JP2011031481A - Fiber-reinforced resin component and method and apparatus for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a fiber-reinforced resin component, a method, and an apparatus for manufacturing the component which allow reducing the number of assembling processes by reducing the number of parts and a cost reduction due to unnecessity of molds for a reinforcing members. <P>SOLUTION: The fiber-reinforced resin component 1 contains fiber base materials 7-9 arranged in two or more layers and impregnated with a resin. In the fiber-reinforced resin component 1, end parts of the fiber base materials 8 and 9 being adjacent to each other and constituting the same layer are superimposed mutually to form a superimposed part 12, and the superimposed parts 12 of respective layers are superimposed mutually in the laminating direction to form a reinforcing part 5. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a fiber reinforced resin component, a manufacturing method thereof, and a manufacturing apparatus.

  In recent years, resins have been used for weight reduction, for example, in structural members for vehicles, and in particular, FRP (fiber reinforced resin) reinforced with a fiber material has been used. As a method for improving the bending rigidity of the structural member made of FRP, for example, there is a method in which a reinforcing member is formed and combined as a separate part (see, for example, Patent Document 1).

Japanese Patent Laid-Open No. 2008-68720

  However, if the rigidity of the structural member is improved by using the reinforcing member, the number of parts increases and the number of assembly steps increases. Moreover, since it is necessary to produce the mold | die of a reinforcement member, cost starts.

  The present invention has been made in order to solve the above-described problems, and can reduce the number of parts to reduce the number of assembling steps, and the fiber reinforcement that can reduce the cost by eliminating the need for a mold for a reinforcing member. An object of the present invention is to provide a resin component, a manufacturing method thereof, and a manufacturing apparatus.

  The fiber-reinforced resin component according to the present invention that achieves the above object is a fiber-reinforced resin component obtained by impregnating a resin into a fiber base material arranged in multiple layers. The fiber reinforced resin component has a reinforcing portion formed by overlapping the end portions of the fiber bases constituting the same layer adjacent to each other to form an overlapping portion, and the overlapping portions of each layer overlapping in the stacking direction. .

  The manufacturing method of the fiber reinforced resin part which concerns on this invention which achieves the said objective is a manufacturing method of the fiber reinforced resin part which made the fiber base material arrange | positioned by multiple layers impregnate resin. In the manufacturing method, an end laminated portion in which at least two of the overlapping portions of each layer are overlapped in the laminating direction while forming overlapping portions by mutually overlapping end portions of fiber bases that constitute the same layer adjacent to each other. And a molding step of impregnating the fiber base material with a resin in a state where the fiber base material is pressed with an elastic body together with at least a part of the fiber base material around the end laminated portion.

  An apparatus for manufacturing a fiber reinforced resin part according to the present invention that achieves the above object is an apparatus for manufacturing a fiber reinforced resin part in which a fiber base material arranged in multiple layers is impregnated with a resin. The manufacturing apparatus includes an end stacking unit in which at least two of the overlapping units of each layer are stacked in the stacking direction while forming overlapping units by overlapping the ends of the fiber bases that are adjacent to each other to form the same layer. Is pressed together with at least a part of the fiber base material around the end laminated portion.

  According to the fiber reinforced resin component configured as described above, the ends of the fiber bases that are adjacent to each other in the same layer overlap to form an overlapping portion, and the overlapping portion of each layer overlaps in the stacking direction. Therefore, it is not necessary to provide a reinforcing member as a separate member. Therefore, the number of parts can be reduced and the number of assembly steps can be reduced. Moreover, since the other shaping | molding die for shape | molding a reinforcement member is unnecessary, installation cost can be reduced.

  According to the method for manufacturing a fiber-reinforced resin component configured as described above, the end laminated portion in which the overlapping portions of the respective layers are laminated in the laminating direction is pressed with an elastic body together with the periphery of the end laminated portion. Since the base material is impregnated with the resin, the elastic body is deformed along the shape of the end laminated portion, and the end laminated portion can be pressurized along the shape. For this reason, the fiber reinforced resin component which has the reinforcement part integrated with the fiber reinforced resin component instead of another member can be manufactured effectively. Therefore, the number of fiber-reinforced resin parts can be reduced, and the number of assembly steps can be reduced. Moreover, since the other shaping | molding die for shape | molding a reinforcement member is unnecessary, installation cost can be reduced.

