JP2003225914A - Fiber-reinforced resin molding - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fiber-reinforced resin molding high in mechanical strength with a hole formed therein. <P>SOLUTION: The fiber-reinforced resin molding has a second member 4 containing reinforcing fibers and a resin to be reinforced, for example a main body 12 formed from FRP or SMC, a first surface layer 131 formed from a first member 3 having a fabric 31 of fiber braids and the resin, a second surface layer 132 formed from a surface forming resin or a second member 4, and a bolt-fastening hole 2. The fiber braids in the fabric 31 in the vicinity of the hole 2 are not cut substantially and detoured to enclose the hole 2. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber-reinforced resin molded product, and more particularly to a fiber-reinforced resin molded product having a high degree of mechanical strength.

[0002]

2. Description of the Related Art A resin molded product reinforced with glass fiber or carbon fiber, so-called FRP, has been known for a long time and is used in various fields as a structural material because it has excellent mechanical strength and moldability. In addition, various proposals for improving the performance have been made so as to meet various industrial requirements.

For example, Japanese Utility Model Publication No. 1-76225 discloses that
A technique for providing a surface layer made of a composite material of a woven fabric of synthetic fibers and a resin is disclosed for the purpose of preventing fraying on the surface of the FRP. Japanese Utility Model Laid-Open No. 4-64113 discloses a technique in which a woven fabric on which a desired pattern is printed is placed on the surface of the FRP and compression-molded together with the FRP so that the printed pattern on the surface is not displaced. JP-A-63-30793
Japanese Patent Publication No. 3 discloses a technique for manufacturing a fishing rod or a golf shaft having excellent mechanical strength by covering a tubular body of FRP with a woven bag-like object and integrating the tubular body with the tubular body. . Further, Japanese Patent Application Laid-Open No. 11-58428 discloses SM for manufacturing structural parts for automobiles having excellent rigidity and mechanical strength.
A technique is disclosed in which a woven fabric of long fiber bundles is placed on both surfaces of a C cured product and integrally molded with the SMC cured product. The surface woven fabric in each of the above prior arts is in a state of being impregnated with the resin oozing out from the FRP when integrated with the FRP inside.

The present inventors focused on the fact that the composite of FRP and fabric disclosed in the above-mentioned prior art has excellent mechanical strength, and tried to use it as a structural material to be bolted. As a result, it was found that the above composite has excellent mechanical strength in a non-porous state, but has a problem that the effect of forming a composite with a woven fabric is halved in a perforated state. Also, the effect is halved that when the bolt holes are punched, the fibers of the fabric located at the location where the bolt holes are provided are cut, and the mechanical strength of the composite around the bolt holes is cut by cutting the fibers. It was also found to be due to an unexpectedly large drop.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above problems in the prior art, and to provide a fiber-reinforced resin molded product having a high mechanical strength even in a perforated state. It is what

[0006]

A fibrous body reinforced resin molded article according to claim 1 of the present invention is a fibrous body reinforced resin molded article containing a non-fabric reinforcing fiber body, a reinforcing cloth and a reinforced resin. There is at least one hole penetrating the reinforcing cloth, and the fibrous body in the reinforcing cloth in the vicinity of the hole is diverted so as to surround the hole in a substantially uncut state. It is characterized by that.

A fibrous body-reinforced resin molded product according to a second aspect of the present invention is characterized in that in the first aspect, the fibrous body is a fiber or a fiber braid.

A fibrous body reinforced resin molded product according to a third aspect of the present invention is the fibrous body reinforced resin molded article according to the first or second aspect, wherein the first member includes the reinforcing cloth and the reinforced resin, and the reinforcing non-cloth shape. It is characterized by being formed from a fibrous body and a second member containing the reinforced resin.

According to a fourth aspect of the present invention, in the fibrous body-reinforced resin molded article according to the third aspect, the main body portion formed of the second member and the first member provided on the surface of the main body portion are formed. It is characterized in that it is provided with a surface layer.

According to a fifth aspect of the present invention, in the fibrous body reinforced resin molded article according to the fourth aspect, the first member has a bag shape.

