JP2001239530A - Method for producing fiber-reinforced resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a fiber-reinforced resin molding which develops a high mechanical strength and is light in weight and easy of handling by the reinforcement with long fibers impregnated sufficiently with a thermosetting resin which is cured thereafter. SOLUTION: In the method for producing the fiber-reinforced resin molding 10, numbers of the long fibers are advanced in one way while being arranged at prescribed intervals, and the bundle 1 of the fibers is impregnated with the thermosetting resin 2. Next, an expandable urethane resin liquid 7 is sprayed to the bundle 1 from above, and the bundle 1, after being coated or impregnated with the liquid 7, is led to a passage for molding. The liquid 7 is expanded and cured, and the thermosetting resin 2 contained in the bundle 1 is cured by the heat of curing of the liquid 7. At least one thermosetting resin 2 selected from the group consisting of an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, and a phenol resin is used in the method.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a method for producing a fiber-reinforced resin molded product.

[0002]

2. Description of the Related Art Various types of long-fiber-reinforced foamed resin moldings having excellent mechanical strength which can be used for structural materials such as building materials as substitutes for wood have been studied. For example, Japanese Patent Publication No. 48-30137. Japanese Patent Application Publication No. 55-15290 and Japanese Patent Publication No. 55-15290 propose a method for producing a fiber-reinforced foamed resin molded article having improved mechanical strength such as bending strength.

In general, the mechanical strength of a long-fiber-reinforced foamed resin molded article, particularly in the longitudinal direction (long-fiber direction), largely depends on the degree of impregnation of long fibers with resin. The greater the length, the higher the mechanical strength of the long fiber reinforced foamed resin molded article.

However, in the method of manufacturing a long fiber reinforced foamed resin molded article proposed above, a foamable resin is used as a resin to be impregnated into the long fiber, and the foamable resin starts a reaction after a certain time. Therefore, there is a problem that the long fiber is not sufficiently impregnated with the resin, and the mechanical strength of the obtained long fiber reinforced foamed resin molded product is not sufficiently improved.

[0005]

SUMMARY OF THE INVENTION In view of the above-mentioned conventional problems, an object of the present invention is to provide excellent mechanical strength by reinforcing with a long fiber which is sufficiently impregnated and cured with a thermosetting resin. It is an object of the present invention to provide a method for producing a fiber-reinforced resin molded product which is expressed and is lightweight and has good handleability.

[0006]

According to the first aspect of the present invention, there is provided a method of manufacturing a fiber-reinforced resin molded article, wherein a plurality of long fibers are advanced in one direction while being aligned at a predetermined interval, and the aligned fibers are aligned. A long fiber bundle composed of a number of long fibers is impregnated with a liquid thermosetting resin, and then a foamable urethane resin liquid is sprayed from above the long fiber bundle to form a foamable urethane resin on the long fiber bundle. After adhering or impregnating the liquid, the liquid is led to a molding passage, the foamable urethane resin liquid is foamed and cured, and the thermosetting resin impregnated in the long fiber bundle by the heat of curing reaction of the foamable urethane resin liquid. Is cured.

Further, according to a second aspect of the present invention, there is provided a method of manufacturing a fiber-reinforced resin molded article according to the first aspect, wherein the thermosetting resin is unsaturated. It is characterized by being at least one kind of thermosetting resin selected from the group consisting of polyester resin, vinyl ester resin, epoxy resin and phenol resin.

The long fibers used in the present invention include, for example, inorganic fibers such as glass fibers, synthetic resin fibers such as polyester fibers and polyamide fibers, and natural fibers such as jute. Used. These long fibers may be used alone or in combination of two or more.