  According to the apparatus for manufacturing a fiber-reinforced resin component configured as described above, the elastic body is provided with an elastic body that pressurizes the end laminated portion together with at least a part of the fiber base material around the end laminated portion. It can deform | transform along the shape of an edge laminated part, and can pressurize an edge laminated part along a shape. For this reason, the fiber reinforced resin component which has the reinforcement part integrated with the fiber reinforced resin component instead of another member can be manufactured effectively. Therefore, the number of fiber-reinforced resin parts can be reduced, and the number of assembly steps can be reduced. Moreover, since the other shaping | molding die for shape | molding a reinforcement member is unnecessary, installation cost can be reduced.

It is a perspective view which shows the floor component (fiber reinforced resin component) which concerns on 1st Embodiment. It is sectional drawing which follows the AA line of FIG. It is a top view which shows the cut pattern of the fiber base material used for floor components. It is sectional drawing which shows an example of the fiber reinforced resin component which has a core material. It is a perspective view which shows the RTM shaping | molding die concerning 1st Embodiment. It is sectional drawing which follows the BB line of FIG. It is sectional drawing which shows the time of arrange | positioning the fiber base material on the molding surface of a lower mold | type. It is sectional drawing which shows the time of clamping a shaping | molding die and inject | pouring resin. It is an expanded sectional view of the site | part in which a reinforcement part is formed when the mold is clamped. It is an expanded sectional view which shows the time of a reinforcement part being formed with the shaping | molding die. It is sectional drawing which shows the reinforcement member as a comparative example provided as another component. It is a graph which shows the relationship between the width | variety of the reinforcement part of 1st Embodiment, and bending rigidity. It is a perspective view which shows the floor component (fiber reinforced resin component) which concerns on 2nd Embodiment. It is a top view which shows the cut pattern of the fiber base material used for the floor component which concerns on 2nd Embodiment. It is sectional drawing which shows the fiber reinforced resin component as a comparative example.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. In the description of the drawings, the same elements are denoted by the same reference numerals, and redundant description is omitted. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation and may be different from the actual ratios.

<First Embodiment>
1 is a perspective view showing a floor part which is a fiber reinforced resin part according to the first embodiment, FIG. 2 is a cross-sectional view taken along line AA of FIG. 1, and FIG. 3 is used for a fiber reinforced resin part. It is a top view which shows the cut pattern of a fiber base material.

A floor part 1 shown in FIG. 1 is a part for a front floor of a vehicle, and is a fiber reinforced plastic part made of carbon fiber reinforced plastic (CFRP) in which a fiber base material that is carbon fiber is impregnated with a resin. Arrow D ₁ of the in the figure represents a direction after longitudinal direction of the vehicle body, an arrow D ₂ indicates a vehicle width direction, an arrow D ₃ indicates the upper direction of the vehicle body vertical direction.

Floor parts 1, the floor panel 2 constituting the vehicle body floor, the sill 3 rising from the floor panel 2 to the upward direction D ₃ at both ends in the vehicle width direction D _2, the floor panel at the center portion in the vehicle width direction D ₂ 2 and a floor tunnel 4 formed in a convex shape upward D ₃ from. The sill 3 and the floor tunnel 4 are formed so as to extend in the front-rear direction.

The floor panel 2 and sills 3, on both sides in the vehicle width direction D ₂ across the floor tunnel 4, the reinforcement portion 5A extending in the vehicle width direction D _2, 5B (hereinafter, 5A, sometimes 5B is referred to as generally 5 .) Is formed. As shown in FIG. 2, the reinforcing portion 5 is formed by overlapping the fiber base material more than the portion different from the reinforcing portion 5 of the floor panel 2 and the sill 3. Details of the reinforcing portion 5 will be described later.

  As shown in FIG. 3, the floor component 1 will be described later using a first fiber substrate 7, second fiber substrates 8A and 8B, and third fiber substrates 9A and 9B cut out from a planar substrate. Molded by the RTM mold 30.

