度和被施加压力负荷时的纤维基材12的厚度之间以下关系式成立：t2/t1＜t2’/t1’和t2/t3＜t2’/t3’，更优选以下关系式成立：t2’/t1’＝3～20；t2’/t3’＝3～20；t2/t1＝2～10；t2/t3＝2～10。
在模腔160内，通过随着规定时间的经过，液态的基体树脂14固化，而最终能够得到纤维增强树脂成型品10。在该纤维增强树脂成型品10中，表层材料16、20和无纺布18维持压缩后的厚度和纤维体积含量不变。
然后，如图9所示，在所述升降机构的作用下使上模140上升来进行开模之后，从成型装置100取出纤维增强树脂成型品10。即，进行所谓的脱模。在此时，例如，顶出针(未图示)等动作。
综上所述，在本实施方式所涉及的制造方法中，使液态的基体树脂14浸渍如下状态的纤维基材12，即，该纤维基材12为因配置于封闭空间170而没有被施加压力负荷而使得表观纤维体积含量较小的状态。据此，能够良好地使基体树脂14浸渍纤维基材12，因此，能够抑制形成有未浸渍部位，从而能够有效率地得到表现出色的强度的纤维增强树脂成型品10。
另外，通过将纤维基材12配置于模腔160内并且对其施加压力负荷，而能够使浸渍了液态的基体树脂14后的表层材料16、20的表观纤维体积含量增大。在该状态下，在使纤维基材12中的液态的基体树脂14固化而得到的纤维增强树脂成型品10中，能够使表层材料16、20的纤维体积含量增大，因此，能够提高弯曲强度、弯曲刚性等弯曲特性。
即，根据该制造方法，能够同时实现纤维增强树脂成型品10的生产效率的提高和弯曲特性的提高。
在该制造方法中，被施加压力负荷之前的纤维基材12的厚度和被施加压力负荷时的纤维基材12的厚度之间上述关系式成立。即，伴随着将压力负荷施加给无纺布18而变化的无纺布18的厚度被设定成大于伴随着将压力负荷施加给第一连续纤维16和第二连续纤维20各自而变化的第一连续纤维16和第二连续纤维20的厚度。据此，在压力负荷被施加给纤维基材12时，能够有效地将来自无纺布18的回弹力施加给表层材料16、20，从而使表层材料16、20的体积含量增大。其结果，能够更良好地得到如下作用效果：能够有效率地得到具有出色的弯曲特性的纤维增强树脂成型品10。
另外，在该制造方法中，如上所述，通过使用针刺处理来形成纤维基材12，使沿厚度方向取向的纤维配置于表层材料16、20和无纺布18的层间。据此，能够通过锚定效应等而使表层材料16、20和无纺布18不容易剥离。另外，沿厚度方向取向的纤维通过形成液态的基体树脂14的流路，来使液态的基体树脂14容易浸渍纤维基材12，从而能够抑制产生未浸渍部位。
其结果，即使纤维增强树脂成型品10被施加了弯曲负荷，也能够抑制表层材料16、20和无纺布18剥离，因此，能够更有效地提高弯曲强度。另外，能够良好地使基体树脂14浸渍纤维基材12，因此，能够更有效地提高纤维增强树脂成型品10的生产效率和强度。
再者，在纤维增强树脂成型品10中，如上所述，具有纤维体积含量大于无纺布18且厚度小于无纺布18的表层材料16、20。据此，能够以比仅具有连续纤维的普通的纤维增强树脂成型品(未图示)少的纤维的使用量来呈现同等的弯曲特性。另外，如上所述，纤维增强树脂成型品10具有厚度方向的中心侧的纤维体积含量小于厚度方向的两端侧的纤维体积含量的无纺布18。据此，由于纤维基材12的厚度方向的表层侧的纤维体积含量大于厚度方向的中心侧的纤维体积含量，因此，能够更有效地提高纤维增强树脂成型品10的弯曲刚性。
本发明并不特别局限于上述的实施方式，在不脱离其主旨的范围内，可以进行各种变更。

Claims (6)

1.一种纤维增强树脂成型品(10)的制造方法，其中该纤维增强树脂成型品(10)具有纤维基材(12)和基体树脂(14)，
该纤维增强树脂成型品(10)的制造方法的特征在于，具有：
将所述纤维基材(12)配置于上模(140)和下模(120)之间的工序，其中所述纤维基材(12)通过将第一连续纤维(16)和第二连续纤维(20)以在彼此之间配置无纺布(18)的方式进行层积来形成；
使所述上模(140)和所述下模(120)接近而在彼此之间形成容量大于模腔(160)的封闭空间(170)，且将液态的所述基体树脂(14)供给至该封闭空间(170)的工序；和
使所述上模(140)和所述下模(120)进一步接近而以使压力负荷被施加给所述纤维基材(12)的方式来形成所述模腔(160)，且使浸渍所述纤维基材(12)的液态的所述基体树脂(14)在所述模腔(160)内固化的工序。
2.根据权利要求1所述的纤维增强树脂成型品(10)的制造方法，其特征在于，
当将所述第一连续纤维(16)、所述无纺布(18)和所述第二连续纤维(20)各自的被施加所述压力负荷之前的厚度设为t1’、t2’、t3’且将所述第一连续纤维(16)、所述无纺布(18)和所述第二连续纤维(20)各自的被施加所述压力负荷时的厚度设为t1、t2、t3时，以下关系式成立：
t2/t1＜t2’/t1’；t2/t3＜t2’/t3’。
3.根据权利要求2所述的纤维增强树脂成型品(10)的制造方法，其特征在于，
以下关系式成立：
t2’/t1’＝3～20；t2’/t3’＝3～20；
t2/t1＝2～10；t2/t3＝2～10。
4.根据权利要求1～3中任一项所述的纤维增强树脂成型品(10)的制造方法，其特征在于，
通过针刺法对所层积的所述第一连续纤维(16)、所述无纺布(18)和所述第二连续纤维(20)进行一体化来形成所述纤维基材(12)。
5.一种纤维增强树脂成型品(10)，其具有纤维基材(12)和基体树脂(14)，
该纤维增强树脂成型品(10)的特征在于，
所述纤维基材(12)具有第一连续纤维(16)、第二连续纤维(20)和配置在所述第一连续纤维(16)和所述第二连续纤维(20)之间的无纺布(18)，
当所述第一连续纤维(16)的厚度和纤维体积含量分别为t1和Vf1且所述无纺布(18)的厚度和纤维体积含量分别为t2和Vf2且所述第二连续纤维(20)的厚度和纤维体积含量分别为t3和Vf3时，以下关系式成立：
Vf1＞Vf2；t1＜t2；Vf3＞Vf2；t3＜t2。
6.根据权利要求5所述的纤维增强树脂成型品(10)，其特征在于，
所述无纺布(18)的厚度方向的中心侧的纤维体积含量小于厚度方向的两端侧的纤维体积含量。
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