JP2013067135A - Composite molding body and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for easily manufacturing a highly-rigid and light-weight composite molding body in a thin form, and to provide a composite molding body manufactured by the method.SOLUTION: In the method for manufacturing a composite molding body, fiber reinforced resin A that is molded in advance is disposed in a mold as a preliminary molding body, foaming resin B is supplied in the mold to be in contact with the fiber reinforced resin A, and the foaming resin B is joined to the fiber reinforced resin A, to manufacture the composite molding body. The capacity of a cavity of a mold in molding the composite molding body containing the foaming resin B is reduced, compared with the capacity of a cavity of a mold in foaming the foaming resin B in the mold, to compression-mold the composite molding body.

Description

  The present invention relates to a composite molded body and a method for producing the same, and more particularly to a method capable of easily producing a highly rigid and lightweight composite molded body in a thin-walled form, and a composite molded body produced by the method.

  It is known that a composite molded body in which a highly rigid skin material, in particular, a skin material made of fiber reinforced resin is bonded to a core layer has a high rigidity while being configured to be lightweight as a whole. In order to further reduce the weight of such a composite molded body, it is considered necessary to make the core layer thin or foam-mold the core layer. However, if the core layer is thinned, it is usually difficult to sufficiently fill the resin over the entire desired region, and if foaming molding is used in combination, the foaming ratio becomes small, which may make molding difficult.

  Regarding foam molding itself, methods using various chemical foaming agents are known, and in recent years, a method using a supercritical fluid has also been developed (for example, Patent Document 1). However, it cannot be said that a method of effectively combining foam molding with respect to the production of a composite molded body has been sufficiently developed.

JP-T-2001-508718

  Therefore, in view of the above circumstances, an object of the present invention is to provide a method capable of easily producing a highly rigid and lightweight composite molded body in a thin-walled form, and a composite molded body manufactured by the method. There is to do.

  In order to solve the above-described problems, a method for producing a composite molded body according to the present invention includes placing a pre-molded fiber reinforced resin A in a mold as a preform, and placing the fiber reinforced resin A in the mold. A method of manufacturing a composite molded body by supplying a foamed resin B so as to be in contact and joining the foamed resin B to the fiber reinforced resin A, wherein the foamed resin B is foamed in a mold. The method comprises compression molding the composite molded body by reducing the volume of the cavity of the mold when molding the composite molded body containing the foamed resin B with respect to the volume of the cavity.

  In such a method for producing a composite molded body according to the present invention, a pre-molded fiber reinforced resin A can be used as the above-mentioned high-rigid skin material, and after placing it in a mold as a preformed body, The foamed resin B is supplied into the mold cavity. The foamed resin B is supplied as a resin constituting the core layer of the composite molded body. However, simply by supplying the foamed resin B into a predetermined volume of the cavity by injection or the like, the injection pressure is directly applied to the core layer. Therefore, the expansion ratio is only about 5% at most, and a sufficient weight reduction effect based on a higher expansion ratio cannot be obtained. In the present invention, a cavity having a larger volume is formed, and the foamed resin B is supplied to the cavity to ensure a sufficiently high expansion ratio. In addition, a high weight reduction is realized as a desired expansion ratio. That is, the volume of the cavity of the mold when the composite molded body containing the foamed resin B is molded is reduced with respect to the volume of the mold cavity when the foamed resin B is foamed in the mold. Is compression-molded. Therefore, a lightweight and high-rigidity composite molded body comprising the core layer having a desired high expansion ratio and the fiber reinforced resin A as a high-rigid skin material can be reliably obtained. Moreover, when the foamed resin B is supplied into the cavity, the cavity volume is sufficiently large. Therefore, it is difficult to fill the resin when the core layer is thinned and the resin is supplied to the corresponding thin volume portion. No problem occurs and compression molding is performed after the foamed resin B is supplied and foamed. Therefore, the core layer can be made sufficiently thin after molding the molded body, and it is lightweight, highly rigid, and thin. The body can be easily manufactured.

  In the method for producing a composite molded body according to the present invention, after the foamed resin B is supplied into the mold with the mold opened in advance, the compression molding can be performed.

