JP2011102013A - Carbon fiber-reinforced resin material and method for manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for quickly manufacturing a carbon fiber-reinforced resin material in a small lot at a low cost using simple equipment. <P>SOLUTION: The method for manufacturing the carbon fiber-reinforced resin material includes: a fiber arranging process for laminating a fabric-like carbon fiber piece 13, which is cut so as to correspond to a mold 15, on a mold face on which a gel coating material is applied; a resin shaping process for filling a joining resin 11 into the laminated carbon fiber piece or pasting it on the mold surface by the joining resin 11 for shaping; a bubble removing process for pressing internal bubbles out by pressurizing a resin face which is partially heated to a resin softening temperature by blowing heated air to a surface of a composite resin layer 23 formed of the joining resin and the carbon fiber piece arranged on the mold face; and a heating and curing process for reheating the composite resin layer, which is cooled to a room temperature as a whole, to a resin curing temperature and keeping for a predetermined period of time. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a carbon fiber reinforced resin material using carbon fibers and a method for producing the same.

Carbon fiber reinforced resin for automobile weight reduction has attracted attention. Carbon fiber reinforced resin with lightweight and high strength properties has been put into practical use mainly in the aircraft industry, and has been developed as a technology to cope with global environmental problems. Automotive outer panels and roofing materials such as electric cars and eco cars Widely used in applications such as notebook PC casings, the demand is increasing year by year.
A carbon fiber reinforced resin material is manufactured by molding a prepreg containing carbon fibers that are reinforcing fibers and a bonding resin, and an autoclave method is known as a method for molding a prepreg that requires strength for automobiles and the like. In this autoclave method, prepreg material wrapped with auxiliary materials such as bag film, bleeder, curl plate, etc. is placed in a vacuum pot, and air is removed from the prepreg material by applying several atmospheres from the outside while pulling the bag film into a vacuum. To do. This is because, in the carbon fiber reinforced resin, the content of bubbles inside the product has a great influence on the bonding property between the resin and the carbon fiber, greatly affects the strength, and eliminating the bubbles leads to an increase in strength. That is, the reason why the prepreg material in which carbon fibers are contained in the resin is high in strength and quality is that this construction method is effective in reducing the content of bubbles inside the product.
Also, regarding molding systems for thermoplastic resins or carbon fiber composites containing thermoplastic resins, techniques such as vacuum molding (RM), pultrusion (pulling), filament winding (FW), injection molding, press molding, etc. are known. In vacuum forming, a slab of heated thermoplastic material (a sheet of constant thickness) is placed in a vacuum mold, and a vacuum is drawn between the mold and the heated plastic material to mold the plastic material. Attract to. In press molding, a method is used in which a pre-heated mass or slab of material is pressed between two molding molds that compress the material into a desired part or shape.
For example, Patent Document 1 relates to a method for producing a carbon fiber reinforced composite material using a mold, a fiber opening step for performing a fiber opening treatment on a carbon fiber, and a resin impregnation step for impregnating a hardened resin into the opened carbon fiber. Further, there is disclosed a production method including a fiber separation / curing step in which a carbon fiber impregnated with a curable resin is clamped with a mold and the carbon fiber is separated to cure the curable resin.

JP 2009-191116 A

  However, the conventional method for producing a carbon fiber reinforced resin material by the autoclave method or the like uses expensive auxiliary materials and heat-treats using a vacuum / high pressure kettle for several hours, which requires labor and production cost. For this reason, there is a need for a method that can be manufactured with simple equipment and low manufacturing costs, especially in the production of parts using small lots and a wide variety of carbon fiber reinforced resins, such as the development of prototype cars such as electric cars and eco cars. Further, in the kneading step of the carbon fiber material using the resin as a matrix, there is a problem that it is difficult to perform an appropriate arrangement process of carbon fibers and a removal process of bubbles in the resin because the viscosity of the resin is high.

