JP2016221885A - Fiber-reinforced resin structure and manufacturing process thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide: a fiber-reinforced resin structure that has less warpage resulting from forming of convex parts, and has improved rigidity and strength of the convex parts; and a fiber-reinforced resin structure manufacturing process.SOLUTION: The fiber-reinforced resin structure is a fiber-reinforced resin structure formed by cold-press working a fiber-reinforced resin sheet in which plural pieces are laminated, and comprises: an inner layer that includes unidirectional fiber-reinforced resin sheet in which the reinforcing fibers are oriented along the uni-direction; a surface layer that includes reinforcing fibers oriented along a direction intersectant to the orientation direction of the inner layer reinforcing fibers; and a convex part formed by the inner layer swelling to the outside from a slit provided in the surface layer along the orientation direction of the inner layer reinforcing fiber.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a fiber reinforced resin structure in which a fiber reinforced resin structure is molded using a fiber reinforced resin sheet obtained by impregnating a matrix resin into a reinforced fiber and a method for manufacturing the fiber reinforced resin structure.

  Conventionally, structural parts of automobile bodies have been made of metal materials such as steel. In recent years, components made of fiber reinforced resin such as carbon fiber reinforced resin (CFRP) are being used to reduce the weight of the vehicle body. The component part which consists of this fiber reinforced resin is shape | molded, for example by laminating | stacking the fiber reinforced resin sheet which impregnated the matrix resin to the reinforced fiber, and pressing the said laminated body using a metal mold | die. In a component made of fiber reinforced resin, convex portions such as ribs may be formed in order to improve the rigidity.

  For example, Patent Document 1 discloses a fiber reinforced resin material having a ribbed structure that can effectively eliminate sink marks that may occur on the panel surface opposite to the surface on which the rib is attached in a panel with ribs made of fiber reinforced resin. A manufacturing method is disclosed. In the fiber reinforced resin material disclosed in Patent Document 1, both the panel and the rib are made of a material in which a fiber material is mixed inside a thermoplastic resin, and the ratio of the weight average fiber length of the material forming the rib forms the panel. It is lower than the ratio of the weight average fiber length of the raw material.

  Patent Document 2 discloses a method for producing a fiber-reinforced thermoplastic resin molded body capable of molding a molded body having a desired three-dimensional shape having standing portions such as ribs while appropriately suppressing the pressing pressure in press molding. Is disclosed. The fiber-reinforced thermoplastic resin molded article disclosed in Patent Document 2 is laminated on at least one surface of a first fiber-reinforced thermoplastic resin layer having a first reinforcing fiber layer in which the reinforcing resin is randomly oriented. And a second fiber-reinforced thermoplastic resin layer having two reinforcing fiber layers. In the fiber reinforced thermoplastic resin molded body, the second fiber reinforced thermoplastic resin layer is broken at the standing portion and the first reinforcing fiber layer is between the surface shape forming portion and the inside of the standing portion. It is extended continuously.

JP 2012-148443 A JP 2014-172241 A

  However, in the fiber reinforced resin material described in Patent Document 1, since the rib is formed by the surface fiber reinforced resin layer, the rib is formed including only fibers arranged in the same direction. For this reason, the rib has higher rigidity and strength along a certain direction, but the rigidity and strength may be lowered in the other directions.

  Moreover, in the fiber reinforced thermoplastic resin molded article described in Patent Document 2, the first fiber reinforced thermoplastic resin layer positioned as the inner layer through the fracture portion of the second fiber reinforced thermoplastic resin layer positioned as the surface layer. The ribs are formed so that the first reinforcing fiber layer continuously extends between the surface shape forming portion and the standing portion. Therefore, when the first reinforcing fiber layer is made of continuous fibers oriented in one direction, it is difficult to bulge the continuous fibers and it is difficult to form local ribs. Moreover, when a continuous fiber is expanded and a rib is formed, there is a possibility that the continuous fiber is pulled and warps the molded product.

  Therefore, the present invention has been made in view of the above problems, and the object of the present invention is less warp due to the formation of the convex portion, and the rigidity and strength of the convex portion are improved. It is providing the manufacturing method of a fiber reinforced resin structure and a fiber reinforced resin structure.

  In order to solve the above-described problem, according to one aspect of the present invention, a fiber-reinforced resin structure formed by cold pressing a plurality of laminated fiber-reinforced resin sheets, the reinforcing fibers are unidirectional An inner layer containing a unidirectional fiber-reinforced resin sheet oriented along the surface, a surface layer containing reinforcing fibers oriented along a direction intersecting the orientation direction of the reinforcing fibers in the inner layer, and an orientation direction of the reinforcing fibers in the inner layer A fiber-reinforced resin structure is provided that includes a convex portion formed by extending an inner layer outward from a slit provided in a surface layer along the outer surface.