  The first fiber base 7 mainly constitutes the reinforcing fiber base of the floor tunnel 4. The second fiber bases 8A and 8B (hereinafter, 8A and 8B may be collectively referred to as 8) mainly constitute the reinforcing fiber bases on the vehicle front side of the floor panel 2 and the sill 3. Third fiber base materials 9A and 9B (hereinafter, 9A and 9B may be collectively referred to as 9) mainly constitute a reinforcing fiber base material on the vehicle rear side of floor panel 2 and sill 3. The plurality of first fiber base materials 7 overlapping in the stacking direction are all base materials having the same cut pattern. In addition, the plurality of second fiber base materials 8 overlapping in the stacking direction are all base materials having the same cut pattern, and the plurality of third fiber base materials 9 overlapping in the stacking direction are all base materials having the same cut pattern.

  The second fiber base material 8A (8B) and the third fiber base material 9A (9B) have overlapping end portions 10 and 11 that overlap each other at adjacent end portions, and the second fibers constituting the same layer. The overlapping portion 12 is formed by overlapping the overlapping end portions 10 and 11 of the substrate 8A (8B) and the third fiber substrate 9A (9B). By superposing a plurality of layers of the second fiber base 8A (8B) and the third fiber base 9A (9B), the overlapping portions 12 of the respective layers are laminated to form the reinforcing portion 5A (5B). Although the thickness of each fiber base material is about 0.15-1.0 mm, it is not necessarily limited to this.

  Here, the second fiber substrate 8A (8B) and the third fiber substrate 9A (9B) in the “same layer” are a pair of adjacent fiber substrates having overlapping end portions 10 and 11 that are in close contact with each other. The two fiber base materials do not necessarily exist on the same plane, and the stacking order of the two fiber base materials does not need to be the same.

  In addition, although the 2nd fiber base material 8 and the 3rd fiber base material 9 of the same layer are separate members in this embodiment, they may be the same members. FIG. 4 is a cross-sectional view showing an example of the fiber reinforced resin component 20 having the core material 21. When the fiber base material 22 covers the periphery of the core material 21 as in this example, the end portions on both sides of the same fiber base material 22 are overlapped to form the reinforcing portion 23. As the core material 21, an elastic body, a foam material, and a honeycomb material can be used, and a foam material and a honeycomb material are preferable for weight reduction. The material of the foam material is not particularly limited. For example, a foam material made of a polymer material such as polyurethane, acrylic, polystyrene, polyimide, vinyl chloride, or phenol can be used. The material of the honeycomb material is not particularly limited, and for example, aluminum alloy, paper, aramid paper, or the like can be used.

As shown in FIG. 2, the number of laminated fiber bases in the reinforcing portion 5 is twice the number of laminated portions in a portion different from the reinforcing portion 5, and therefore the thickness X ₁ of the reinforcing portion 5 is different from that of the reinforcing portion 5. It is about twice the thickness X ₂ sites. As an example, the thickness _{X 1} is 4 mm, the thickness _{X 2} is 2 mm. Vf (fiber volume content) in the reinforcing part 5 is higher than Vf of a part different from the reinforcing part 5. When the Vf of the fiber reinforced resin is high, the elastic modulus is improved, so that the rigidity in the reinforcing portion 5 is increased and the reinforcing function is improved. As an example, Vf in the reinforcing part 5 is 70%, and Vf of a part different from the reinforcing part 5 is 50%. In addition, the measuring method of Vf (fiber volume content) is defined by JISK7052.

  The reinforcing portion 5 is formed with a width W. The larger the value of the width W, the higher the rigidity of the reinforcing portion 5 and the reinforcing function is improved.

  Carbon fibers are used as the fiber base material, and glass fibers, aramid fibers, metal fibers, boron fibers, alumina fibers, silicon carbide high-strength synthetic fibers, and the like can be used. The form of the reinforcing fiber base is not particularly limited, and a unidirectional sheet, a woven fabric, or the like can be adopted, and is used in the form of a preform (preform) shaped in advance as necessary.

  As the resin to be used, a thermosetting resin having a low viscosity and easily impregnating the reinforcing fiber or a monomer for RIM (resin injection molding) that forms a thermoplastic resin is preferable. Examples of thermosetting resins include epoxy resins, unsaturated polyester resins, polyvinyl ester resins, phenol resins, guanamine resins, polyimide resins such as bismaleide and triazine resins, furan resins, polyurethane resins, polydiallyl phthalate resins, Examples include melamine resin, urea resin, and amino resin.