  In the manufacturing method of Patent Document 1, since the mold is clamped with a uniform pressure along the mold surface to be a mold, it is difficult to adjust the consolidation of each part part with different load conditions. There was also a problem of lack of compatibility. Furthermore, the carbon fiber reinforced resin material is a heterogeneous material formed by molding carbon fibers that are reinforcing fibers and a bonding resin, so that there is a large difference between the physical properties in the arrangement direction of the reinforcing fibers and the physical properties in other directions. In particular, a carbon fiber reinforced resin material using a thermosetting resin as a bonding resin reflects the low toughness of the bonding resin, and has a property of being easily broken against stress from other than the direction in which the reinforcing fibers are arranged.

The present invention has been made to solve the above-described conventional problems.
An object of the present invention is to provide a carbon fiber reinforced resin material excellent in durability, reliability, and versatility by allowing carbon fibers to be distributed and adjusted in a properly controlled state in a resin. .
Another object of the present invention is to provide a method for producing a carbon fiber reinforced resin material capable of producing a small lot of products quickly and at low cost with simple equipment.

(1) The method for producing the carbon fiber reinforced resin material of the present invention comprises:
(A) a fiber placement step of laminating cloth-like carbon fiber pieces cut in accordance with a mold on a mold surface coated with a gel coat material;
(B) Filling the laminated carbon fiber pieces with a bonding resin or attaching the resin to the mold surface with a bonding resin for shaping;
(C) A bubble that pressurizes a partially heated resin surface at a resin softening temperature by blowing heated air onto the surface of a composite resin layer composed of a carbon fiber piece and a bonding resin disposed on the mold surface to push out the internal bubbles. A removal step;
(D) A heating curing step in which the composite resin layer is reheated to a curing temperature and held for a predetermined time.

(2) The method for producing a carbon fiber reinforced resin material of the present invention is as described in (1) above.
A plurality of composite resin layers prepared by the (a) fiber placement step to the (c) bubble removal step are stacked on the mold, and sequentially crimped, so that the whole is integrally molded according to the mold. Features.

(3) In the manufacturing method of the carbon fiber reinforced resin material of the present invention,
The carbon fiber disposed in the composite resin layer is imparted with an orientation that extends in a fixed direction, and each of the adjacent composite resin layers is disposed with a different orientation.

(4) The manufacturing method of the rear wing of the present invention includes a hollow portion in which a carbon fiber reinforced resin material is surrounded by a shell of a composite resin layer, and the surface is represented by a substantially meniscus-like columnar portion disposed in the hollow portion. A method of manufacturing a rear wing whose back side is connected and supported,
(A) Fiber placement step to (c) A plurality of composite resin layers created by the bubble removal step are respectively laminated on a pair of molds that can be opened and closed, sequentially crimped, and shaped according to the mold, A support wing is disposed between the molds in an open state, and the molds are pressure-bonded to each other to manufacture a rear wing incorporating the support column.
(5) The carbon fiber reinforced resin material of the present invention is
A carbon fiber reinforced resin material for weight reduction of parts produced by the method for producing a carbon fiber reinforced resin material of (1) to (3), wherein a bending moment and shear force applied to the part parts are distributed. According to the profile, the number and thickness of the composite resin layers, the carbon fiber content, and the type of bonding resin are set.

(6) The carbon fiber reinforced resin material of the present invention is a carbon fiber reinforced resin material for weight reduction of part parts produced by the method for producing a carbon fiber reinforced resin material of (1) to (3) above. The mass ratio (A / B) of the carbon fiber (A) and the bonding resin (B) in the composite resin layer is (40-50) / (60-50).