According to a sixth aspect of the present invention, in the fibrous body-reinforced resin molded article according to the fifth aspect, the surface layer is formed on the first surface layer formed of the first member and on the first surface layer. It is characterized in that it is provided with a surface forming resin or a second surface layer formed from the second member.

According to a seventh aspect of the present invention, there is provided a fibrous body-reinforced resin molded article according to any one of the fourth to sixth aspects.
The main body is characterized in that it contains an electric member and / or a magnetic member.

According to an eighth aspect of the present invention, in the fibrous body-reinforced resin molded article according to the first aspect, a metal body is attached to the hole.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiment 1. 1 to 4 are views for explaining Embodiment 1 of a fibrous body reinforced resin molded product according to the present invention, FIG. 1 is a perspective view of Embodiment 1, and FIG. 3 is a cross-sectional view taken along the X-ray, and FIG.
FIG. 4 is an enlarged plan view of the above-mentioned reinforcing cloth at a portion indicated by an arrow Y in FIGS. 1 and 2, and FIG. 4 is an enlarged plan view of a reinforcing cloth at a portion other than the above-mentioned portion indicated by an arrow Y.

1 to 4, a fibrous body-reinforced resin molded product 1 is a structure having a convex cross-sectional shape as shown in FIG. 2, and is a pair of plate bodies 11a and 11b and a plate body 11.
Each of the pair of plate members 11a and 11b is provided with a bolt fastening hole 2 as an example of the hole. Further, the fibrous body reinforced resin molded product 1 is formed of a first member 3 and a second member 4 as shown in FIG.

The first member 3 is located substantially at the center in the thickness direction of the fibrous body reinforced resin molded product 1, and the second member 4 is the first member 3.
It is provided so as to sandwich it from both sides. First member 3
Includes a woven fabric 31 (see FIGS. 3 and 4) of a fiber braid 311 as an example of the reinforcing cloth and a resin to be reinforced, and the resin to be reinforced is preferably between the fiber braids 311 and preferably the fiber. It is impregnated between the fibers in the braid 311. The second member 4 contains a fiber as an example of the reinforcing non-fabric fiber body and a resin to be reinforced, and examples thereof include a normal FRP and a sheet molding compound (SMC). As shown in FIG. 3, the fiber braid 311 in the vicinity of the bolt fastening hole 2 is substantially uncut.
There is a detour around the hole. That is, in the vicinity of the bolt fastening hole 2, the weaving method is changed so that the fiber braid 311 forms a round hole, and the fiber braid 311 in the vicinity of the bolt fastening hole 2 also imitates the outer edge of the round hole. , The fibrous braid 31 that is combined as it goes away from the round hole
The shape formed by 1 is a square.

As the resin to be reinforced contained in the first member 3 and the second member 4, various organic polymers known in the art may be used without limitation, and examples thereof include epoxy resin, unsaturated polyester resin, and carboxylic acid. Thermosetting resins such as formalin resin, melamine resin, urea resin, phenol resin, xylene resin, diallyl phthalate resin, silicon resin, vinylidene chloride resin, vinyl alcohol resin, acrylic ester resin, styrene resin, acrylonitrile-styrene resin, These include thermoplastic resins such as acrylonitrile-butadiene resin, polyolefin, and polyamide.

As the fibers forming the fiber braid 311 and the fibers forming the reinforcing non-fabric fibrous body contained in the second member 4, various known ones having good mechanical strength conventionally known in the art are not limited. It may be applied, for example, organic polymer fibers such as aramid fibers, polyamide fibers, polyester fibers, and inorganic fibers such as glass fibers, carbon fibers, and metal fibers, or a mixed fiber body of two or more kinds. The fiber braid 311 can be obtained by bundling or twisting several to thousands of such fibers. The reinforcing non-woven fiber body included in the second member 4 may be a fiber or a fiber braid.

The fibrous body reinforced resin molded product 1 is manufactured, for example, by the following method. That is, as a mold, the second member 4, the first member 3 and the second member 4 are stacked in this order in a lower mold having columnar protrusions for forming the bolt fastening holes 2 at the four corners. At that time, the first member 3 is housed in such a manner that the fiber braids 311 at a part of the four corners of the first member 3 are spread out so that the columnar projections penetrate the fiber braid 311 without cutting them, and then the upper mold It is put on a predetermined position and heat compression molded. Alternatively, when the reinforced resin used for the second member 4 is one that is sufficiently fluid even at a high temperature during the heat compression molding, the woven fabric 31 is used instead of the first member 3.
Only one may be used. In that case, a part of the resin to be reinforced in the second member 4 migrates into the woven fabric 31 during the heat compression molding and is impregnated with the fiber braid 311 of the woven fabric 31 to form the first member 3.