The above long fibers are preferably formed into a roving shape by bundling filaments in consideration of productivity, but are not limited to the roving shape. Although the filament diameter is not particularly limited, it is 5 to 10
It is preferably 00 μm. 5μ filament diameter
If less than m, a large amount of thermosetting resin is required when impregnating the thermosetting resin, which may be economically disadvantageous, and conversely, if the filament diameter exceeds 1000 μm,
The contact area between the long fiber and the thermosetting resin becomes small, the reinforcing effect is not sufficiently exhibited, and the mechanical strength of the obtained fiber-reinforced resin molded product may be insufficient.

The liquid thermosetting resin used in the present invention is mainly composed of a thermosetting resin in an uncured state, and a curing agent or a curing agent corresponding to the thermosetting resin is added to the thermosetting resin. It refers to an uncured liquid thermosetting resin composition to which one or more of a curing accelerator, a cross-linking agent, a cross-linking auxiliary, a reaction catalyst, and the like are added.

The liquid thermosetting resin is 50 to 150.
It is preferably one that can be cured at a curing temperature of ° C.
In other words, it is preferable that the resin can be cured by the heat of curing reaction of the foamable urethane resin liquid described later. The liquid thermosetting resin preferably has a pot life of one hour or more at room temperature. Pot life of liquid thermosetting resin at room temperature is 1
If the time is less than the time, the long fibers may not be sufficiently impregnated, or the interval for removing the thermosetting resin staying in the impregnated portion may be short, and the workability may be reduced.

In the above-mentioned liquid thermosetting resin, for example, chopped glass fiber, silica sand, calcium carbonate, clay, talc, incinerated ash and the like may be used as needed within a range not to impair the achievement of the object of the present invention. Inorganic fillers, organic fillers such as FRP cuttings, reinforcing materials, softeners, plasticizers, surfactants, coupling agents, heat stabilizers, antioxidants (antiaging agents), ultraviolet absorbers One or more of various additives such as a flame retardant, an antistatic agent, a colorant, and an organic solvent may be added.

The liquid thermosetting resin is preferably non-foamable, but it does not matter if it has some foaming properties. Specifically, the density of the foamed thermosetting resin is preferably 0.4 g / cm ³ or more. When the above-mentioned density of the thermosetting resin is less than 0.4 g / cm ³ , the contact area between the long fiber and the thermosetting resin becomes small, the reinforcing effect is not sufficiently exhibited, and the obtained fiber-reinforced resin molding is obtained. The mechanical strength of the body may be insufficient.

The thermosetting resin used as a main component of the liquid thermosetting resin includes, for example, unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol resin, urethane resin, xylene resin, diallyl phthalate resin, An oligoester acrylate resin, a furan resin, a polyimide resin, a melamine resin, a guanamine resin, a urea resin, a maleic acid resin, or an oligomer or prepolymer thereof, and the like are preferably used. These thermosetting resins may be used alone or in combination of two or more.

In the present invention, among the above thermosetting resins, unsaturated polyester resins, vinyl ester resins,
At least one thermosetting resin selected from the group consisting of an epoxy resin and a phenol resin is particularly preferably used. These thermosetting resins may be used alone or in combination of two or more.

Unsaturated polyester resins have the advantage of being inexpensive and easy to control the curing reaction, and cured vinyl ester resins have the advantage of being excellent in corrosion resistance, impact resistance, thermal stability and the like. . Also, cured epoxy resin has the advantage of being excellent in mechanical strength such as tensile strength and compressive strength and electrical insulation properties, and cured phenolic resin has mechanical strength such as tensile strength and compressive strength. It has the advantage of excellent heat resistance. Therefore, by properly using each of the advantages, it is possible to obtain a fiber-reinforced resin molded article having various broad characteristics.

The unsaturated polyester resin may be an orthophthalic unsaturated polyester resin, an isophthalic unsaturated polyester resin, or a bisphenol unsaturated polyester resin. These unsaturated polyester resins may be used alone or in combination of two or more.

The vinyl ester resin may be a bisphenol vinyl ester resin, a novolak vinyl ester resin, or a halogenated vinyl ester resin such as a brominated vinyl ester resin. These vinyl ester resins may be used alone or in combination of two or more.