According to the present invention, a fiber placement step of laminating cloth-like carbon fiber pieces cut in accordance with a mold on a mold surface to which a gel coat material is applied, and whether the laminated carbon fiber pieces are filled with a bonding resin. Alternatively, a resin shaping step for shaping by bonding to the mold surface with a bonding resin, and a resin softening temperature by blowing heated air onto the surface of the composite resin layer made of carbon fiber pieces and bonding resin arranged on the mold surface A partially-heated resin surface is pressed to extrude the internal bubbles, and the composite resin layer is reheated to a curing temperature and maintained for a predetermined time. A small lot of carbon fiber reinforced resin material can be produced quickly and at low cost with simple equipment without using it.
Furthermore, since the present invention includes a bubble removing step that can be performed under atmospheric pressure, roller pressure conditions and partial heating conditions corresponding to the implementation status such as the bonding property between the bonding resin and the carbon fiber on the mold surface Can be set as appropriate, and requirements such as uniformity and strength of fiber dispersion for automobiles and the like can be satisfied quickly and inexpensively.

It is explanatory drawing of the bubble removal process in the manufacturing method of the carbon fiber reinforced resin material of embodiment. It is explanatory drawing of roller operation in the bubble removal process of the manufacturing method of the carbon fiber reinforced resin material of embodiment. It is explanatory drawing which shows the mold manufacturing process applied to the manufacturing method of the carbon fiber reinforced resin material of embodiment. It is a flowchart of the manufacturing method of the carbon fiber reinforced resin material of embodiment. It is a graph which shows the time change of the temperature in the composite resin layer of embodiment. 1 is a perspective view of a carbon fiber reinforced resin material of Example 1. FIG. 1 is a flowchart of a method for producing a carbon fiber reinforced resin material of Example 1. FIG. It is sectional drawing of the carbon fiber reinforced resin material of Example 1, and its explanatory drawing.

The manufacturing method of the carbon fiber reinforced resin material of the present embodiment uses a blower fan or a blower that can be operated by hand such as a blower fan on the surface of the composite resin layer made of carbon fiber pieces and bonding resin arranged on the mold surface. Then, heated air is blown to partially heat the resin surface to the resin softening temperature.
The composite surface is molded and cooled while pressing and removing the internal bubbles while adjusting the resin surface with a tool such as a roller or a scissors while facing the mold surface. It can be reheated and cured.
This eliminates or reduces the air bubbles inside the product that greatly affect the bondability between the bonding resin and the carbon fiber, so that a high-strength, high-quality carbon fiber reinforced resin material can be quickly and cost-effectively provided with simple equipment. Can be produced.

  A fiber arrangement | positioning process is a process of laminating | stacking and arrange | positioning a carbon fiber piece in molds, such as for automotive parts components. The parts for automobiles to be reduced in weight are, for example, outer plates such as fenders, doors, trunks, and hardtops, and the mold is formed from a metal material, a wood material, a resin material, a plaster, or the like. A gel coat layer is formed on the mold surface for the purpose of obtaining a molded article having excellent surface smoothness and protecting fibers. The gel coat layer can be formed by, for example, applying a release treatment to the mold and then applying an epoxy resin or the like by spraying or the like.

  The carbon fiber piece is in the form of a cloth cut in accordance with a mold, and is formed of carbon fiber having a desired strength. Here, the weaving shape of the carbon fiber is selected in accordance with the curved shape of the mold to be prototyped, and the conditions such as the method of attaching to the mold surface and the direction of attaching the carbon fiber are set.

  The resin shaping step is a step of filling the carbon fiber pieces laminated on the mold surface with the bonding resin or attaching the carbon fiber pieces to the mold surface with the bonding resin and shaping the carbon fiber pieces, and adjusted to a predetermined viscosity in advance. The bonding resin containing carbon fiber pieces is molded by filling the bonding resin so as to extend as thinly as possible using a brush or the like.

  As the bonding resin impregnated into the carbon fiber pieces, various thermosetting resins and thermoplastic resins can be applied. Examples of the thermosetting resin include an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, and a urethane resin. Incidentally, the composition containing the carbon fiber and the thermosetting resin can contain additives such as fillers, thermoplastic resins, and other low shrinkage agents. For example, the bonding resin can be suitably selected from epoxy resins that are particularly excellent in properties (strength / reliability) for automobile parts and can be heated and cured under the optimum conditions.