  Further, polyamides such as nylon 6, nylon 66 and nylon 11, or copolymer polyamides of these polyamides, polyesters such as polyethylene terephthalate and polybutylene terephthalate, or copolymer polyesters of these polyesters, polycarbonate, polyamideimide, Polyphenylene sulfide, polyphenylene oxide, polysulfone, polyethersulfone, polyetheretherketone, polyetherimide, polyolefin, and the like, and thermoplastic elastomers typified by polyester elastomers, polyamide elastomers, and the like are also included.

  Also, a resin in which a plurality selected from the above-mentioned thermosetting resins, thermoplastic resins, and rubbers are mixed can be used.

  Next, the RTM mold 30 (molding apparatus) for molding the floor component 1 will be described.

  FIG. 5 is a perspective view showing an RTM mold according to the embodiment of the present invention, and FIG. 6 is a cross-sectional view taken along line BB in FIG.

  As shown in FIGS. 5 and 6, the RTM mold 30 has an upper mold 31 as one mold and a lower mold 32 as the other mold, and an intermediate between the upper mold 31 and the lower mold 32. It has an intermediate plate 33 as a member. The upper mold 31 and the intermediate plate 33 form a resin injection flow path and an injection port to the base material. A resin injection pipe 35 that supplies resin from the outside is connected to the upper mold 31. The resin injection pipe 35 is composed of a metal pipe or a resin tube. An O-ring 36 that is in close contact with the intermediate plate 33 is provided in the periphery of the upper mold 31.

  On the surface of the intermediate plate 33 on the upper mold side, a resin flow channel groove 37 communicating with the resin injection pipe 35 provided in the upper mold 31 is processed. On the lower mold side surface of the intermediate plate 33, an elastic sheet 38 (elastic body) made of silicon rubber is installed with a uniform thickness Y. The intermediate plate 33 and the elastic sheet 38 are formed with a plurality of through holes 39 penetrating from the respective resin flow channel grooves 37 to the lower mold side surface. The through holes 39 are provided more in the region L corresponding to the reinforcing portion 5 of the floor component 1 to be molded than in other regions. Therefore, the aperture ratio of the through hole 39 in the region L corresponding to the reinforcing portion 5 of the floor component 1 to be molded is higher than the aperture ratio of the through hole 39 in the other regions. The aperture ratio represents the area of the through hole 39 occupying the surface area of the elastic sheet 38. Increasing the aperture ratio can be realized not only by increasing the number of through holes 39 but also by increasing the diameter of the through holes 39.

  The thickness Y of the elastic sheet 38 is 4 mm, for example. In the present embodiment, as will be described later, the elastic sheet 38 is assumed to be deformed by 2 mm at the maximum, and therefore silicon rubber that can withstand a compression rate of 50% is applied. The thickness Y of the elastic sheet 38 is preferably set to an optimal value in consideration of the material and hardness of the elastic sheet 38, the assumed deformation amount, the compression rate, and the like. In addition, although it is preferable that the hardness of the elastic sheet 38 is 70-90 mN by the hardness defined by JISK6253, it is not necessarily limited to this.

  The elastic sheet 38 is not limited to silicon rubber, and other rubber such as fluorine rubber or ethylene propylene rubber, elastomer, polymer resin, or the like can be applied.

  The lower mold 32 is connected to a resin discharge pipe 40 for discharging excess resin out of the mold. The resin discharge pipe 40 is composed of a metal pipe or a resin tube. An O-ring 41 that is in close contact with the intermediate plate 33 is provided on the periphery of the lower mold 32.

  Next, a molding process (molding method) of the floor component 1 using the above-described RTM mold 30 will be described.

  FIG. 7 is a cross-sectional view showing the fiber base disposed on the molding surface of the lower mold, and FIG. 8 is a cross-sectional view showing the resin injected by clamping the mold. FIG. 9 is an enlarged cross-sectional view of a portion where a reinforcing portion is formed when the mold is clamped, and FIG. 10 is an enlarged cross-sectional view showing a case where the reinforcing portion is formed by the forming die.