The fibrous body-reinforced resin molded product 1 contains the first member 3 and has a bolt fastening hole 2 which is generally a weak point in terms of strength, but the periphery of the hole 2 is a non-cut fiber braid. Since it is surrounded by 311, a comparative product of the same external shape formed only by the second member 4 or a comparative product of the same external shape in which the fiber braid around the hole 2 is cut,
It has outstanding mechanical strength such as tensile strength.

Embodiment 2. FIG. 5 is a cross-sectional view for explaining Embodiment 2 of the fibrous body reinforced resin molded product according to the present invention, which is another cross-sectional view taken along line XX of FIG. 1.
In the second embodiment and the subsequent embodiments, the same parts as those shown in FIGS. 1 to 4 are denoted by the same reference numerals and the description thereof may be omitted.

Fiber Reinforced Resin Molded Product 1 of Embodiment 2
Is composed of a body portion 12 and a surface layer 13 provided on the surface of the body portion 12, and the body portion 12 includes the second member 4
The surface layer 13 is formed of the first member 3 respectively. Therefore, the second embodiment is different from the first embodiment only in the position where the first member 3 is structurally provided, and is the same as the first embodiment in other respects. The matters described above also apply to the present embodiment.

The fibrous body reinforced resin molded product 1 has its entire surface covered with a continuous surface layer 13, and the fiber braids near the bolt fastening holes 2 at the four corners are substantially as shown in FIG. It is bypassed so as to surround the hole 2 in a non-cutting state. The fibrous body reinforced resin molded product 1 of the second embodiment is
Since the entire surface is covered with the unbroken surface layer 13, in addition to the advantage that the fibrous body-reinforced resin molded article 1 of Embodiment 1 has high mechanical strength, there are the following advantages. That is,
In the comparative product including only the second member 4 without the surface layer 13 of the first member 3, there is a problem that a weld occurs due to the orientation or wrinkling of the reinforcing non-fabric fibrous body in the second member 4 during its molding. However, the surface layer 13 has the effect of preventing the occurrence of such welds and forming an uneven surface, and improves and stabilizes the mechanical strength of the fiber-reinforced resin molded product 1.

Fibrous body reinforced resin molded article 1 of Embodiment 2
Is produced, for example, by the following method. That is, first, only the second member 4 is preformed into the shape shown in FIG. 1 or a shape close thereto, and the second member 4 is put into the bag-shaped woven fabric 31 and put in the mold. In addition, the above-mentioned preform is woven 31
You may sew the opening part of the said bag-shaped object after putting it in. At that time, the fabric 31 is attached to the columnar protrusions to form the bolt fastening holes 2 as described in the first embodiment. Then, heat compression molding is performed.

Embodiment 3. FIG. 6 is a view for explaining the third embodiment of the fibrous body-reinforced resin molded product according to the present invention, and is still another cross-sectional view taken along line XX of FIG. In FIG. 6, the surface layer 13 is the first surface layer 131.
And a second surface layer 132 provided on the surface layer 131
It is composed of two layers. The first surface layer 131 is formed from the first member 3, and the second surface layer 132 is a kind of the reinforced resin as an example of the surface forming resin,
For example, it is formed of the same resin as the reinforced resin in the first surface layer 131. The third embodiment is different from the second embodiment in that the surface layer 13 is composed of the above-mentioned two layers, and the other configurations are the same.

When the surface layer 13 is composed of only the first member 3 as in the second embodiment, a part of the fiber braid of the woven fabric 31 contained in the first member 3 is a fiber-reinforced resin molded product 1. Exposed on the surface of the, the surface smoothness becomes poor,
Or part of the exposed fiber braid is cut by external force,
However, the second surface layer 132
By providing the surface layer 132 with the first surface layer 13
1 acts as a protective film to solve the above problem.
The thickness of the second surface layer 132 varies depending on the size of the fibrous body-reinforced resin molded product 1 and the purpose of use, but is generally about 0.1 mm to 1 mm.