When a thermosetting resin is used, it is cured by applying a chemical change that crosslinks its molecular structure after applying heat and pressure. Thermosetting plastics are resistant to high temperatures due to a strong cross-linked structure and generally have higher dimensional stability than thermoplastic materials.
In the case of a thermoplastic resin, conditions are not restricted as much as a thermosetting resin, and can be reused, changed in shape, and a new part can be made. Examples of the thermoplastic resin include polypropylene (PP) and polyethylene (PE ), Polyether ether ketone (PEEK), and those containing nylon are applicable.

In the bubble removal process, first, the resin surface is partially heated by blowing heated air onto the surface of the composite resin layer composed of carbon fiber pieces and bonding resin arranged on the mold surface using a blower such as a blower or a dryer. To do. The product strength can be improved by removing the internal bubbles interposed between the carbon fiber and the resin while pressurizing the resin surface partially heated to the resin softening temperature using a tool such as a roller or a scissors.
To increase the strength of the carbon fiber reinforced resin, it is necessary to improve the adhesion between the carbon fiber and the epoxy resin by using an epoxy resin that has the ability to dissolve the coating agent coated on the surface of the carbon fiber as the bonding resin. it can.

In the bubble removing step, heated air is blown onto the surface of the composite resin layer disposed on the mold serving as a mold through a dryer or a blower to heat the air. Thus, when the resin softening temperature of the bonding resin is reached, the resin viscosity suddenly drops and it becomes easy to flow smoothly.
When the resin softening temperature at which the viscosity of the resin suddenly changes (falls), the surface of the epoxy resin soaked in the carbon fiber undulates with hot air, so that it can be determined whether the reheating temperature has been reached. it can.

As shown in FIG. 1, when the viscosity of the bonding resin 11 suddenly drops, the bubbles 12 that cause the greatest decrease in the strength of the carbon fiber reinforced resin material 10 can easily come out of the bonding resin 11.
As shown in FIG. 2, by using a roller 14 or the like while maintaining the bonding resin 11 in a state where it can easily penetrate the carbon fiber 13 by partial heating treatment of the resin surface with a dryer or the like (see FIG. 2B). The bubbles are forcibly discharged to the outside (see FIG. 2A), and the composite resin layer 15 in which the bonding resin 11 is infiltrated into the carbon fibers 13 is formed on the surface of the mold 16 serving as a mold.
The carbon fiber 13 is preliminarily coated with a coating agent for smooth contact and slippage between the fibers. The bonding resin used in the present invention has a role of improving the strength of the entire carbon fiber reinforced resin material by directly adhering and bonding to the fiber while dissolving the coating agent.

The heat curing step is a step of making the composite resin layer uniform, stabilizing, and improving the strength by reheating the composite resin layer, which has been cooled to room temperature, to the curing temperature and holding it for a predetermined time.
The curing temperature in the heat curing treatment does not indicate a specific temperature, but is a temperature higher than the previous resin softening temperature and sufficient to cure the carbon fiber reinforced resin material. Incidentally, when an epoxy resin is used as the bonding resin, it is about 80 ° C. and the processing time is about 2 hours.

The manufacturing method of the carbon fiber reinforced resin material of this embodiment repeats a series of processes consisting of the (a) fiber placement process to the (c) bubble removal process a plurality of times, and laminates and shapes the whole to a mold. Can do. As a result, it is possible to efficiently produce and prototype light-weight parts for automobiles (monocoque chassis, rear wing, fender, door, trunk, hardtop and other outer plates) whose thickness is not necessarily constant.
Thus, for example, the present invention can be applied to development of molds for manufacturing large products having a width of about 1000 mm × length of about 1500 mm or more and processing methods (resins, heating conditions, reinforcing parts), and the like. As a result, mechanical strength equivalent to or higher than that of the conventional autoclave method (for example, tensile strength of about 700 MPa) can be ensured, and production at a cost of 1/3 or less of the autoclave method can be performed without requiring large-scale equipment expansion. It is said.