  First, as shown in FIG. 7, a preform 50 (preform) in which the first fiber substrate 7, the second fiber substrate 8, and the third fiber substrate 9 are preliminarily shaped on the molding surface of the lower mold 32. ). In order to shape the preform 50 in advance, a general mold (not shown) can be applied. In this shaping, after the first fiber base material 7, the second fiber base material 8, and the third fiber base material 9 are laminated in the preforming die, the final shape of the floor component 1 is reached by performing preforming. The previous preliminary shape is applied to the preform 50. The shape of the first fiber base material 7, the second fiber base material 8, and the third fiber base material 9 in the preform 50 is held by a small amount of shape holding agent. The shape-retaining agent can be appropriately selected from the resins described above as examples of the resin impregnated in the reinforcing fiber.

  Depending on the shape of the fiber reinforced resin component, the first fiber base 7, the second fiber base 8, and the third fiber base 9 may be arranged directly on the RTM mold 30 without being preformed. Good.

  As shown in FIG. 9, the preform 50 has a second fiber base 8A (8B) and a third fiber base 9A (9B) alternately stacked in multiple layers to form the same layer. (8B) and the overlap part 10 and 11 of 3rd fiber base material 9A (9B) have the edge part lamination | stacking part 51 laminated | stacked in the same position. And between the laminated body which laminated | stacked 2nd fiber base material 8A and 3rd fiber base material 9A, and the laminated body which laminated | stacked 2nd fiber base material 8B and 3rd fiber base material 9B, the 1st fiber base material The laminated body which laminated | stacked 7 is arrange | positioned, and each is hold | maintained with the shape retention agent.

  In addition, although the edge part lamination | stacking part 51 is hold | maintained in the state laminated | stacked with the shape retention agent in this embodiment, in the case of the form arrange | positioned directly to an RTM shaping | molding die, without preforming a fiber base material. In some cases, a plurality of fiber base materials are simply stacked without using a shape-retaining agent.

Next, as shown in FIG. 8, the upper mold 31 and the lower mold 32 are clamped, and the preform 50 is pressed in the cavity between the intermediate plate 33 and the lower mold 32. At this time, as shown in FIG. 10, since the elastic sheet 38 is provided on the lower mold side surface of the intermediate plate 33, the preform 50 is pressed by the elastic force. At this time, the number of laminated fiber substrates at the end stacking portion 51, since twice the number of the laminated portion that is different from the end stacking portion 51, the thickness X ₁ of the end stacking portion 51, the end lamination becomes part 51 about twice the different sites thickness X _2, the elastic sheet 38 greatly deformed at the site corresponding to the end stacking portion 51. As a result, the preform 50 receives a stronger force in the end layered portion 51 than in other parts. In this embodiment, the thickness _{X 1} is 4mm end lamination portion 51, a thickness _{X 2} is 2mm site different from the end stacking portion 51, the compression ratio of the elastic sheet 38 is 50% maximum.

  Thereafter, the resin is injected under pressure from the resin injection tube 35, and the resin flows between the upper mold 31 and the intermediate plate 33 sealed by the O-ring 36. The flowed resin first flows rapidly along the resin flow channel groove 37 of the intermediate plate 33 and spreads over a wide area. And, through the plurality of through holes 39, the fibers are injected into the fiber bases 7, 8, and 9 substantially simultaneously from a plurality of locations, and the resin is satisfactorily and quickly over a wide area of the fiber bases 7, 8, and 9. It is impregnated. Since the end laminated portion 51 is thicker than the portion different from the end laminated portion 51, it is difficult to impregnate the resin, but the opening ratio of the region L that presses the end laminated portion 51 of the intermediate plate 33 and the elastic sheet 38 is Since it is higher than the opening ratio in the area | region which presses a site | part different from the edge laminated part 51, the reinforcement part 5 can be effectively impregnated with resin.

  When the impregnation is performed, the end laminated portion 51 receives a stronger compressive force than the other portions by the elastic sheet 38, and thus the Vf of the reinforcing portion 5 formed by impregnating the end laminated portion 51 with the resin is It becomes higher than Vf of other parts. As an example, in this embodiment, Vf of the reinforcing part 5 is 70%, and Vf of a part different from the reinforcing part 5 is 50%.

  The inside of the cavity between the lower mold 32 and the intermediate plate 33 sealed by the O-ring 41 is sucked by vacuum from the resin discharge pipe 40. The surplus resin after impregnation flows to a film gate / runner (not shown) provided around the cavity and is discharged from the resin discharge pipe 40 to the outside. After the resin is impregnated in the entire area of the preform 50, the resin discharge pipe 40 is closed and cured by heating while maintaining the resin pressure.

