CN117601471A - Resin molded article and method for producing same - Google Patents
Resin molded article and method for producing same Download PDFInfo
- Publication number
- CN117601471A CN117601471A CN202311823470.3A CN202311823470A CN117601471A CN 117601471 A CN117601471 A CN 117601471A CN 202311823470 A CN202311823470 A CN 202311823470A CN 117601471 A CN117601471 A CN 117601471A
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- mold
- resin
- fiber
- resin molded
- prepreg
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- 229920005989 resin Polymers 0.000 title claims abstract description 213
- 239000011347 resin Substances 0.000 title claims abstract description 213
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 22
- 238000000465 moulding Methods 0.000 claims abstract description 36
- 239000000835 fiber Substances 0.000 claims abstract description 22
- 238000010438 heat treatment Methods 0.000 claims abstract description 18
- 239000000463 material Substances 0.000 claims description 31
- 238000005187 foaming Methods 0.000 abstract description 13
- 238000003825 pressing Methods 0.000 abstract description 2
- 238000000034 method Methods 0.000 description 7
- 229920000049 Carbon (fiber) Polymers 0.000 description 6
- 239000004917 carbon fiber Substances 0.000 description 6
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 5
- 229920005992 thermoplastic resin Polymers 0.000 description 5
- 229920001187 thermosetting polymer Polymers 0.000 description 5
- 238000010586 diagram Methods 0.000 description 4
- 239000003733 fiber-reinforced composite Substances 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- -1 polyethylene Polymers 0.000 description 4
- 229920002635 polyurethane Polymers 0.000 description 4
- 239000004814 polyurethane Substances 0.000 description 4
- 239000002994 raw material Substances 0.000 description 3
- VPWNQTHUCYMVMZ-UHFFFAOYSA-N 4,4'-sulfonyldiphenol Chemical compound C1=CC(O)=CC=C1S(=O)(=O)C1=CC=C(O)C=C1 VPWNQTHUCYMVMZ-UHFFFAOYSA-N 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- BZHJMEDXRYGGRV-UHFFFAOYSA-N Vinyl chloride Chemical compound ClC=C BZHJMEDXRYGGRV-UHFFFAOYSA-N 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 2
- 230000001070 adhesive effect Effects 0.000 description 2
- 239000002131 composite material Substances 0.000 description 2
- 238000000748 compression moulding Methods 0.000 description 2
- 239000003822 epoxy resin Substances 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229920001568 phenolic resin Polymers 0.000 description 2
- 239000005011 phenolic resin Substances 0.000 description 2
- 229920002239 polyacrylonitrile Polymers 0.000 description 2
- 229920006122 polyamide resin Polymers 0.000 description 2
- 229920005668 polycarbonate resin Polymers 0.000 description 2
- 239000004431 polycarbonate resin Substances 0.000 description 2
- 229920000647 polyepoxide Polymers 0.000 description 2
- 229920001225 polyester resin Polymers 0.000 description 2
- 239000004645 polyester resin Substances 0.000 description 2
- 229920013716 polyethylene resin Polymers 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 229920005990 polystyrene resin Polymers 0.000 description 2
- 230000003746 surface roughness Effects 0.000 description 2
- 229920006337 unsaturated polyester resin Polymers 0.000 description 2
- 229920001567 vinyl ester resin Polymers 0.000 description 2
- KXGFMDJXCMQABM-UHFFFAOYSA-N 2-methoxy-6-methylphenol Chemical compound [CH]OC1=CC=CC([CH])=C1O KXGFMDJXCMQABM-UHFFFAOYSA-N 0.000 description 1
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 229920002943 EPDM rubber Polymers 0.000 description 1
- BRLQWZUYTZBJKN-UHFFFAOYSA-N Epichlorohydrin Chemical compound ClCC1CO1 BRLQWZUYTZBJKN-UHFFFAOYSA-N 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 239000004677 Nylon Substances 0.000 description 1
- 239000004952 Polyamide Substances 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 229910001069 Ti alloy Inorganic materials 0.000 description 1
- JRBRVDCKNXZZGH-UHFFFAOYSA-N alumane;copper Chemical compound [AlH3].[Cu] JRBRVDCKNXZZGH-UHFFFAOYSA-N 0.000 description 1
- 229920000229 biodegradable polyester Polymers 0.000 description 1
- 239000004622 biodegradable polyester Substances 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000000805 composite resin Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 150000001993 dienes Chemical class 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000004744 fabric Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 229920001778 nylon Polymers 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920002647 polyamide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920005749 polyurethane resin Polymers 0.000 description 1
- 230000002265 prevention Effects 0.000 description 1
- 239000011342 resin composition Substances 0.000 description 1
- 238000009958 sewing Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000011800 void material Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- 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
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/84—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks by moulding material on preformed parts to be joined
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Mechanical Engineering (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
The present invention provides a resin molded article and a method for producing the same, comprising: a step of preparing a pair of a first mold and a second mold for molding the resin molded product; disposing a fiber-reinforced resin prepreg on molding surfaces of the resin molded articles in the first mold and the second mold; a step of introducing a foamable resin onto the fiber reinforced resin prepreg placed in the first mold; a step of bringing one of the first mold and the second mold close to the other and heating under pressure in a state where the first mold and the second mold are brought into contact to seal the arranged fiber reinforced resin prepreg and foamable resin; and a step of deforming the fiber reinforced resin prepreg according to the shape of the molding surface by foaming the foamable resin by heating and pressing the fiber reinforced resin prepreg against the molding surface of the mold.