  In addition, a movable core is provided in the mold, and after the foamed resin B is supplied into the mold, the movable core is operated in the direction of enlarging the volume of the cavity of the mold to foam the foamed resin B. It is also possible to enlarge the volume of the material and thereafter perform the compression molding. In any method, a sufficiently large cavity volume is secured when foaming resin B is foamed, and after foaming, compression molding is performed so as to obtain a desired foaming ratio as a core layer of the composite molded body.

  Further, in the present invention, a composite molded body having a form in which the foamed resin B is supplied to one side of the fiber reinforced resin A and the layer of the foamed resin B as a core layer is present on one side of the fiber reinforced resin A. Can be manufactured. Alternatively, at least two fiber reinforced resins A are disposed in the mold so as to be spaced from each other, the foamed resin B is supplied between the fiber reinforced resins A, and foamed as a core layer between the fiber reinforced resins A. It is also possible to produce a sandwich-shaped composite molded body in which the resin B layer is present. Which form should be used may be determined according to the required specifications of the molded product.

  In the present invention, the foaming method of the foamed resin B is not particularly limited, and any method can be adopted. For example, the foamed resin B can be foamed using any one selected from chemical foaming agents, foam beads, and supercritical fluid. Here, foaming using supercritical fluid means that carbon dioxide or nitrogen is used as a foaming agent and supercritical fluid (temperature and pressure are raised above the critical point) is as high as liquid and as high as gas. And low viscosity, and the solubility in the molten resin is increased. Therefore, these supercritical fluids are directly supplied to the molten resin, dissolved and foamed. This method was developed at MIT (Massachusetts Institute of Technology) about 20 years ago. This method can also be applied to foaming of the foamed resin B in the present invention.

  In the present invention, the final foaming ratio of the foamed resin B (that is, the final foaming ratio after manufacturing a composite molded body as a molded product) is preferably 50% or more. By setting it as such a high foaming ratio, the weight reduction effect outstanding as a composite molded object is acquired.

  Further, in the present invention, the form of the fiber reinforced resin A as the preform is not particularly limited, but forms the skin material of the composite molded body to be finally molded, and is accurately arranged at a predetermined contour position. Since it is desired to be performed, it is preferable that the fiber reinforced resin A is made of a plate-shaped or sheet-shaped molded body or prepreg in consideration of aspects such as ease of molding and dimensional accuracy of the outer shape.

  Moreover, in this invention, it is preferable that the said fiber reinforced resin A consists of fiber reinforced resin containing the reinforced fiber of fiber length (average fiber length) 1 mm or more. If the fiber length is too short, the airframe characteristics of the fiber reinforced resin A that requires a function as a highly rigid skin material may be reduced. Moreover, in order to ensure the favorable moldability of the fiber reinforced resin A, it may be preferable that the average fiber length of a reinforced fiber is 100 mm or less. If the average fiber length is too long, it becomes close to continuous fibers, so that the formability of the reinforcing fiber base and the moldability of the fiber reinforced resin A may be lowered.

  It is also preferable that the reinforcing fibers of the fiber reinforced resin A are oriented in one direction. When the reinforcing fibers are oriented in this way, the mechanical properties in a specific direction can be improved efficiently with a smaller amount of reinforcing fibers, so this is especially true when the reinforcing direction of the molded body is determined in a specific direction. This form is desirable.

  Moreover, in this invention, it does not specifically limit as a kind of the reinforced fiber of the said fiber reinforced resin A, The use of the reinforced fiber of the mixed form which combined carbon fiber, glass fiber, an aramid fiber, etc. further, or any of these is used. Although it is possible, in order to implement | achieve a higher mechanical characteristic, it is preferable that the reinforced fiber of the said fiber reinforced resin A contains a carbon fiber.

  In the present invention, the matrix resin of the fiber reinforced resin A is not particularly limited. However, when the matrix resin is made of a thermoplastic resin, good moldability, particularly injection moldability can be obtained. Examples of the thermoplastic resin that can be used include polyolefin, polyamide, polyester, polyphenylene sulfide, polycarbonate, polyether ketone, polyether imide, and the like.