  The manufacturing method of the carbon fiber reinforced resin material of this embodiment is arrange | positioned in the said composite resin layer in the process of repeating the series of processes which consist of said (a) fiber arrangement | positioning process-(c) bubble removal process in multiple times. While providing orientation to carbon fiber, it can arrange | position with each orientation differing for every adjacent composite resin layer. As a result, the orientation of the carbon fibers in the composite resin layer is arranged in a specific direction according to the bending moment and shearing force applied to the part parts, and the entire structure is laminated by layering them. Therefore, it is possible to obtain a carbon fiber reinforced resin material having high strength and high tension while having a small amount of carbon fiber.

  The carbon fiber used for improving the reinforcing effect due to such orientation is preferably a long fiber rather than a short fiber, and is selected according to the type of part part to be applied or its use. In addition, physical properties such as rigidity and dimensional stability of the composite material are affected by the amount and type of fibers. In a general fiber reinforced composite material in which carbon fibers are randomly dispersed, the impact strength or the like may not satisfy the required value. However, a carbon fiber reinforced resin material composed of a laminate of composite resin layers in which carbon fibers are oriented can also produce effects such as three-dimensional weaving.

The manufacturing method of the rear wing of the present embodiment includes a hollow portion in which a carbon fiber reinforced resin material is surrounded by a shell of a composite resin layer, and the front and back sides of the front and back sides are formed by a substantially meniscus-shaped column portion disposed in the hollow portion. A manufacturing method of a rear wing to be connected and supported,
(A) Fiber placement step to (c) A plurality of composite resin layers created by the bubble removal step are respectively laminated on a pair of molds that can be opened and closed, sequentially crimped, and shaped according to the mold, A support wing is disposed between the molds in an open state, and the molds are pressure-bonded to each other to manufacture a rear wing incorporating the support post. As a result, a high-strength, high-quality carbon fiber reinforced resin material can be provided as a rear wing excellent in reliability at a low cost.

The carbon fiber reinforced resin material of the present embodiment is a carbon fiber reinforced resin material for weight reduction of part parts, and the composite resin layer is laminated according to a distribution profile of bending moment and shear force applied to the part parts. The number of sheets, thickness, carbon fiber content, and type of bonding resin are set, respectively. This makes it possible to economically and efficiently provide a lightweight structure having a predetermined mechanical characteristic when manufacturing parts such as a rear wing of a car and a wing of a glider that require weight reduction.
The number of composite resin layers can be changed as appropriate within a range of, for example, 1 to 3 or 1 to 10, and is proportional to the numerical value of the bending moment or shear force predicted by design for each shape part. The required number of sheets (number of layers) can be set.

  The method for producing a carbon fiber reinforced resin material of the present embodiment is a carbon fiber reinforced resin material for weight reduction of a part member produced by the method for producing a carbon fiber reinforced resin material, the carbon fiber (A) and the carbon fiber reinforced resin material It is comprised so that mass ratio (A / B) with joining resin (B) may be (40-50) / (60-50). Moreover, it is preferable that the tensile strength is 600-800 MPa. Thereby, it can be set as the carbon fiber reinforced resin material which was excellent in the construction workability | operativity of carbon fiber and bonding resin on a mold, and was provided with predetermined intensity | strength and durability. Furthermore, by using a prepreg comprising the resin composition having the above specific composition, the carbon fiber reinforced resin having excellent mechanical properties by improving the adhesion and dispersibility between the bonding resin composition such as epoxy resin and the carbon fiber. Material can be provided.

  Next, an example of a mold manufacturing method used in the carbon fiber reinforced resin material manufacturing method will be described with reference to the mold manufacturing explanatory diagram shown in FIG. Here, a simple mold suitable for small-lot trial production was created in order to examine the characteristics and conditions of the mold assuming molding of automotive parts.