Description
Technical Field
The present invention relates to a resin molded article and a method for producing the same.
Background
Fiber-reinforced composite resins have been attracting attention in recent years as lightweight and high-strength materials. In the compression molding, a molded article using a fiber-reinforced composite resin can be produced by compression molding a laminate in which a prepreg of the fiber-reinforced composite resin is laminated.
When it is intended to make the laminate of prepregs itself have a large volume, if only a fiber-reinforced resin is used as the laminate constituent material, it is necessary to laminate many layers of prepregs, resulting in very high cost. Accordingly, in the related art, a molded body of a metal or a resin having a certain size is made to have a large volume by sandwiching it between prepregs.
The molded body used as the inner member may have precise irregularities on the upper and side surfaces. The material constituting the surface of the molded article is preferably a fiber-reinforced resin, but the surface is molded using wax or the like because it takes time to cut the fiber-reinforced resin to form dense irregularities.
As the molded article, for example, as shown in patent document 1, there is a molded article having moldability (shape formability) when hot-pressed by providing prepregs on the upper and lower surfaces of a base portion including a thermosetting resin and fibers (patent document 1).
Patent document 2 describes a method of manufacturing a composite product having a complex shape by disposing a carbon fiber fabric in a mold having a cavity and filling a film-like resin filler into a void portion to perform molding (patent document 2).
(patent document 1) Japanese patent application laid-open No. 2019-26703
(patent document 2) Japanese patent application laid-open No. 2004-99731
Disclosure of Invention
Technical problem to be solved
In the technique of patent document 1, in producing a usable molded article, hard materials such as prepregs are used on the upper and lower surfaces of the base, and thus the moldability is not necessarily sufficient, and there is a problem that it is difficult to mold fine portions having complex shapes on the surfaces. Further, patent document 2 is an RFI molding technique, and when a general resin is filled in a gap between a preform and a mold and molded, even a composite product of a complex shape can be easily manufactured, but there is a problem in that the resin does not reach every corner of the mold and the accuracy is insufficient.
In addition, there is a problem in that the surface is shaped with wax, and is sensitive to heat.
The present invention aims to provide a method for manufacturing a resin molded product and a resin molded product, which can easily mold complex surface shapes without cutting the surface composed of fiber reinforced resin.
Solution to the problem
As a result of intensive studies, the present inventors have found that a resin molded article having a high-precision surface shape can be provided even if the molding surface is a complex shape by disposing a fiber-reinforced resin prepreg in a mold having a cavity, disposing a preform thereon as needed, introducing a foamable resin onto the fiber-reinforced resin (or onto a wire-reinforced resin and around the preform), foaming the foamable resin by heating, and pressing the fiber-reinforced resin prepreg against the molding surface of the mold.
Namely, the present invention includes the following.
(1) A method for producing a resin molded article, comprising:
a step of preparing a pair of a first mold and a second mold for molding the resin molded product;
disposing a fiber-reinforced resin prepreg on molding surfaces of the resin molded articles in the first mold and the second mold;
a step of introducing a foamable resin onto the fiber reinforced resin prepreg placed in the first mold;
a step of bringing one of the first mold and the second mold close to the other and heating under pressure in a state where the first mold and the second mold are brought into contact to seal the arranged fiber reinforced resin prepreg and foamable resin; and
And a step in which the foamable resin is foamed by heating, and the fiber-reinforced resin prepreg is pressed against the molding surface of the mold, whereby the fiber-reinforced resin prepreg is deformed according to the shape of the molding surface.