  In the present invention, the method for supplying the foamed resin B into the mold is not particularly limited, but it is preferable that the foamed resin B is supplied into the mold by injection. That is, the composite molded body is preferably manufactured by injection molding. By injection molding, it can easily cope with mass production and the like, and excellent moldability can be obtained.

  The foamed resin B is also preferably made of a thermoplastic resin in view of moldability. Examples of the thermoplastic resin constituting the foamed resin B include polyolefin, polyamide, polyester, polyphenylene sulfide, ABS resin, and the like. However, as the foaming method, any method can be appropriately employed as described above. Further, the foamed resin B can also contain reinforcing fibers (for example, reinforcing fibers of short fibers), whereby the mechanical properties of the entire composite molded body can be improved. Furthermore, when the reinforcing fiber is included, it is preferable that the reinforcing resin of the foamed resin B also includes carbon fiber. By including the carbon fiber, it is possible to improve the mechanical properties of the core layer portion, and thus the composite molded body as a whole.

  In the present invention, the size of the composite molded body, such as the thickness, is not particularly limited, but the present invention has an advantage that good moldability can be obtained even with a thin wall. Therefore, even when the thickness of the fiber reinforced resin A is 1 mm or less and the thickness of the composite molded body is 3 mm or less, it can be molded sufficiently satisfactorily.

  The composite molded body according to the present invention is manufactured by the method as described above, and is characterized in that the foaming ratio of the foamed resin B is 50% or more. In other words, the foamed resin B layer as the core layer is sufficiently lightweight, and the foamed resin B layer is reinforced with the fiber reinforced resin A as the skin material, and as a whole is a lightweight and highly rigid composite molded body.

  According to the composite molded body and the method for manufacturing the same according to the present invention, after foaming resin B is foamed in a sufficiently large volume of the cavity, the cavity volume is reduced and compression molding is performed. While ensuring a good filling state and a high expansion ratio, the desired high expansion ratio as a final molded body can be achieved, and it has high-rigidity fiber reinforced resin A as the skin material, and the overall rigidity is increased. In addition, a composite molded body that has been reduced in weight and can be easily manufactured with excellent moldability.

It is a schematic sectional drawing of the metal mold | die which shows each step in the manufacturing method of the composite molded object which concerns on one embodiment of this invention. It is a schematic sectional drawing of the metal mold | die which shows each step in the manufacturing method of the composite molded object which concerns on another embodiment of this invention. It is a schematic sectional drawing of the metal mold | die which shows each step in the manufacturing method of the composite molded object which concerns on another embodiment of this invention. It is a schematic block diagram which shows the example in the case of producing the reinforced fiber base material of the fiber reinforced resin A with a card apparatus in this invention.

Hereinafter, more specific embodiments of the present invention will be described.
In the method for producing a composite molded body according to the present invention, a pre-molded fiber reinforced resin A is placed in a mold as a preform, and a foamed resin B is supplied in contact with the fiber reinforced resin A in the mold. The foamed resin B is bonded to the fiber reinforced resin A to produce a composite molded body. First, a molding example of the fiber reinforced resin A that is molded in advance will be described with reference to FIG.

  The card device 41 shown in FIG. 4 includes a cylinder roll 42, a take-in roll 43 provided on the upstream side in the vicinity of the outer peripheral surface, and an outer periphery of the cylinder roll 42 on the downstream side opposite to the take-in roll 43. A doffer roll 44 provided close to the surface, a plurality of worker rolls 45 provided close to the outer peripheral surface of the cylinder roll 42 between the take-in roll 43 and the doffer roll 44, and a worker roll 45 Is mainly composed of a stripper roll 46 provided in the vicinity of the feed roller 47, a feed roll 47 and a belt conveyor 48 provided in the vicinity of the take-in roll 43.