The epoxy resin may be a bisphenol epoxy resin, a novolak epoxy resin, a cycloaliphatic epoxy resin, or a halogenated epoxy resin such as a brominated epoxy resin. good. These epoxy resins may be used alone or in combination of two or more.

The phenol resin may be a novolak phenol resin or a resol phenol resin. These phenolic resins may be used alone or in combination of two or more.

The ratio between the long fibers and the liquid thermosetting resin impregnated in the long fibers varies depending on the properties of the long fibers, the fiber diameter, and the like, and is not particularly limited. By weight ratio, liquid thermosetting resin / long fiber = 0.
It is preferably 2 to 2. When the ratio of the liquid thermosetting resin / long fiber (weight ratio) is less than 0.2, the long fiber cannot be sufficiently impregnated with the liquid thermosetting resin, and the machine of the obtained fiber-reinforced resin molded body cannot be impregnated. Strength may be insufficient, and conversely, the liquid thermosetting resin / long fiber (weight ratio) is 2
If it exceeds, an excessive thermosetting resin will be used, which may be economically disadvantageous.

The foamable urethane resin liquid used in the present invention comprises a polyisocyanate compound and a polyol.

As the polyisocyanate compound constituting the foamable urethane resin liquid, for example, toluene diisocyanate, diphenylmethane diisocyanate (MD
And polyisocyanate compounds generally used in the synthesis of urethane resins such as I), polymeric MDI, isophorone diisocyanate, hexamethylene diisocyanate and derivatives thereof and in the production of urethane foam moldings. Among them, MDI and polymeric MDI, which are excellent in reactivity, safety and the like, are more preferably used. These polyisocyanate compounds may be used alone or in combination of two or more.

The polyisocyanate compound is not particularly limited, but preferably has a viscosity at 25 ° C. of 50 to 1500 mPa · s. If the viscosity of the polyisocyanate compound is less than 50 mPa · s, the rigidity of the cured foamed urethane resin liquid becomes too low, and the mechanical strength of the obtained fiber-reinforced resin molded product may be insufficient. Conversely, if the viscosity of the polyisocyanate compound exceeds 1500 mPa · s, the adhesiveness and impregnation of the foamable urethane resin liquid with the long fibers are reduced, and the mechanical strength of the obtained fiber-reinforced resin molded product is poor. May be sufficient.

As the polyol constituting the foamable urethane resin liquid, for example, it is generally used for the synthesis of urethane resins such as polyether polyols, polyester polyols, polymer polyols and the like, and for the production of urethane foam moldings. A polyol is used, and is preferably used. These polyols may be used alone or in combination of two or more.

Examples of the polyether polyol include, for example, polyethylene glycol, polypropylene glycol, polytetramethylene glycol and the like, and are preferably used. These polyether polyols may be used alone or in combination of two or more.

Examples of polyester polyols include terephthalic acid, isophthalic acid, 1,5-naphthalic acid, 2,6-naphthalic acid, succinic acid, glutaric acid, adipic acid, pimelic acid, suberic acid, azelaic acid, sebacic acid , Decamethylene dicarboxylic acid, dicarboxylic acids such as dodecamethylene dicarboxylic acid and the like, ethylene glycol, diethylene glycol, propylene glycol,
1,3-propanediol, 1,4-butanediol,
Neopentyl glycol, 1,5-pentanediol,
Polyester polyols obtained by reaction with polyols such as 1,6-hexanediol and cyclohexanediol, and poly-ε-caprolactone polyols obtained by ring-opening polymerization of ε-caprolactam, and the like are preferably used. . These polyester polyols may be used alone or in combination of two or more.