  Thereafter, the molded floor component 1 is removed. In demolding, the upper mold 31 is raised, the floor component 1 is taken out from the lower mold 32 together with the intermediate plate 33, and separated from the intermediate plate 33. When separation from the intermediate plate 33 or resin protrusions adhere to the floor part 1 and time is required for post-processing, a release cloth or the like is previously disposed between the intermediate plate 33 and the reinforcing fiber base. It is good to leave.

  Next, the result of having calculated the rigidity of the reinforcement part 5 of the floor component 1 which concerns on this embodiment is shown.

  FIG. 11 is a cross-sectional view showing a reinforcing member as a comparative example provided as a separate part, and FIG. 12 is a graph showing the relationship between the width of the reinforcing portion and the bending rigidity of this embodiment.

As shown in FIG. 11, a reinforcing member 70 as a comparative example is a member that is attached to reinforce a floor component that does not include the reinforcing portion 5 as in the present embodiment, and is provided as a separate member from the floor component. It is done. The calculation results of the bending stiffness K ₂ of the reinforcing member 70, shown by a dotted line in the graph of FIG. 12.

Dots in FIG. 12 shows the calculation results of the stiffness K ₁ of only the reinforcing portion 5 of the floor parts 1 according to this embodiment. That is, the bending rigidity of the portion within the range of the width W in FIG. The thickness _{X 1} of the reinforcement section 5 4 mm, Vf of the reinforcing portion 5 70%, the Young's modulus E as 50 GPa, to calculate the bending stiffness _{K 1.}

As a result, when the width W is about 80mm or more, the stiffness K ₁ of the reinforcement portion 5 has been confirmed to be a more equal and stiffness K ₂ of the reinforcing member 70 in the comparative example. Thus, it is possible to modify the stiffness by changing the width W, the performance of the models, can set the width W with the desired stiffness K _1.

  Next, the effect of this embodiment will be described.

  FIG. 15 is a cross-sectional view showing a fiber-reinforced resin part as a comparative example. As shown in FIG. 15, the fiber reinforced resin component 80 as a comparative example is abutted against the ends of the fiber bases 81 and 82 constituting the same layer, and the butt 83 of each layer is shifted in order to maintain rigidity. Laminated. Such a fiber reinforced resin component 80 requires a separate reinforcing member (see FIG. 11) in order to increase the rigidity, and therefore requires another mold for molding the reinforcing member. Moreover, since the cut patterns of the fiber base material of each layer are all different, the number of parts increases and the number of assembly steps also increases.

  On the other hand, in the floor component 1 (fiber reinforced resin component) according to the present embodiment, the end portions of the fiber bases 8 and 9 constituting the same layer adjacent to each other overlap to form the overlapping portion 12, and Since the overlapping portion 12 overlaps in the stacking direction to form the reinforcing portion 5, it is not necessary to provide a reinforcing member as a separate member. Therefore, the number of parts can be reduced and the number of assembly steps can be reduced. Moreover, since the other shaping | molding die for shape | molding a reinforcement member is unnecessary, installation cost can be reduced. Furthermore, in order to overlap the overlapping portions 12 of the respective layers in the stacking direction, it can be easily realized by making the cut patterns of the fiber base material overlapping in the vertical direction the same. Therefore, the cut pattern can be reduced and the yield of the material can be improved.

  Moreover, since Vf (fiber volume content) in the reinforcement part 5 is higher than Vf in the site | part different from the reinforcement part 5, the fiber reinforced resin component with the higher intensity | strength of the reinforcement part 5 is realizable.

  In the fiber reinforced resin component manufacturing method and manufacturing apparatus according to the present embodiment, the end laminated portion 51 in which the overlapping portions 12 of the respective layers are stacked in the stacking direction is pressed by the elastic body 38 together with the periphery of the end laminated portion 51. In this state, since the fiber base materials 7 to 9 are impregnated with the resin, the elastic body 38 is deformed along the shape of the end laminated portion 51, and the end laminated portion 51 can be pressurized along the shape. For this reason, the fiber reinforced resin component which has the reinforcement part 5 integrated with the fiber reinforced resin component instead of another member can be manufactured effectively. Therefore, the number of fiber-reinforced resin parts can be reduced, and the number of assembly steps can be reduced. Moreover, since the other shaping | molding die for shape | molding a reinforcement member is unnecessary, installation cost can be reduced. Moreover, even if the fiber reinforced resin component has irregularities, it is possible to apply a target molding pressure by the elastic body 38.