  On the belt conveyor 48, as the reinforcing fiber of the fiber reinforced resin A in the present invention, for example, an aggregate of discontinuous carbon fibers 49 cut to a weight average fiber length of 50 mm is supplied. Are introduced onto the outer circumferential surface of the cylinder roll 42 through the outer circumferential surface of the take-in roll 43. Until this stage, the discontinuous carbon fibers 29 are in a cotton-like form. A part of the cotton-like carbon fiber introduced on the outer peripheral surface of the cylinder roll 42 is wound around the outer peripheral surface of each worker roll 45, but this carbon fiber is peeled off by each stripper roll 46 and again the cylinder roll 42. It is returned to the outer peripheral surface of. A large number of needles and protrusions are present on the outer peripheral surface of each of the feed roll 47, the take-in roll 43, the cylinder roll 42, the worker roll 45, and the stripper roll 46. Is opened into a single fiber shape by the action of the needle, and at the same time, the orientation direction of most carbon fibers is aligned with a specific direction, that is, the rotation direction of the cylinder roll 42. The carbon fiber that has been opened through such a process and whose fiber orientation has been advanced moves onto the outer peripheral surface of the doffer roll 44 as a sheet-like web 50 that is one form of the carbon fiber aggregate. Further, by pulling the web 50 while reducing its width to a predetermined width, a sheet-like base material made of discontinuous carbon fibers is formed.

  In the carding as described above, the aggregate of the discontinuous carbon fibers 49 may be composed of only carbon fibers, but the carding is performed by mixing discontinuous organic fibers, particularly fibers made of thermoplastic resin. Can also be done. In particular, it is preferable to add thermoplastic resin fibers when carding, because the carbon fibers can be prevented from breaking during carding. Since carbon fiber is rigid and brittle, it is difficult to be entangled and easily broken. Therefore, in the carbon fiber aggregate which consists only of carbon fiber, there exists a problem that a carbon fiber is easy to cut during carding, or a carbon fiber tends to drop out. Therefore, by including thermoplastic resin fibers that are flexible, difficult to break, and easily entangled, it is possible to form a carbon fiber aggregate in which the carbon fibers are hardly cut and the carbon fibers are not easily dropped. It is also preferable to perform carding by mixing such thermoplastic resin fibers, and after the carding, at least a part of the thermoplastic resin fibers is melted and then pressed. That is, a state in which a moderately small amount of thermoplastic resin fiber is mixed and the carbon fiber is subjected to a predetermined carding treatment, for example, a carding treatment so that a part of the carbon fibers are oriented in a specific direction. By melting at least a part of the thermoplastic resin fiber, the thermoplastic resin fiber serves as a binder for maintaining the form of the predetermined sheet-like base material, and is retained by applying a press in that state. It is also preferable that the formed shape is appropriately fixed through thermoplastic resin fibers.

  When the thermoplastic resin fibers are included in the carbon fiber aggregate as described above, the carbon fiber content in the carbon fiber aggregate is preferably 50 to 95 mass%, more preferably 70 to 95 mass%. is there. If the proportion of carbon fiber is low, it will be difficult to obtain high mechanical properties when carbon fiber reinforced plastic is used, and conversely if the proportion of thermoplastic resin fiber is too low, the above-mentioned carbon fiber aggregate will contain thermoplastic resin fibers. The role of the thermoplastic resin fiber when mixing is not expected or becomes smaller.

  Moreover, in order to further enhance the entanglement effect by the above-described thermoplastic resin fibers, it is preferable to crimp the thermoplastic resin fibers. The degree of crimping is not particularly limited, but generally, thermoplastic resin fibers having a number of crimps of about 5 to 25 crests / 25 mm and a crimping rate of about 3 to 30% can be used.

  There is no restriction | limiting in particular as a material of this thermoplastic resin fiber, It can select suitably in the range which does not reduce the mechanical characteristic of carbon fiber reinforced resin significantly. For example, polyolefin resins such as polyethylene and polypropylene, polyamide resins such as nylon 6, nylon 6,6, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyether ketone, polyether sulfone, aromatic polyamide, etc. A fiber obtained by spinning a resin of the above can be used. It is preferable that the material of the thermoplastic resin fiber is appropriately selected depending on the combination with the matrix resin of the carbon fiber reinforced resin. In particular, a thermoplastic resin fiber using the same resin as the matrix resin, a resin compatible with the matrix resin, or a resin having high adhesiveness with the matrix resin is preferable because it does not deteriorate the mechanical properties of the carbon fiber reinforced resin.

  In addition, as described above, as a method of pressing in the case where a thermoplastic resin fiber is mixed with carbon fiber to perform carding as described above, and after carding, at least a part of the thermoplastic resin fiber is melted and then pressed. However, it is not particularly limited, and for example, a normal press machine that presses between flat plates or a calender roll that presses between a pair of rolls can be used.