  A part of the surface layer may be raised along the convex portion.

  The fiber reinforced resin sheet of the surface layer is composed of a unidirectional fiber reinforced resin sheet, and the orientation direction of the reinforcing fibers of the surface unidirectional fiber reinforced resin sheet may intersect with the orientation direction of the reinforcing fibers of the inner layer.

  The fiber reinforced resin sheet of the surface layer is a fiber reinforced resin sheet in which reinforcing fibers are oriented along at least two directions, and at least two directions may intersect with the orientation directions of the reinforcing fibers of the inner layer.

  The height of the convex portion may be a value within the range of 0.1 to 5.0 mm.

  In order to solve the above problems, according to another aspect of the present invention, a step of laminating a plurality of fiber reinforced resin sheets impregnated with a matrix resin into reinforced fibers to form a fiber reinforced resin laminate, A step of heating the fiber reinforced resin laminate, and a step of pressing the heated fiber reinforced resin laminate using a cold press to form a fiber reinforced resin structure, and the fiber reinforced resin laminate. The fiber reinforced resin sheet of the inner layer includes a unidirectional fiber reinforced resin sheet in which the reinforced fibers are oriented along one direction, and the surface layer is along the orientation direction of the reinforced fibers in the unidirectional fiber reinforced resin sheet of the inner layer. By forming a slit along the direction intersecting the reinforcing fiber in the fiber reinforced resin sheet and pressing it, the reinforced fiber and matrix resin of the unidirectional fiber reinforced resin sheet in the inner layer are slit. And it swelled from the surface via, forming a convex portion on the surface of the fiber-reinforced resin structure, method for producing a fiber-reinforced resin structure is provided.

  A concave portion is provided at a position facing the slit on the pressing surface of the die of the cold press apparatus, and the reinforced fiber and matrix resin of the unidirectional fiber reinforced resin sheet that bulges from the slit is caused to enter the concave portion to form the convex portion You may shape | mold.

  The slit width may be a value of 5.0 mm or less.

  A fiber reinforced resin laminate may be formed by disposing a fiber reinforced resin sheet provided with slits in advance on the surface layer.

  After forming the fiber reinforced resin laminate, a slit may be formed from the surface layer side, and the fiber reinforced resin laminate may be installed in a cold press apparatus.

  As described above, according to the present invention, in the fiber reinforced resin structure, there is little warpage due to the formation of the convex portion, and the rigidity and strength of the convex portion can be improved.

It is a perspective view which shows an example of a fiber reinforced resin structure. It is sectional drawing which shows the convex-shaped part of a fiber reinforced resin structure. It is explanatory drawing which shows the manufacturing method of a fiber reinforced resin structure. It is explanatory drawing which shows the mode at the time of the start of a cold press process. It is explanatory drawing which shows the mode during the press of a cold press process. It is explanatory drawing which shows the mode at the time of completion | finish of a cold press process.

  Exemplary embodiments of the present invention will be described below in detail with reference to the accompanying drawings. In addition, in this specification and drawing, about the component which has the substantially same function structure, duplication description is abbreviate | omitted by attaching | subjecting the same code | symbol. In the present specification and drawings, a plurality of components having substantially the same functional configuration may be distinguished by adding different alphabets after the same reference numeral. However, when it is not necessary to particularly distinguish each of a plurality of constituent elements having substantially the same functional configuration, only the same reference numerals are given.

<1. Fiber Reinforced Resin Structure>
FIG. 1 is a perspective view showing an example of a fiber reinforced resin structure 20 according to the present embodiment. The fiber reinforced resin structure 20 is formed using a fiber reinforced resin, and has high strength while being lighter than a structure made of a steel plate. Although the use of the fiber reinforced resin structure 20 is not particularly limited, the fiber reinforced resin structure 20 is used, for example, as a structural component for an automobile body. In addition, the fiber reinforced resin structure 20 should just have the bending part R in which the structure surface was bent, and is not restricted to the shape illustrated in FIG.

(1-1. Fiber reinforced resin sheet)
The fiber reinforced resin sheet as a molding material of the fiber reinforced resin structure 20 is formed by impregnating a matrix resin into a reinforced fiber. The reinforcing fiber used is not particularly limited, and may be, for example, carbon fiber, glass fiber, aramid fiber, or the like, or may be used in combination of these reinforcing fibers. Among these, carbon fibers have high mechanical properties and are easy to design for strength. Therefore, it is preferable that the reinforcing fibers include carbon fibers.