Examples of the polymer polyol include a graft polymer obtained by graft-polymerizing an ethylenically unsaturated compound such as acrylonitrile, styrene, methyl (meth) acrylate and the like to the above-mentioned polyether polyol or polyester polyol; Examples thereof include polybutadiene polyol, 1,4-polybutadiene polyol, and hydrogenated products thereof, which are suitably used. These polymer polyols may be used alone or in combination of two or more.

The above polyol is not particularly limited, but has a viscosity at 25 ° C. of from 1500 to 600.
Those having a pressure of 0 mPa · s are preferred. When the above viscosity of the polyol is less than 1500 mPa · s, the rigidity of the cured product of the foamable urethane resin liquid is too low, and the mechanical strength of the obtained fiber-reinforced resin molded product may be insufficient, When the viscosity of the polyol exceeds 6000 mPa · s, the adhesiveness and impregnation of the foamable urethane resin liquid with the long fibers are reduced, and the mechanical strength of the obtained fiber-reinforced resin molded product becomes insufficient. There is.

The cured product of the foamable urethane resin liquid composed of the polyisocyanate compound and the polyol is not particularly limited, but has a density of 0.15 to 0.5.
It is preferably 6 g / cm ³ . When the density of the cured product of the foamable urethane resin liquid is less than 0.15 g / cm ³ , the strength of the urethane resin portion in the obtained fiber-reinforced resin molded product becomes too low, and the mechanical strength of the fiber-reinforced resin molded product is reduced. When the strength of the foamed urethane resin liquid exceeds 0.6 g / cm ³ , the obtained fiber-reinforced resin molded article becomes too large in weight, and the handleability becomes poor. And may be economically disadvantageous.

The ratio between the long fiber and the liquid thermosetting resin impregnated in the long fiber and the foamable urethane resin liquid is not particularly limited, but the ratio by weight is long. It is preferable that the total amount of the shaving fibers and the liquid thermosetting resin / the foamable urethane resin liquid = 1 to 10. When the total amount of the long fibers and the liquid thermosetting resin / the foamable urethane resin liquid (weight ratio) is less than 1, the amount of the reinforcing fibers becomes too small, and the mechanical strength of the obtained fiber-reinforced resin molded product is reduced. If the strength is insufficient, conversely, if the total amount of long fibers and liquid thermosetting resin / foamable urethane resin liquid (weight ratio) exceeds 10, the amount of foamable urethane resin liquid is small. If it becomes too much, the appearance of the obtained fiber-reinforced resin molded article may be impaired.

The fiber-reinforced resin molded article obtained by the production method of the present invention is a foamed urethane resin-based molded article which is reinforced in the longitudinal direction by a long fiber bundle impregnated with a thermosetting resin and cured. Although not performed, the density is preferably 0.3 to 2 g / cm ³ . When the density of the fiber-reinforced resin molded article is less than 0.3 g / cm ³ , the mechanical strength becomes insufficient and the application may be restricted, and conversely, the density of the fiber-reinforced resin molded article is 2 g / cm 3. ^Three
If it exceeds, the price may be high and the application may be restricted.

Next, a method for producing a fiber-reinforced resin molded product according to the present invention will be described with reference to the drawings. FIG. 1 is a schematic view showing one example of a method for producing a fiber-reinforced resin molded article according to the present invention, and FIG. 2 is a cross-sectional view showing one example of a fiber-reinforced resin molded article obtained by the production method of the present invention.