  In addition, although the above demonstrated the method of producing a carbon fiber base material by performing a carding process, it is also possible to produce a carbon fiber base material only by papermaking, without performing a carding process. For example, by supplying an aggregate of discontinuous carbon fibers 49 cut to a weight average fiber length of 50 mm on the belt conveyor 48 in FIG. 4 and pressurizing it using, for example, a calendar roll as described above, It is also possible to produce a sheet-like carbon fiber substrate. In this case, as described above, it is preferable that thermoplastic resin fibers are mixed in the carbon fiber aggregate and have a binder function for maintaining the sheet-like substrate form.

  The fiber reinforced resin A of the present invention is preliminarily formed by impregnating a predetermined matrix resin into the base material and curing the base material thus prepared. The preformed fiber reinforced resin A is placed as a preform at a predetermined position in the mold, and the supply, foaming, and compression molding of the foamed resin B in the present invention are performed as follows, for example. Below, these shaping | molding operation | movement in this invention is illustrated with reference to FIGS. 1-3.

  FIG. 1 shows each step in the method for producing a composite molded body according to an embodiment of the present invention. As shown in FIG. 1 (A), for example, a plate-like fiber reinforced resin A (1) preliminarily molded as described above is disposed in a cavity 5 of a mold 4 composed of molds 2 and 3 that are arranged to face each other. Is done. At this time, in this embodiment, the mold 4 is opened to some extent, and the cavity 5 is formed to have a sufficiently large volume. In other words, a sufficiently large cavity volume is ensured compared to the reduced volume of the mold cavity when the composite molded body containing the foamed resin B described below is molded.

  In this state, as shown in FIG. 1 (B), for example, the foamed resin B (7) (foamed thermoplastic resin B) melted in the cavity 5 through the resin supply path 6 formed in one mold 3. Are injected and supplied by injection into a portion that can be bonded to one side of the fiber reinforced resin A (1). At this time, since the volume of the cavity 5 is sufficiently enlarged, even when the expansion ratio of the foamed resin B (7) is increased in the cavity 5, a sufficiently large expansion ratio is achieved. Further, since the volume of the cavity 5 is sufficiently enlarged, the supplied foamed resin B (7) easily fills a sufficiently wide area, but the resin spreads in the next compression molding step. In consideration of the above, in the step shown in FIG. 1B, it is not necessary to fill the foamed resin B (7) throughout the cavity 5.

  Next, as shown in FIG. 1 (C), the molds 2 and 3 are clamped with high accuracy, for example, through the mutual spigot structure, and the volume of the cavity 5 is reduced. Due to the reduction of the cavity volume, the inside of the cavity 5 of the mold 4 is compressed, and the foamed resin B (7) is expanded to fill the cavity 5 with the reduced volume, and the foamed resin B (7). It itself is pressed and compression molded, and its expansion ratio is slightly reduced. However, since foaming is performed at a sufficiently high expansion ratio in the previous step, the expansion ratio of the foamed resin B (7) after compression molding is maintained sufficiently high, for example, an expansion ratio of 50% or more is easy even after molding. Secured. Rather, by this compression molding, the expansion ratio of the foamed resin B (7) as the final molded product is controlled to the target expansion ratio. After cooling the whole, the composite molded body 8 as a molded product in which the foamed resin B (7) as the core layer and the fiber reinforced resin A (1) as the reinforcing skin material are integrally bonded is removed. The Thus, the composite molded body 8 having high rigidity and light weight as a whole is obtained through the compression molding.

  As described above, an arbitrary method can be applied to the foaming resin B (7). For example, the foaming resin B (7) can be foamed by chemical foaming agent, foam beads, supercritical. Any one selected from fluids can be used. More specifically, as the foamed resin B (7), a thermoplastic resin blended with a chemical foaming agent or foam beads, or a supercritical fluid injected into a cylinder may be used.