As the surface forming resin forming the second surface layer 132, various organic polymers can be used other than the reinforced resin. Furthermore, the second surface layer 132
May be a second member having the same material as the second member 4 forming the main body 12 or another composition.

Fourth Embodiment 7 to 8 are diagrams for explaining a fourth embodiment of the fibrous body reinforced resin molded product according to the present invention, and FIG. 7 is a perspective view of the fourth embodiment.
FIG. 8 is a sectional view taken along line XX of FIG. 7. 7 to 8, the fibrous body reinforced resin molded product 1 is composed of a plate body 14, and the plate body 14 is provided with ¼ circular cutouts 141 at the four corners of the surface thereof. Each of the bolt fastening holes 2 is drilled, and a recessed portion 142 is provided on the back surface as shown in FIG. Note that the recessed portion 142 may not be provided.

Fibrous body reinforced resin molded article 1 of Embodiment 4
Is composed of a body portion 12 and a surface layer 13 provided on the surface of the body portion 12, and the surface layer 13 further includes a first surface layer 131 and a second surface layer provided on the surface layer 131. It is composed of two layers 132. Also, the main body 12
The built-in unit 5 is built in. As the built-in unit 5,
Examples are electric members such as electric conductors and electric coils, or magnetic members such as magnetic bodies and composites of magnetic bodies and non-magnetic bodies. The built-in portion 5 may be both at least one of the electric member and at least one of the magnetic member. The materials for forming the main body 12, the first surface layer 131, and the second surface layer 132 are the same as those in the third embodiment. From the fourth embodiment, the fibrous body reinforced resin molded product 1 having an electric member or a magnetic member built therein and high mechanical strength can be obtained.

The invention is not limited to the first to fourth embodiments described above, but includes various modifications in the spirit of the present invention. For example, the reinforcing cloth may be a fiber braid, a twill weave, a plain weave, a satin weave of fibers, or other woven fabrics, and may be a non-woven fabric in which the fibers are bonded to each other by adhesion or welding. When such a non-woven fabric is used as a reinforcing cloth, the interfiber bonds of the fibers located around the holes such as bolt fastening holes are once broken to form the holes, and then the fibers around the holes are rebonded. Alternatively, it may be welded. The holes of the fibrous body-reinforced resin molded product of the present invention may be formed for various purposes other than bolt fastening, and a metal body may be attached to the holes.

[0031]

As described above, the fiber-reinforced resin molded product of the present invention is a fiber-reinforced resin molded product containing a reinforcing non-fabric fiber, a reinforcing cloth, and a resin to be reinforced, It has one or more holes penetrating the reinforcing cloth, and the fibrous body in the reinforcing cloth in the vicinity of the hole is diverted so as to surround the hole in a substantially uncut state. The fibrous body is, for example, a fiber or a fiber braid, and includes, for example, a first member including the reinforcing cloth and the reinforced resin, the reinforcing non-woven fiber body, and the reinforced resin. Since it is formed from the second member, it has a hole such as a bolt fastening hole which is generally a weak point in terms of strength, but the circumference of the hole is surrounded by an uncut fiber braid or fiber. Therefore, a comparative product of the same external shape composed only of the second member, Rui than comparative product having the same external shape of fibers braids or fibers around the hole is cut,
It has outstanding mechanical strength such as tensile strength. Therefore, the fibrous body-reinforced resin molded product of the present invention is suitable for various applications where holes are required for bolt fastening or other reasons.

Further, a main body formed of the above-mentioned second member,
When the surface layer provided on the surface of the main body portion and provided with the first member is provided, the orientation of the reinforcing non-woven fiber body in the second member during the molding of the fiber body-reinforced resin molded article or A wrinkle-like formation does not occur, a weld is prevented from being generated, and a fibrous body-reinforced resin molded product having a surface with no unevenness and further excellent mechanical strength can be obtained.

When the first member has a bag shape, it becomes easy to manufacture a fibrous body reinforced resin molded product whose entire surface is covered with a continuous surface layer.