  Further, since the pressure is applied by the elastic sheet 38 fixed to the intermediate plate 33 arranged inside the mold 30, the elastic sheet 38 can be easily arranged in the mold 30. That is, it is not necessary to arrange only the elastic body in the mold, and the man-hour can be reduced.

  Moreover, since resin flows into the fiber base materials 7-9 from the through-hole 39 formed in the intermediate | middle board 33 and the elastic sheet 38, resin can be made to flow uniformly into the wide range of the fiber base materials 7-9.

  Moreover, the opening ratio of the through hole 39 in the region L that presses the end laminated portion 51 of the elastic sheet 38 is larger than the opening ratio of the through hole 39 in the region that presses a portion different from the end laminated portion 51 of the elastic sheet 38. Since it is high, the resin can be efficiently impregnated into the end laminated portion 51 that is thick and difficult to impregnate with resin.

  Further, the elastic sheet 38 having a constant thickness pressurizes at least a part of the end layered portion 51 and the fiber substrate around the end layered portion 51, so that even if the molded product has irregularities, the target molding is performed. Pressure can be applied. Furthermore, since the elastic sheet 38 is deformed along the shape of the end laminated portion 51, it can be pressed by the same elastic sheet 38 even if the position or shape of the reinforcing portion 5 is changed.

Second Embodiment
FIG. 13 is a perspective view showing a floor part which is a fiber reinforced resin part according to the second embodiment, and FIG. 14 is a plan view showing a cut pattern of a fiber base material used in the fiber reinforced resin part according to the second embodiment. It is.

  As shown in FIG. 13, the floor component 60 (fiber reinforced resin component) according to the second embodiment includes three first reinforcing portions 65, second reinforcing portions 66 extending in a direction inclined with respect to the front-rear direction of the vehicle, and A third reinforcing portion 67 is provided.

  As shown in FIG. 14, the floor component 60 uses a first fiber base 61, a second fiber base 62, a third fiber base 63 and a fourth fiber base 64 cut out from a planar base. The RTM mold 30 described in the first embodiment is molded.

  The 1st reinforcement part 65 is formed when the overlapping edge parts 61A and 62A which the 1st fiber base material 61 and the 2nd fiber base material 62 mutually adjoin mutually overlap. The 2nd reinforcement part 66 is formed when the overlapping edge parts 62B and 63A which the 2nd fiber base material 62 and the 3rd fiber base material 63 mutually adjoin mutually overlap. The third reinforcing portion 67 is formed by overlapping the overlapping end portions 63B and 64A of the third fiber base 63 and the fourth fiber base 64 that are adjacent to each other.

  As described above, the positions of the reinforcing portions 65 to 67 can be arbitrarily changed from those in the first embodiment. And even if it changes the position of the reinforcement parts 65-67 in this way, the floor component 60 can be shape | molded using the RTM shaping | molding die 30 used in 1st Embodiment. That is, since the elastic sheet 38 is formed with a constant thickness Y, the elastic sheet 38 can be deformed along the shape of the end laminated portion even if the position and shape of the reinforcing portions 65 to 67 are changed. . Thereby, even if the position and shape in which the reinforcement parts 65-67 are provided are changed, it can shape | mold using the same RTM shaping | molding die 30, it is not necessary to produce the separate shaping | molding die 30, and cost reduction Is possible.

  The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the claims. For example, the present invention may be applied to fiber reinforced resin parts other than floor parts. Moreover, in 1st Embodiment, although the superimposition part 12 of all the layers overlapped and the reinforcement part 5 was formed, the at least 2 superimposition part 12 should just overlap. Moreover, the cut pattern of each fiber base material does not necessarily have to be the same. In this case, the cross-sectional shape of the reinforcing portion can be set to an arbitrary shape such as a trapezoid or a rectangle. Further, the thickness Y of the elastic sheet 38 is not necessarily uniform. In addition, the fiber reinforced resin component according to the present invention does not necessarily have to be molded by RTM molding, and may be molded by other molding methods.