  FIG. 2 shows each step in the method of manufacturing a composite molded body according to another embodiment of the present invention. As shown in FIG. 2 (A), in this embodiment, two fiber reinforced resins A (11) and (12) are used as reinforcing skin materials, and are formed of molds 13 and 14 with a gap therebetween. Fifteen cavities 16 are opposed to each other. In the present embodiment, a movable core 17 that is movable in the cavity 16 is provided in the cavity 16, and the movable core 17 is a driving means 18 (for example, a ball screw) provided in one mold 13. The driving means) can forcibly move in the cavity 16 in both directions.

  In this state, as shown in FIG. 2 (B), the foamed resin B (20) (foamed thermoplastic resin B) melted in the cavity 16 via the resin supply means 19 is the fiber reinforced resin A (11). , (12) are injected and supplied by injection. At this time, since the volume of the cavity 16 is sufficiently enlarged, even when the expansion ratio of the foamed resin B (20) is increased in the cavity 16, a sufficiently large expansion ratio is achieved. Further, since the volume of the cavity 16 is sufficiently enlarged, the supplied foamed resin B (20) easily fills a sufficiently wide area, but the resin spreads in the next compression molding step. In consideration of the above, in the step shown in FIG. 2 (B), it is not necessary to fill the foamed resin B (20) throughout the cavity 16.

  Next, as shown in FIG. 2C, the movable core 17 is forcibly moved in the cavity 16 by the driving means 18, and the volume of the cavity 16 is reduced. Due to the reduction of the cavity volume, the foamed resin B (20) is expanded to fill the cavity 16 with the reduced volume, and the foamed resin B (20) itself is also pressed and compression-molded, and its expansion ratio Decreases slightly. However, since foaming is performed at a sufficiently high expansion ratio in the previous step, the expansion ratio of the foamed resin B (20) after compression molding is maintained sufficiently high, for example, an expansion ratio of 50% or more is easy even after molding. Secured. Rather, by this compression molding, the expansion ratio of the foamed resin B (20) as the final molded product is accurately controlled to the target expansion ratio. After cooling the whole, the composite molded body 21 as a molded product in which the foamed resin B (20) as the core layer and the fiber reinforced resins A (11) and (12) as the reinforcing skin material are integrally joined. Is demolded. Thus, a composite molded body 21 in the form of a sandwich that is highly rigid and lightweight as a whole is obtained through the compression molding.

  FIG. 3 shows each step in the method of manufacturing a composite molded body according to still another embodiment of the present invention. As shown in FIG. 3 (A), two fiber reinforced resins A (11) and (12) are provided as reinforcing skin materials in the same manner as shown in FIG. 2 (A). In this embodiment, the cavity 31 having a relatively small volume is formed by the movement of the movable core 17.

  Then, as shown in FIG. 3 (B), the foamed resin B (31) (foamed thermoplastic resin B) melted in the cavity 31 through the resin supply means 19 in the cavity 31 is the fiber reinforced resin A. Injected and supplied between (11) and (12) by injection. In this embodiment, when the foamed resin B (31) is supplied, the foamed resin B (31) is not yet foamed at a sufficiently large foaming ratio.

  Next, as shown in FIG. 3C, the movable core 17 is forcibly moved (core-backed) in the cavity 31 by the driving means 18, and the volume of the cavity 31 is expanded. Since the expansion of the cavity volume ensures a sufficiently large volume for the expansion of the foamed resin B (31) injected and supplied into the cavity 31, the foamed resin B (20) is sufficient. Thus, foaming can be performed in the cavity 31 with a large expansion ratio.

  Next, as shown in FIG. 3D, the movable core 17 is forcibly moved in the cavity 31 by the driving means 18, and the volume of the cavity 31 is reduced. Due to the reduction of the cavity volume, the foamed resin B (32) is expanded to fill the cavity 31 with the reduced volume, and the foamed resin B (32) itself is also pressed to be compression-molded, and its expansion ratio Decreases slightly. However, since foaming is performed at a sufficiently high expansion ratio in the previous step, the expansion ratio of the foamed resin B (32) after compression molding is maintained sufficiently high, for example, an expansion ratio of 50% or more is easy even after molding. Secured. Rather, by this compression molding, the foaming ratio of the foamed resin B (32) as the final molded product is accurately controlled to the target foaming ratio. After cooling the whole, the composite molded body 33 as a molded product in which the foamed resin B (32) as the core layer and the fiber reinforced resins A (11) and (12) as the reinforcing skin material are integrally joined. Is demolded. Thus, a composite molded body 33 in the form of a sandwich that is highly rigid and lightweight as a whole is obtained through the compression molding.