In the manufacturing method of the present invention, as shown in FIG. 1, first, a long fiber bundle 1 produced by advancing a number of long fibers in one direction while aligning them at predetermined intervals is placed in an impregnation tank 3. Is immersed in the liquid thermosetting resin 2 stored in the container, and the air in the long fiber bundle 1 is degassed by the impregnating roll 4, so that the impregnating property of the long fiber bundle 1 is improved. The fiber bundle 1 is impregnated with a liquid thermosetting resin 2. next,
After adjusting the impregnation amount of the liquid thermosetting resin 2 in the long fiber bundle 1 to a desired impregnation amount by the squeezing roll 5, the long fiber bundle 1 impregnated with the liquid thermosetting resin 2 is adjusted. hand,
From above, the foamable urethane resin liquid 7 is sprayed by the sprayer 6, and the foamable urethane resin liquid 7 is sprayed on the long fiber bundle 1.
Is adhered or impregnated. Next, after adjusting the impregnation amount of the foamable urethane resin liquid 7 in the long fiber bundle 1 to a desired impregnation amount by the foamable urethane resin liquid impregnated plate 8, a passage for forming the long fiber bundle 1 is formed. Endless belt 9
The foaming urethane resin liquid 7 is foamed and hardened in the molding passage, and the liquid impregnated in the long fiber bundle 1 by the curing reaction heat generated during the foaming hardening of the foamable urethane resin liquid 7. By going through the step of curing the thermosetting resin 2, the fiber-reinforced resin molded body 10 of the present invention can be manufactured.

In the production method of the present invention, the method of impregnating a liquid thermosetting resin into a long fiber bundle is not limited to the above method (immersion method). After applying a liquid thermosetting resin to the resin, the liquid thermosetting resin is impregnated by sandwiching a long fiber bundle with a reciprocating plate or the like (application method). A method may be adopted in which a stored tank is prepared, and a long fiber bundle is passed through the tank to impregnate the liquid thermosetting resin (passing method).

Regardless of the impregnation method described above, the time for impregnating the liquid thermosetting resin in the long fiber bundle may be within the pot life of the liquid thermosetting resin. However, it is preferable that the time is such that the liquid thermosetting resin can sufficiently impregnate the long fiber bundle.

It is preferable that the impregnation amount of the liquid thermosetting resin into the long fiber bundle can be controlled by some method. For example, when the impregnation method is a coating method, it is preferable to be able to control the amount of liquid thermosetting resin applied per unit time, and when the impregnation method is a pass-through method, the liquid thermosetting resin is impregnated. It is preferable to be able to control the impregnation amount of the liquid thermosetting resin in the long fiber bundle by providing a drawing device, a handling device, and the like for the long fiber bundle.

In the production method of the present invention, the method of attaching or impregnating the foamable urethane resin liquid to the long fiber bundle impregnated with the liquid thermosetting resin is not limited to the above method. The foaming urethane resin liquid may be applied to the surface of the long fiber bundle by any application method, or the foaming urethane resin liquid may be applied to the surface of the long fiber bundle by any application method, for example, reciprocating movement is possible. A method may be adopted in which the long fiber bundle is sandwiched between flat plates or the like, and rubbed, squeezed, or handled.

In the manufacturing method of the present invention, the molding passage is not limited to the molding passage formed by the endless belt, but may be, for example, a molding passage formed by a fixed mold. Alternatively, a belt-type molding passage that moves in conjunction with the fiber-reinforced resin molded body may be used.

The sectional shape of the molding passage is not particularly limited. For example, the sectional shape may be any shape such as a square, a trapezoid, a circle, etc. It is preferred that the shapes be the same size.

As shown in FIG. 2, the thus obtained fiber-reinforced resin molded article of the present invention has a sea-island composed of 11 phases of urethane foam resin, and 12 phases of a composite of a long fiber and a cured thermosetting resin. It has a structural structure and exhibits excellent mechanical strength.

[0042]

The fiber-reinforced resin molded article obtained by the production method of the present invention is different from the method proposed in the prior art, that is, the method of directly impregnating a long fiber bundle with a foamable resin. First, the fiber bundle is impregnated with a non-foamable or low-foamable liquid thermosetting resin, and then the foamable urethane resin liquid is attached to or impregnated into the long fiber bundle. The bundle is sufficiently impregnated with a liquid thermosetting resin, and the long fiber bundle and the cured product of the thermosetting resin form a strong composite.