1 Floor parts (fiber reinforced plastic parts),
5A, 5B reinforcement part,
7 first fiber substrate,
8A, 8B second fiber substrate,
9A, 9B third fiber substrate,
10,11 Overlapping end,
12 superimposition part,
20 Fiber reinforced plastic parts,
22 Fiber substrate,
23 Reinforcement part,
30 RTM mold (molding device),
31 Upper mold,
32 Lower mold,
33 intermediate plate,
38 Elastic sheet (elastic body),
39 through hole,
51 end laminates,
60 Floor parts (fiber reinforced plastic parts),
61 1st fiber base material,
62 second fiber substrate,
63 third fiber substrate,
64 fourth fiber substrate,
61A, 62A, 62B, 63A, 63B, 64A Overlapping ends,
65, 66, 67 reinforcement part,
K ₁ rigidity of the reinforcement,
W Width of reinforcing part (end laminated part),
X ₁ reinforcing portion thickness of the (end stacking portion).

Claims (12)

A fiber reinforced resin component obtained by impregnating a resin into a fiber base material arranged in multiple layers,
A fiber reinforced resin part having a reinforcing part formed by overlapping ends of adjacent fiber bases constituting the same layer to form an overlapping part, and the overlapping part of each layer overlapping in the stacking direction.   The fiber reinforced resin part according to claim 1, wherein a fiber volume content ratio indicating a volume ratio of a fiber base material to a unit volume of the fiber reinforced resin part is higher than a part where the reinforcing part is different from the reinforcing part. A method for producing a fiber reinforced resin component in which a fiber base material arranged in multiple layers is impregnated with a resin,
An end laminated portion formed by overlapping at least two of the overlapping portions of each layer in the laminating direction while forming overlapping portions by mutually overlapping the end portions of the fiber bases that are adjacent and constitute the same layer The fiber reinforced resin part manufacturing method which has a shaping | molding process which makes the said fiber base material impregnate resin in the state pressurized with the elastic body with at least one part of the fiber base material of the circumference | surroundings of the said edge part lamination | stacking part.   In the molding step, at least a part of the end laminated portion and the fiber substrate around the end laminated portion are pressed by an elastic sheet fixed to an intermediate plate arranged inside the mold. 4. A method for producing a fiber-reinforced resin part according to item 3.   5. The fiber-reinforced resin component according to claim 4, wherein in the molding step, a resin is caused to flow into the fiber base material from a through-hole formed in the intermediate plate and the elastic sheet, and the fiber base material is impregnated with the resin. Production method.   The opening ratio of the through-hole in the area | region which presses the said edge part lamination | stacking part of the said elastic sheet is higher than the opening ratio of the through-hole in the area | region which presses a site | part different from the said edge part lamination | stacking part of the said elastic sheet. The manufacturing method of the fiber reinforced resin component as described in 2.   In the said formation process, at least one part of the fiber base material of the circumference | surroundings of the said edge part laminated | stacking part and the said edge part laminated | stacking part is pressurized with the elastic sheet with constant thickness. The manufacturing method of the fiber reinforced resin component of description. An apparatus for manufacturing a fiber reinforced resin component in which a resin is impregnated with a fiber base material arranged in multiple layers,
While forming the overlapping portion by overlapping the end portions of the fiber bases constituting the same layer adjacent to each other, the end stacked portion in which at least two of the overlapping portions of each layer are stacked in the stacking direction An apparatus for manufacturing a fiber-reinforced resin part having an elastic body that pressurizes together with at least a part of a fiber base material around a laminated portion.   The said elastic body is a manufacturing apparatus of the fiber reinforced resin component of Claim 8 which is an elastic sheet fixed to the intermediate | middle board arrange | positioned inside a shaping | molding die.   The said intermediate | middle board and an elastic sheet are the manufacturing apparatuses of the fiber reinforced resin component of Claim 9 which has a through-hole into which resin flows in.   The opening ratio of the through-hole in the area | region which presses the said edge part lamination | stacking part of the said elastic sheet is higher than the opening ratio of the through-hole in the area | region which presses a site | part different from the said edge part lamination | stacking part of the said elastic sheet. An apparatus for producing fiber-reinforced resin parts as described in 1.   The said elastic sheet is a manufacturing apparatus of the fiber reinforced resin component of any one of Claims 8-11 whose thickness is constant.

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