(2) A method for producing a resin molded article, comprising:
a step of preparing a pair of a first mold and a second mold for molding the resin molded product;
disposing a fiber-reinforced resin prepreg on molding surfaces of the resin molded articles in the first mold and the second mold;
a step of preparing a preform having a smaller volume than the resin molded product;
disposing the preform on the fiber reinforced resin prepreg disposed in a first mold;
a step of introducing a foamable resin onto the fiber reinforced resin prepreg placed in the first mold;
a step of bringing one of the first mold and the second mold close to the other and heating under pressure in a state where the first mold and the second mold are brought into contact to seal the arranged fiber reinforced resin prepreg and foamable resin; and
And a step in which the foamable resin is foamed by heating, and the fiber-reinforced resin prepreg is pressed against the molding surface of the mold, whereby the fiber-reinforced resin prepreg is deformed according to the shape of the molding surface.
(3) The manufacturing method according to (1) or (2), wherein the first mold has a first cavity, and the second mold has a second cavity.
(4) The production method according to (1) or (2), wherein a material of the preform is the same as a material of the foamable resin.
(5) A resin molded article, comprising:
a preform having a smaller volume than the resin molded article;
a foamed resin layer covering at least a part or all of the surface of the preform; and
And a fiber-reinforced resin layer which is derived from a prepreg and covers the foamed resin layer or the preform.
ADVANTAGEOUS EFFECTS OF INVENTION
The following resin molded articles can be provided: the resin molded article uses a preform smaller than a resin molded article as a finished product, and does not need to precisely mold a surface roughness, and a foamable resin is used to spread over the entire gap between the preform and the mold, thereby providing a surface shape with high precision.
Drawings
Fig. 1 is a perspective view of a resin molded product 1.
Fig. 2 is a perspective view of the preform 2.
Fig. 3 is a diagram showing a process for producing a resin molded product according to embodiment 1, and each of the diagrams is a cross-sectional view.
Fig. 4 is a diagram showing a process for producing a resin molded product according to embodiment 2, and each of the diagrams is a cross-sectional view.
(description of the reference numerals)
1 resin molded article 11 resin molded article protrusion
2 preform 21 preform protrusion
31 lower die 32 upper die
33 first chamber 34 second chamber
4 fiber-reinforced resin, fiber-reinforced resin prepreg 51 foamable resin (unfoamed)
52 foamable resin (after foaming)
Detailed Description
(resin molded article)
Fig. 1 shows the appearance of a resin molded article 1 obtained by the manufacturing method of embodiment 1, and fig. 3 (g) shows the resin molded article 1 taken out of a mold (cross-sectional view). The resin molded article 1 is formed by covering at least a part or the whole of the surface of the preform 2 with the resin 52 after foaming, and further covering the resin 52 after foaming with the fiber-reinforced resin 6. The surface of the resin molded product 1 may have irregularities like the resin molded product protrusions 11. In another embodiment, in fig. 4, a resin molded article 1A is molded without using a preform 2. The resin molded article is composed of a resin after foaming, and the surface is covered with a fiber-reinforced resin.
The resin 52 after foaming is not particularly limited as long as it can be expanded by heating the foamable resin (not foamed) to press the fiber-reinforced resin prepreg disposed in the mold against the molding surface of the mold, and polyurethane, semi-rigid polyurethane, polyethylene, polypropylene, ethylene Propylene Diene Monomer (EPDM), polyamide epichlorohydrin resin (PAE), melamine resin (MF), biodegradable polyester-based plastic (BPP), bisphenol S (BPS), and the like can be used.
Specific examples of the commercially available foamable resin include epoxy foamable resin (liquid type) manufactured by Sanyu Rec corporation, rigid polyurethane 30-fold foamed rigid manufactured by mamio industrial corporation, and foamed polyurethane (single type) M5270 manufactured by han high japan corporation.
The preform 2 is a blank of the resin molded product 1 shown in fig. 2, and has a smaller volume than the resin molded product 1, and the surface roughness does not need to be high-precision. Specifically, the length, width, and height of the preform 2 are smaller than those of the resin molded product 1.