Since the fiber-reinforced resin molded article obtained by the production method of the present invention is reinforced by the above-mentioned composite comprising a long fiber bundle and a cured product of a thermosetting resin, it exhibits excellent mechanical strength. At the same time, since the foamable urethane resin liquid is foamed and cured, it is a lightweight and easy-to-handle fiber-reinforced resin molded product.

Further, by using at least one thermosetting resin selected from the group consisting of unsaturated polyester resin, vinyl ester resin, epoxy resin and phenol resin as the thermosetting resin, mechanical strength is remarkably increased. It is possible to obtain a fiber-reinforced resin molded article which is excellent and has various wide characteristics.

According to the method for producing a fiber-reinforced resin molded article of the present invention, a fiber-reinforced resin molded article having the above-mentioned excellent mechanical strength and various broad characteristics, light weight and good handleability can be produced. You can get good.

[0046]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in more detail with reference to Examples, but the present invention is not limited to these Examples.

In the following examples, the following raw materials were used. The amount of long fibers, the amount of liquid thermosetting resin impregnated, and the amount of foamable urethane resin liquid are all g per liter of the fiber-reinforced resin molded product. [Raw materials used] (1) Long fiber a. Glass fiber: A glass roving obtained by aligning a large number of monofilaments having a fiber diameter of 17 μm.
Use No. 00 b. Jute fiber: Twisted fibers having a fiber diameter of 20 μm are used. The number 4000 is used. (2) Liquid thermosetting resin Unsaturated polyester resin: Viscosity at 25 ° C. is 50
Unsaturated polyester resin with 0/4 mPa · s, unsaturated / saturated ratio (weight ratio) of 6/4 and styrene monomer content of 40% by weight, mixed with 2% by weight of a medium temperature curing agent. : 500 m viscosity at 25 ° C.
A bisphenol-based vinyl ester resin of Pa · s is used by adding and mixing 2% by weight of a medium curing agent. Epoxy resin: The viscosity at 25 ° C. is 500 mPa · s.
s bisphenol-based epoxy resin and amine-based medium-temperature curing agent 5 wt% added and mixed. Phenol resin: For resole-based phenolic resin,
(3) Foamable urethane resin solution polyether polyol (viscosity at 25 ° C .: 380)
0 mPa · s, average number of functional groups: 3) 100 parts by weight, water 1
Parts by weight of a polyol composition comprising 1 part by weight of silicone oil and 1 part by weight of dibutyltin dilaurate,
Polymeric M having a viscosity of 200 mPa · s at 5 ° C
Use mixed DI

(Example 1) Glass fiber 3 as long fiber
After impregnating 180 g of an unsaturated polyester resin as a liquid thermosetting resin with respect to 70 g, a foamable urethane resin liquid is sprayed onto the glass fiber impregnated with the unsaturated polyester resin to foam the glass fiber. 200 g of a liquid urethane resin solution was adhered or impregnated. Next, while foaming and curing the foamable urethane resin liquid, the unsaturated polyester resin is cured by the curing reaction heat at that time,
A fiber-reinforced resin molding was produced. The obtained fiber-reinforced resin molded article had a cross-sectional size of 50 mm in height and 200 mm in width, and had a density of 0.74 g / cm ³ .

Example 2 In the production of a fiber-reinforced resin molded product, 300 g of jute fiber was used as a long fiber.
A fiber-reinforced resin molded product was produced in the same manner as in Example 1 except that the amount of the unsaturated polyester resin impregnated was 300 g, and the amount of the foamable urethane resin liquid attached or impregnated was 140 g.

Example 3 In the production of a fiber-reinforced resin molded product, a vinyl ester resin 180 was used as the liquid thermosetting resin instead of the unsaturated polyester resin 180 g.
A fiber-reinforced resin molded body was produced in the same manner as in Example 1 except that g was impregnated.