Such a mold creates a male mold and creates a female mold based on the male mold.
Male mold creation in mold production was produced by the following procedures (1) to (3).
(1) A basic skeleton is formed with a thin plate.
(2) A urethane foam material is embedded between thin plates.
(3) A polyester resin is applied to the surface to complete a male mold.

The female type | mold was created in the procedure of the following (4)-(6) based on the created male type | mold.
(4) A resin mat is attached to the upper surface of the male mold.
(5) Strengthen the outside of the female mold with a reinforcing material for preventing deformation of the mold.
(6) Remove the male mold from the female mold using compressed air, etc., and wash the interior of the female mold with water to complete the simple mold.

  A carbon fiber reinforced resin material was created by applying a hand layup method including a resin shaping step and a bubble removal step to the mold created as described above as a method for producing a carbon fiber reinforced resin material. Then, a durability strength test and manufacturing cost evaluation of the produced carbon fiber reinforced resin material are performed, and the test results and the like are fed back to the design and molding conditions.

Hereinafter, a method for manufacturing an automotive part component aimed at weight reduction will be described with reference to the flowchart shown in FIG. The manufacturing method of the carbon fiber reinforced resin material of the present example includes the following steps (a) to (f) as shown in the flowchart of FIG.
(A) A gel coat material that does not require painting is applied in advance to a mold that is a mold for manufacturing a monocoque chassis for automobiles, rear wings, and the like, and dried.
(B) The carbon fiber piece is cut according to the mold. As the fibers constituting these carbon fiber pieces, carbon fibers that are high-strength fibers or high-elasticity fibers can be used. For example, rayon-based carbon fibers, polyacrylonitrile-based carbon fibers, pitch-based carbon fibers, or the like are used. be able to. The carbon fiber piece may be in the form of filament, yarn, tape, braided product, or the like.
(C) The carbon fiber whose length is adjusted is shaped into a mold and attached with a resin. In the present invention, for example, an infusion molding epoxy resin (DENATITE XNR6815) manufactured by Nagase Chemtech Co., Ltd. is used as a bonding resin, and this curing agent (DENATITE XNH6815) is used at a blending weight ratio of 100: 27. It was.
(D) Carbon fiber pieces while pressing the softened resin surface by heating the softened resin surface with a tool such as a roller that can be operated by hand by appropriately heating the resin surface to 60 to 65 ° C. using a hot air blower such as a hair dryer. And the bubble between resin is discharged | emitted outside (refer FIG. 2).
(E) The composite resin layer composed of the heated carbon fiber piece and the bonding resin is cooled to room temperature.
(F) The entire composite resin layer is again heated to 80 ° C. and held for about 2 hours, and then a curing treatment for cooling is performed. Here, FIG. 5 is a graph showing the time change of the temperature of the composite resin layer disposed on the mold surface, and shows an example of the temperature change pattern (twice heating) in the partial heating and curing treatment.

The conventional hand lay-up method can produce a carbon fiber reinforced resin material in a small scale in a short time without cost, but the product strength is difficult, and in order to obtain the required strength, the prepreg / autoclave method has to be taken. However, this method has a drawback in that it takes a long time to manufacture and costs a lot.
According to the present embodiment, by using a hot air blower and a roller that can be manually adjusted, adjustments such as an arrangement state of carbon fibers and a bubble-containing state are partially performed according to the degree of resin formation on the mold surface. Therefore, it is possible to provide a construction method having the advantages of the conventional hand lay-up construction method and the autoclave construction method. In this way, it is possible to produce a high-quality product that takes advantage of the light weight and high strength characteristics of the carbon fiber reinforced resin material.