The material of the preform 2 is not particularly limited as long as it can withstand the heat press molding, and any of a thermosetting resin, a thermoplastic resin, and a metal can be used.
Specifically, as the thermosetting resin, epoxy resin, vinyl ester resin, unsaturated polyester resin, urethane resin, phenolic resin, and the like can be cited, and these can be used in combination. Examples of the thermoplastic resin include acrylic resins, polyester resins, polycarbonate resins, polypropylene resins, polyethylene resins, polystyrene resins, vinyl chloride resins, and polyamide resins. These may be used alone or in combination. However, a thermoplastic resin capable of withstanding the temperature of hot pressing is preferable.
As the metal, for example, copper aluminum, aluminum alloy, magnesium alloy, titanium alloy, steel, copper alloy, or the like can be used, but is not limited thereto.
The resin molded body 1 further includes a fiber-reinforced resin 4 covering a part or the whole of the resin after foaming. The material of the fiber-reinforced resin is not particularly limited, and as the resin of the fiber-reinforced resin 4, a thermosetting resin, a thermoplastic resin, and a resin composition including one of them may be used. Examples of the thermosetting resin include epoxy resins, vinyl ester resins, unsaturated polyester resins, polyurethane resins, and phenolic resins, and these resins may be used in combination. Examples of the thermoplastic resin include acrylic resins, polyester resins, polycarbonate resins, polypropylene resins, polyethylene resins, polystyrene resins, vinyl chloride resins, and polyamide resins. These may be used alone or in combination.
The fiber of the fiber-reinforced resin may be any of long fibers and short fibers, and as a material, any of carbon fibers, glass fibers, and metal fibers may be used, or a combination thereof may be used.
The fibrous base material in the fiber-reinforced resin is preferably a carbon fiber material having a thickness of 0.03mm to 0.5mm, but is not limited thereto. As the carbon fiber, PAN-based carbon fiber using polyacrylonitrile as a raw material, pitch-based carbon fiber using pitch as a raw material, and the like can be used.
The fiber-reinforced resin 4 may be a commercially available fiber-reinforced resin, and may be laminated according to the purpose. In addition, for convenience, the prepreg before molding of the fiber-reinforced resin will also be used with the same reference numeral (4) as the fiber-reinforced resin 4.
The resin molded product 1 having such a structure is covered with the high-strength fiber-reinforced composite resin 4, and further, since the preform is internally contained, the volume of the fiber-reinforced resin molded product having high strength and high durability can be increased without incurring a large cost by using the preform of an inexpensive material. Further, accurate surface irregularities can be formed as in the resin molded product convex portion 11 in fig. 1.
(method for producing resin molded article)
A method for producing the resin molded product 1 using the preform 2 (embodiment 1) will be described. First, as shown in fig. 3 (a), a lower mold 31 as a first mold and an upper mold 32 as a second mold are prepared. The lower die 31 has a first cavity 33. The upper mold 32 has a second cavity 34, and further, has a groove 35 for determining the surface shape of the resin molded product. The grooves 35 are used to form the resin molded product convex portions 11.
Next, as shown in fig. 3 (b), the fiber-reinforced resin prepreg 4 is lightly pressed against the molding surface of the resin molded article 1 in the first chamber 33 and the molding surface of the resin molded article in the second chamber 34. At this time, the resin-reinforced resin prepreg 4 is not required to be firmly pressed against the molding surface of the groove 35 in the mold, but may be disposed so that the fiber-reinforced prepreg 4 enters the groove 3 to some extent during molding.
Next, as shown in fig. 3 (c), the preform 2 is arranged on the fiber-reinforced resin prepreg 4 in the first chamber 33. At this time, the preform 2 is arranged with a gap between the preform and the mold using an object smaller in volume than the resin molded product 1 as a completed product.
The preform 2 disposed in the first chamber 33 is a green body of the resin molded article 1 as a completed product.
The blank may have preform projections 21 corresponding to the resin molding projections 11 like the preform 2 shown in fig. 2, and even if the resin molding 1 requires high-precision surface irregularities, the preform 2 may have preform projections 21 that are small in projection and have different shapes. Specifically, the preform 2 preferably has a similar shape that is smaller in perspective than the resin molded product 1, but the shape of the preform 2 does not need to be highly precise. Further, if the resin molded product protrusion 11 is small, the preform 2 may not have the preform protrusion 21. This is because the surface shape can be formed by the foamable resin 51 (foamed resin 52) described later and the fiber reinforced resin pressed into the groove 35.