  The present invention can be applied to the production of any composite molded body composed of the fiber reinforced resin A and the foamed resin B.

1, 11, 12 Fiber reinforced resin A
2, 3, 13, 14 Mold 4, 15 Mold 5, 16, 31 Cavity 6 Resin supply path 7, 20, 32 Foamed resin B
8, 21, 33 Composite molded body 17 Movable core 18 Drive means 19 Resin supply means 41 Card device 42 Cylinder roll 43 Taker roll 44 Doffer roll 45 Worker roll 46 Stripper roll 47 Feed roll 48 Belt conveyor 49 Discontinuous carbon fiber 50 sheet-like web

Claims (18)

  A preformed fiber reinforced resin A is placed in a mold as a preform, and a foamed resin B is supplied into the mold so as to be in contact with the fiber reinforced resin A. The foamed resin B is supplied to the fiber reinforced resin A. A method of manufacturing a composite molded body by bonding, wherein the composite molded body including the foamed resin B is molded with respect to the volume of the cavity of the mold when the foamed resin B is foamed in the mold. A method for producing a composite molded body, comprising compressing the composite molded body by reducing the volume of a cavity of a mold.   The manufacturing method of the composite molded object of Claim 1 which performs the said compression molding after supplying the said foaming resin B in a metal mold | die in the state which opened the said metal mold | die beforehand.   In order to foam the foamed resin B by providing a movable core in the mold and supplying the foamed resin B into the mold and then operating the movable core in the direction of enlarging the volume of the cavity of the mold. The method for producing a composite molded body according to claim 1, wherein the compression molding is performed after the volume of the resin is expanded.   The manufacturing method of the composite molded object in any one of Claims 1-3 which supplies the said foamed resin B to the single side | surface side of the said fiber reinforced resin A.   The composite molding according to any one of claims 1 to 3, wherein at least two fiber reinforced resins A are disposed opposite to each other with a gap in the mold, and the foamed resin B is supplied between the fiber reinforced resins A. Body manufacturing method.   The manufacturing method of the composite molded object in any one of Claims 1-5 which foams the said foamed resin B using any one chosen from a chemical foaming agent, a foam bead, and a supercritical fluid.   The manufacturing method of the composite molded object in any one of Claims 1-6 which makes final foaming ratio of the said foamed resin B 50% or more.   The manufacturing method of the composite molded object in any one of Claims 1-7 in which the said fiber reinforced resin A consists of a plate-shaped or sheet-shaped molded object or a prepreg.   The manufacturing method of the composite molded object in any one of Claims 1-8 in which the said fiber reinforced resin A consists of fiber reinforced resin containing the reinforced fiber of fiber length 1mm or more.   The manufacturing method of the composite molded object in any one of Claims 1-9 in which the reinforced fiber of the said fiber reinforced resin A is orientated in one direction.   The manufacturing method of the composite molded object in any one of Claims 1-10 in which the reinforced fiber of the said fiber reinforced resin A contains carbon fiber.   The manufacturing method of the composite molded object in any one of Claims 1-11 in which the matrix resin of the said fiber reinforced resin A consists of thermoplastic resins.   The manufacturing method of the composite molded object in any one of Claims 1-12 with which the said foamed resin B is supplied in a metal mold | die by injection.   The method for producing a composite molded body according to claim 1, wherein the foamed resin B is made of a thermoplastic resin.   The manufacturing method of the composite molded object in any one of Claims 1-14 in which the said foamed resin B contains a reinforced fiber.   The method for producing a composite molded body according to claim 15, wherein the reinforcing fibers of the foamed resin B include carbon fibers.   The manufacturing method of the composite molded object in any one of Claims 1-16 whose wall thickness of the said fiber reinforced resin A is 1 mm or less, and the thickness of a composite molded object is 3 mm or less.   A composite molded article produced by the method according to claim 1, wherein the foaming ratio of the foamed resin B is 50% or more.

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