Next, the carbon fiber reinforced resin material of Example 1 will be described with reference to a perspective view of the carbon fiber reinforced resin material shown in FIGS.
As shown in the drawing, a rear wing 20 of an automotive part component which is an example of a carbon fiber reinforced resin material is configured in a hollow shape having an upper wing portion 21 and a lower wing portion 22, and the upper and lower wing portions 21, 22 are arranged in parallel with a space in the vertical direction through a column portion 26 formed in a substantially half moon shape on the left, right, and center.
The upper and lower wing portions 21 and 22 each have an internal structure configured by laminating three composite resin layers 23, 24, and 25. Both ends of the upper and lower wing portions 21 and 22 are connected by vertical blades 27, and the lower wing 22 is fixed to the rear portion of the vehicle body via a pair of left and right vehicle body mounting members 28. .

The rear wing 20 is manufactured by a manufacturing method substantially similar to the manufacturing method of the carbon fiber reinforced resin material shown in the embodiment, and more specifically, the entire hollow rear wing is integrated with the mold. A process of shaping is included.
Hereinafter, this shaping step will be described with reference to FIG.
As shown in the figure, a mold 30 for manufacturing the rear wing 20 includes a pair of left and right molds 31 and 32. The molds 31 and 32 are arranged with their lower ends 31a and 32a fitted to each other, and the upper side thereof is attached so as to be freely opened and closed.

  First, as shown in FIG. 7 (1), the upper part of the mold 30 is held open, and a gel coat material is applied in advance to the mold surfaces of the molds 31 and 32 on which the composite resin layers are laminated. deep. Next, the first sandwiching jig 33 is used to suspend the first layer of carbon fiber pieces via the weight 34 from the open upper portions of the molds 31 and 32 (FIG. 7 (2)). .

Next, a bonding resin is applied onto the carbon fiber pieces, and bubbles in the resin layer softened by a laminating tool such as a roller 14 are pushed out while being heated by a heating tool such as a hot air blower, so that a predetermined resin load is applied. A shaping process, a bubble removal process, a heat curing process, etc. are performed (FIG. 7 (3)). Thereby, the composite resin layer 23 to be the first layer is formed on the mold surface.
In FIG. 7 (4), the second composite resin layer 24 made of carbon fiber pieces separated into two parts having a slightly shorter dimension than the first carbon fiber pieces is formed in the same manner with the dies 31, 32. Then, as shown in FIG. 7 (5), a process of pressing and adhering bubbles while extruding and removing bubbles in the composite resin layer formed on each mold surface is performed using a roller 14.

In FIG. 7 (6), after the composite resin layer 25, which is the third layer separated into two parts having a shorter dimension than the second layer, is arranged in the same manner, as shown in FIG. 7 (7). Then, the final finishing process is performed by the hot air blower or the roller 14.
Thus, after the composite resin layers 23 to 25 made of the first to third carbon fiber cloths and the bonding resin are shaped as described above, the column portions 26 that are substantially half-moon-shaped ribs are covered with the composite resin layer. It inserts and arrange | positions from the open end of the upper metal mold | dies 31 and 32 (FIG. 7 (8)).

Next, the molds 31 and 32 of the mold 30 in which the column part 26 is built and held are pressurized from the outside, and the open end sides of the upper parts of the molds 31 and 32 are adhered and bonded using the lower ends 31a and 32a as fulcrums. As a result, as shown in FIG. 7 (9), the rear wing 20 is formed which incorporates the column portion 26 erected between the three composite resin layers 23 to 24.
Finally, as shown in FIG. 7 (10), the left and right molds 31, 32 of the mold 30 are separated and opened, and the rear wing 20 having a built-in support 26 and having excellent strength can be taken out as a finished product. it can.

  When the upper wing 21 having the internal structure as shown in FIG. 8A is used, a load distribution as shown in FIG. 8B is applied. Therefore, the upper and lower wings 21 and 22 supported via the support column 26 are assumed to have a shearing force distribution as shown in FIG. 8C and a bending moment distribution as shown in FIG. Become.