In the first embodiment, the preform 2 may occupy 10% or more, preferably 20% or more, more preferably 30% or more of the volume of the resin molded product 1. The volume of the preform 2 is preferably 99.9% or less, more preferably 99% or less of the volume of the resin molded product 1. When the volume of the preform 2 is a large part of the total volume, a resin molded article 1 having high strength and weight can be produced, and when the volume of the foamable resin 52 is a large part of the total volume, a lightweight resin molded article 1 can be produced.
Next, as shown in fig. 3 (d), a liquid foamable resin 51 (not foamed) is introduced into the first chamber 33 in which the fiber reinforced resin prepreg 4 and the preform 2 are disposed. When the foamable resin 51 has a high viscosity and it is difficult to introduce the foamable resin (unfoamed) 51 due to the high viscosity, it is possible to heat to such an extent that foaming does not start.
At this time, the material of the preform 2 and the material of the foamable resin (unfoamed) 51 may be different or the same.
As shown in fig. 3 (e), the upper mold 32 is placed on the lower mold 31 on which the preform 2 is placed, and heated. When the upper die 32 is disposed on the lower die 31, it is preferable to seal without a gap so that the foamable resin 51 does not flow out. As shown in fig. 3 (e), in order to manufacture a desired resin molded article, it is preferable that the cavity of the lower mold 31 is arranged so as to precisely and firmly correspond to the cavity of the upper mold 32.
After the upper mold 32 is arranged, the upper mold 32 and the lower mold 31 are heated (see fig. 3 (f)). The foamable resin 51 is foamed by heating, and as shown in fig. 3, becomes a foamed resin 52 (after foaming). The foam-completed resin 52 may press the fiber-reinforced resin prepreg 4 onto the molding surface of the second chamber by heating. Accordingly, even when the resin molded product 1 having a complicated surface shape like the resin molded product protrusion 11 is manufactured, a high-precision surface can be obtained.
Although the shape shown in fig. 1 is an example having a semicylindrical-shaped protrusion and a resin molded product protrusion 11, this is only an example, and is not limited to the shape shown in the drawing, and may be any shape.
Since the convex portion of the preform 2 as a blank is not necessarily of a similar shape to the resin molded product protrusion 11, it can be manufactured at low cost.
The shape shown in fig. 1 has the resin molded product protrusion 11 on the upper surface, but even in the case of complex shapes such as the side surface and the lower surface having the protrusion, the corner can be accurately formed.
Further, similar to the lower mold 31, the upper mold 32 may have a second chamber 34.
In the production of the resin molded article 1 of the present invention, the heating temperature is not particularly limited, but is preferably 190℃or higher, more preferably 210℃or higher, and still more preferably 230℃or higher. The upper limit is preferably 350 ℃. If the heating temperature is less than 190 ℃, sufficient foaming may not be obtained. Further, if the heating temperature exceeds 350 ℃, the molding temperature is higher than the desired temperature, and the conformality of the resin is lowered, and there is a possibility that the foamed molded article cannot be stably produced.
In the production of the resin molded product 1, the heating time is not particularly limited, but is preferably 10 minutes to 12 hours, more preferably 15 minutes to 4 hours, from the viewpoints of reaction rate and productivity, prevention of decomposition of raw materials, and the like.
As shown in fig. 3 (g), the resin molded article 1 in which the preform 2 and the resin 52 after foaming are integrated is removed from the mold to obtain the resin molded article 1.
The resin molded article 1 is formed by covering at least a part or the whole of the surface of the preform 2 with the resin 52 after foaming. The covering with the expandable resin 52 may be such that the preform protrusion 21 like the preform 2 covers only a portion having a complicated shape.
Such a resin molded product 1 is applicable to all structures. By way of example, by sandwiching the completed resin molded article 1 as the inner member 1 between a plurality of prepregs and sewing or bonding the joint portions between the prepregs with an adhesive or a nylon wire or with an adhesive or the like, even if the molded article of the prepreg has a complicated surface shape, it is possible to make it have a large volume and to manufacture a molded article of a fiber-reinforced resin composite body having the same volume as the resin molded article 1 at low cost.