The surface layer is a first surface layer composed of the first member, a surface-forming resin provided on the first surface layer or a second surface formed of the second member. When it has a layer, the second surface layer acts as a protective film on the first surface layer to prevent the fiber braids contained in the first surface layer from being exposed, thereby improving the smoothness of the surface. A fiber-reinforced resin molded product having excellent mechanical strength and stability can be obtained.

When the main body contains an electric member and / or a magnetic member, it is possible to fasten a bolt and the like, and a high mechanical strength fibrous body reinforced resin molding in which the electric member and the magnetic member are incorporated. Goods are obtained.

When the metal body is mounted in the hole, a fiber-reinforced resin molded article having high mechanical strength and having various shapes of metal bodies formed of various metal materials can be obtained.

[Brief description of drawings]

FIG. 1 is a perspective view of a first embodiment.

FIG. 2 is a sectional view taken along line XX of FIG.

FIG. 3 is an enlarged plan view of a reinforcing cloth at a portion indicated by an arrow Y in FIGS. 1 and 2.

FIG. 4 is an enlarged plan view of the reinforcing cloth at a portion other than the portion indicated by the arrow Y in FIGS. 1 and 2.

5 is another cross-sectional view of the second embodiment taken along the line XX of FIG.

FIG. 6 is yet another cross-sectional view of the third embodiment taken along line XX of FIG. 1.

FIG. 7 is a perspective view of the fourth embodiment.

8 is a cross-sectional view taken along line XX of FIG.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Fibrous body reinforced resin molded product, 12 main-body part, 13 surface layer, 131 1st surface layer, 132 2nd surface layer, 2 bolt fastening hole, 3 1st member, 31 textiles, 311 fiber braid, 4 2nd member, 5 Built-in part.

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Yoshihiro Jizo             2-3 2-3 Marunouchi, Chiyoda-ku, Tokyo             Inside Ryo Electric Co., Ltd. (72) Inventor Yoshifumi Itabashi             2-3 2-3 Marunouchi, Chiyoda-ku, Tokyo             Inside Ryo Electric Co., Ltd. (72) Inventor Akihiro Fujita             2-3 2-3 Marunouchi, Chiyoda-ku, Tokyo             Inside Ryo Electric Co., Ltd. (72) Inventor Yasushi Hamada             1706-7 Kido, Shiga-machi, Shiga-gun, Shiga Prefecture (72) Inventor Asami Nakai             Kyoto Prefecture Kyoto City Kamigyo Ward Imadegawa Dori Karasuma East             647-7 Teramonmae Yayoi Heights 202 (72) Inventor Tsuyoshi Okawa             542-8 Hiokiso Nishimachi, Sakai City, Osaka Prefecture F-term (reference) 4F204 AA36 AD02 AD16 AG03 AG28                       FA01 FB01 FB11 FF05 FF50                       FG05

Claims (8)

[Claims] 1. A fibrous body-reinforced resin molded article containing a non-fabric fiber material for reinforcement, a reinforcing cloth, and a resin to be reinforced, which has one or more holes penetrating the reinforcing cloth, The fibrous body-reinforced resin molded article, wherein the fibrous body in the reinforcing cloth near the hole is diverted so as to surround the hole in a substantially uncut state. 2. The fibrous body-reinforced resin molded product according to claim 1, wherein the fibrous body is a fiber or a fiber braid. 3. A first member containing the reinforcing cloth and the resin to be reinforced, and a second member containing the non-cloth fiber material for reinforcing and the resin to be reinforced. The fibrous body reinforced resin molded product according to claim 1 or 2. 4. The fibrous body according to claim 3, further comprising a main body portion formed of the second member and a surface layer formed on the surface of the main body portion and formed of the first member. Reinforced resin molded product. 5. The fiber-reinforced resin molded product according to claim 4, wherein the first member has a bag shape. 6. The surface layer is a first surface layer formed of the first member, a surface-forming resin provided on the first surface layer, or a second surface formed of the second member. The fibrous body reinforced resin molded article according to claim 5, which has a layer. 7. The fibrous body reinforced resin molded product according to claim 4, wherein the main body portion has an electric member and / or a magnetic member built therein. 8. The fibrous body-reinforced resin molded product according to claim 1, wherein a metal body is attached to the hole.