  The rear wing 20 of the first embodiment is obtained by adjusting the number of laminated composite resin layers in accordance with the profile of the above shearing force distribution and bending moment distribution. That is, the column portion 26 is directly attached, and the composite resin layer corresponding to the wing surface where the load increases becomes three layers (composite resin layers 23, 24, and 25), and two layers (right and left) ( By arranging the composite resin layers 23, 24) and other surfaces in one layer (composite resin layer 23) to form the rear wing 20, the profile of the shear force distribution and the bending moment distribution is made to substantially match. Yes. As a result, the weight of the entire rear wing 20 can be reduced efficiently, and the amount of carbon fiber reinforced resin material used can be reduced, contributing to further weight reduction and cost reduction.

  The present invention provides a carbon fiber reinforced resin material that is excellent in light weight, mechanical properties, durability, and the like. According to the method for producing a carbon fiber reinforced resin material of the present invention, components for eco-cars and electric vehicles are used. It can be widely applied at low manufacturing costs without using expensive secondary materials and equipment, and industrial applicability is extremely high.

10 Carbon fiber reinforced resin material 11 Bonding resin 12 Air bubble 13 Carbon fiber (carbon fiber piece)
14 Roller 15 Mold
20 Rear wing (carbon fiber reinforced resin material)
21 Upper wing part 22 Lower wing part 23-25 Composite resin layer 26 Prop part (rib)
27 Vertical blade 28 Car body mounting member 30 Mold 31, 32 Mold 31a, 32a Lower end of mold 33 Dedicated clamping jig 34 Weight

Claims (6)

(A) a fiber placement step of laminating cloth-like carbon fiber pieces cut in accordance with a mold on a mold surface coated with a gel coat material;
(B) Filling the laminated carbon fiber pieces with a bonding resin or attaching the resin to the mold surface with a bonding resin for shaping;
(C) A bubble that pressurizes a partially heated resin surface at a resin softening temperature by blowing heated air onto the surface of a composite resin layer composed of a carbon fiber piece and a bonding resin disposed on the mold surface to push out the internal bubbles. A removal step;
(D) A heating and curing step in which the composite resin layer is reheated to a curing temperature and held for a predetermined time, and the method for producing a carbon fiber reinforced resin material. A plurality of composite resin layers prepared by the (a) fiber placement step to the (c) bubble removal step are stacked on the mold, and sequentially crimped, so that the whole is integrally molded according to the mold. The method for producing a carbon fiber reinforced resin material according to claim 1, characterized in that:   3. The carbon fiber disposed in the composite resin layer is imparted with an orientation that extends in a fixed direction, and each of the adjacent composite resin layers is disposed with a different orientation. Manufacturing method of carbon fiber reinforced resin. This is a method for manufacturing a rear wing in which a carbon fiber reinforced resin material is provided with a hollow portion surrounded by a shell of a composite resin layer, and the front and back sides thereof are connected and supported by a substantially meniscus-like columnar portion disposed in the hollow portion. And
(A) Fiber placement step to (c) A plurality of composite resin layers created by the bubble removal step are respectively laminated on a pair of molds that can be opened and closed, sequentially crimped, and shaped according to the mold, A method of manufacturing a rear wing, wherein a rear wing having a built-in support column is manufactured by placing a support column between the molds in an open state and crimping the molds together. A carbon fiber reinforced resin material for weight reduction of parts produced by the method for producing a carbon fiber reinforced resin material of (1) to (3), wherein a bending moment and shear force applied to the part parts are distributed. A carbon fiber reinforced resin material, wherein the number and thickness of the composite resin layers, the carbon fiber content, and the type of bonding resin are set according to the profile. A carbon fiber reinforced resin material for weight reduction of part parts produced by the method for producing a carbon fiber reinforced resin material of (1) to (3), wherein the carbon fiber (A) and the bonding resin ( A carbon fiber reinforced resin material having a mass ratio (A / B) to (B) of (40 to 50) / (60 to 50).