Further, as other examples, the prepreg may be used for a prepreg which is required to have precise irregularities on the upper surface and the side surface, for example, for an interior material for transportation equipment, an exterior material for transportation equipment, or the like. Herein, "transporter" refers to an apparatus for transporting cargo and personnel, such as aircraft, automobiles, aircraft, and the like.
Examples of the interior material for transportation equipment include, but are not limited to, cabin ceiling panels, cabin interior panels, cabin floors, cockpit ceiling panels, cockpit interior panels, cockpit floors, luggage walls, locker walls, door liners, window covers, bench seats, passenger seats, cabin attendant seats, various seats such as passenger seats, and various aircraft interior materials such as toilet interior materials, automobile interior materials, marine interior materials, railroad interior materials, and space interior materials.
On the other hand, as exterior materials for transportation equipment, exterior materials for aircraft such as ailerons, flaps, elevators, rudders, spoilers, and fuselages, exterior materials for automobiles such as bumpers, door panels, engine hood panels, and car bodies, and the like are exemplified, but not limited thereto.
The interior material for transportation equipment and the exterior material for transportation equipment each have a complicated surface shape, and from the viewpoints of safety and transportation efficiency, light weight and high mechanical strength are required. Therefore, the resin molded product 1 is particularly preferably used.
The resin molded article 1 may be applied to the entire inner member, the interior material, and the exterior material of these prepreg molded articles, or may be applied to only a part thereof.
As a second embodiment, fig. 4 shows a method for manufacturing a resin molded article 1A that does not use the preform 2 as in the first embodiment. In embodiment 2, molding can be performed in the same process as embodiment 1 except that the preform 2 is not used, and the inside is made of a foamed resin, so that a lightweight resin molded product can be produced.
Claims (5)
1. A method for producing a resin molded article, comprising:
a step of preparing a pair of a first mold and a second mold for molding the resin molded product;
disposing a fiber-reinforced resin prepreg on molding surfaces of the resin molded articles in the first mold and the second mold;
a step of introducing a foamable resin onto the fiber reinforced resin prepreg placed in the first mold;
a step of bringing one of the first mold and the second mold close to the other and heating under pressure in a state where the first mold and the second mold are brought into contact to seal the arranged fiber reinforced resin prepreg and foamable resin; and
And a step in which the foamable resin is foamed by heating, and the fiber-reinforced resin prepreg is pressed against the molding surface of the mold, whereby the fiber-reinforced resin prepreg is deformed according to the shape of the molding surface.
2. A method for producing a resin molded article, comprising:
a step of preparing a pair of a first mold and a second mold for molding the resin molded product;
disposing a fiber-reinforced resin prepreg on molding surfaces of the resin molded articles in the first mold and the second mold;
a step of preparing a preform having a smaller volume than the resin molded product;
disposing the preform on the fiber reinforced resin prepreg disposed in a first mold;
a step of introducing a foamable resin onto the fiber reinforced resin prepreg placed in the first mold;
a step of bringing one of the first mold and the second mold close to the other and heating under pressure in a state where the first mold and the second mold are brought into contact to seal the arranged fiber reinforced resin prepreg and foamable resin; and
And a step in which the foamable resin is foamed by heating, and the fiber-reinforced resin prepreg is pressed against the molding surface of the mold, whereby the fiber-reinforced resin prepreg is deformed according to the shape of the molding surface.
3. The manufacturing method according to claim 1 or 2, wherein,
the first mold has a first cavity and the second mold has a second cavity.
4. The manufacturing method according to claim 1 or 2, wherein,
the material of the preform is the same as that of the foamable resin.
5. A resin molded article, comprising:
a preform having a smaller volume than the resin molded article;
a foamed resin layer covering at least a part or all of the surface of the preform; and
And a fiber-reinforced resin layer which is derived from a prepreg and covers the foamed resin layer or the preform.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2023-186475 | 2023-10-31 | ||
| JP2023186475A JP7493286B1 (en) | 2023-10-31 | 2023-10-31 | Resin molded product and its manufacturing method |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN117601471A true CN117601471A (en) | 2024-02-27 |
Family
ID=89948227
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202311823470.3A Pending CN117601471A (en) | 2023-10-31 | 2023-12-27 | Resin molded article and method for producing same |
Country Status (2)
| Country | Link |
|---|---|
| JP (1) | JP7493286B1 (en) |
| CN (1) | CN117601471A (en) |
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