Example 4 The procedure of Example 1 was repeated except that 180 g of epoxy resin was used instead of 180 g of unsaturated polyester resin as the liquid thermosetting resin in the preparation of the fiber-reinforced resin molded article. Similarly, a fiber-reinforced resin molded product was produced.

Example 5 The procedure of Example 1 was repeated except that 180 g of a phenolic resin was used instead of 180 g of an unsaturated polyester resin as a liquid thermosetting resin in producing a fiber-reinforced resin molded product. Similarly, a fiber-reinforced resin molded product was produced.

(Comparative Example 1) In the production of a fiber-reinforced resin molded product, 370 g of a foamable urethane resin liquid was directly applied without impregnating glass fibers with a liquid thermosetting resin (unsaturated polyester resin). A fiber-reinforced resin molded body was produced in the same manner as in Example 1 except that the fiber-reinforced resin was adhered or impregnated.

(Comparative Example 2) In the preparation of a fiber-reinforced resin molded product, 440 g of a foamable urethane resin liquid was directly introduced into a jute fiber without impregnating the liquid thermosetting resin (unsaturated polyester resin). A fiber-reinforced resin molded body was produced in the same manner as in Example 2 except that the impregnation was performed.

The flexural modulus of the seven types of fiber-reinforced resin molded products obtained in Examples 1 to 5 and Comparative Examples 1 and 2 was measured by the following method. The results were as shown in Table 1.

[Method for measuring flexural modulus] JIS Z-2
The flexural modulus (MPa) of the fiber-reinforced resin molded article was measured according to 101 "Test Method for Wood".

[0057]

[Table 1]

As is clear from Table 1, all of the fiber-reinforced resin molded articles of Examples 1 to 5 obtained by the production method of the present invention have a high flexural modulus and exhibit excellent mechanical strength. did.

On the other hand, the fiber-reinforced resin moldings of Comparative Examples 1 and 2 in which the foamable urethane resin liquid was directly adhered or impregnated without impregnating the long fibers with the liquid thermosetting resin. The body had low flexural modulus and poor mechanical strength.

[0060]

As described above, according to the method for producing a fiber-reinforced resin molded article of the present invention, excellent mechanical strength is exhibited, and at the same time, it is lightweight and has good handleability. As a result, it is possible to obtain a fiber-reinforced resin molded product that can be suitably used for various uses including structural materials such as building materials with high productivity.

[0061]

[Brief description of the drawings]

FIG. 1 is a schematic view showing one example of a method for producing a fiber-reinforced resin molded article according to the present invention.

FIG. 2 is a cross-sectional view showing one example of a fiber-reinforced resin molded product obtained by the production method of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Long fiber bundle 2 Liquid thermosetting resin 3 Impregnation tank 4 Impregnation roll 5 Squeezing roll 6 Sprayer 7 Foamable urethane resin liquid 8 Foamable urethane resin liquid impregnated plate 9 Endless belt forming forming passage 10 Fiber reinforced resin Molded product 11 Foamed urethane resin 12 Composite of long fiber and cured product of thermosetting resin

Claims (2)

[Claims] 1. A method in which a large number of long fibers are made to progress in one direction while being aligned at a predetermined interval, and a liquid thermosetting resin is impregnated in a long fiber bundle composed of the aligned long fibers, Next, the foamable urethane resin liquid is sprayed from above the long fiber bundle to adhere or impregnate the long fiber bundle with the foamable urethane resin liquid, and then guided to a molding passage, and the foamable urethane resin liquid is discharged. A method for producing a fiber-reinforced resin molded article, comprising foaming and curing, and curing a thermosetting resin impregnated in a long fiber bundle by heat of curing reaction of the foamable urethane resin liquid. 2. The thermosetting resin according to claim 1, wherein the thermosetting resin is at least one thermosetting resin selected from the group consisting of an unsaturated polyester resin, a vinyl ester resin, an epoxy resin and a phenol resin. 3. The method for producing a fiber-reinforced resin molded article according to 1.).