  As the reinforcing fiber, a continuous fiber continuous from one end to the other end of the fiber reinforced resin sheet is used. Moreover, as a fiber reinforced resin sheet, the unidirectional fiber reinforced resin sheet in which the reinforced fiber orientated along one direction, and the fiber reinforced resin sheet in which the reinforced fiber orientated in several directions are used. However, the fiber reinforced resin sheet constituting the inner layer of the fiber reinforced resin structure 20 includes at least one unidirectional fiber reinforced resin sheet. On the other hand, the fiber reinforced resin sheet constituting the surface layer of the fiber reinforced resin structure 20 may be a unidirectional fiber reinforced resin sheet, or may be a fiber reinforced resin sheet in which reinforced fibers are oriented in a plurality of directions. Good.

  A thermoplastic resin is used for the matrix resin of the fiber reinforced resin sheet. Examples of the matrix resin include polyethylene resin, polypropylene resin, polyvinyl chloride resin, ABS resin, polystyrene resin, AS resin, polyamide resin, polyacetal resin, polycarbonate resin, thermoplastic polyester resin, PPS (polyphenylene sulfide) resin, and fluorine resin. , Polyetherimide resin, polyetherketone resin, polyimide resin and the like. One type of these thermoplastic resins or a mixture of two or more types can be used. These thermoplastic resins may be used alone, as a mixture, or as a copolymer. In the case of a mixture, a compatibilizer may be used in combination. Further, brominated flame retardants, silicon-based flame retardants, red phosphorus and the like may be added as flame retardants.

  In this case, examples of the thermoplastic resin used include polyolefin resins such as polyethylene and polypropylene, polyamide resins such as nylon 6 and nylon 66, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyether ketone, Examples of the resin include polyether sulfone and aromatic polyamide. Among them, the plastic matrix resin is preferably at least one selected from the group consisting of polyamide, polyphenylene sulfide, polypropylene, polyether ether ketone, and phenoxy resin.

  The plurality of fiber reinforced resin sheets to be laminated may be different in the type and content of the reinforcing fibers. Moreover, in the some fiber reinforced resin sheet | seat laminated | stacked, the different materials in which matrix resin has compatibility may be sufficient, or different additives etc. may be mixed with respect to the same matrix resin. Even in this case, it is preferable that the melting point of the matrix resin is approximated so that the fiber-reinforced resin sheet can be efficiently melted and cured.

  The fiber reinforced resin sheet is manufactured by, for example, a method of impregnating the reinforcing fiber with the matrix resin while continuously feeding the reinforcing fiber by a process such as a general film impregnation method or a melt impregnation method. By cutting this fiber reinforced resin sheet into a desired size, a fiber reinforced resin sheet as a molding material is obtained. You may form the fiber reinforced resin sheet of a desired width and length by mutually joining the edge part of the width direction of the several fiber reinforced resin sheet cut | disconnected to the desired size with an adhesive agent. The thickness of a fiber reinforced resin sheet can be made into the value within the range of 0.03-0.50 mm, for example.

(1-2. Convex part)
In this embodiment, the fiber reinforced resin structure 20 shape | molded using a fiber reinforced resin sheet has the convex-shaped part 22, as shown in FIG. For example, the convex portion 22 is formed as a rib for increasing the rigidity of the fiber reinforced resin structure 20. However, the purpose of forming the convex portion 22 in the fiber reinforced resin structure 20 is not limited to this. For example, the convex portion 22 may be for preventing warpage in an automobile structural member.

  FIG. 2 is a cross-sectional view showing a cross section of a portion of the fiber reinforced resin structure 20 where the convex portion 22 is formed. FIG. 2 shows a cross section in a direction orthogonal to the extending direction of the convex portion 22. The fiber reinforced resin structure 20 includes a first surface layer 24a and a second surface layer 24b, and an inner layer 26.

  In the present embodiment, each of the first surface layer 24a and the second surface layer 24b is formed by melting and curing one unidirectional fiber-reinforced resin sheet. The continuous fibers F1a and F1b included in the first surface layer 24a and the second surface layer 24b are oriented along a direction intersecting the extending direction of the convex portion 22. The inner layer 26 is formed by melting and curing three unidirectional fiber reinforced resin sheets. The continuous fibers F2 included in the inner layer 26 are oriented along the extending direction of the convex portions 22.

  The convex portion 22 is formed on the surface on the first surface layer 24a side. The convex portion 22 is formed by the inner layer 26 bulging out from the slit SL provided in the first surface layer 24a. In addition, at the root portion of the convex portion 22, a part of the first surface layer 24 a is raised along the convex portion 22. That is, the surface of the root portion of the convex portion 22 is constituted by the first surface layer 24 a, and many other portions of the convex portion 22 are constituted by the inner layer 26.

  Therefore, the convex portion 22 includes continuous fibers F2 oriented mainly along the extending direction of the convex portion 22. The orientation direction of the continuous fiber F2 is along the direction of the slit SL provided in the first surface layer 24a, and the inner layer 26 bulges outside through the slit SL when the fiber reinforced resin structure 20 is molded. It has become easier. Moreover, even if it is a case where the inner layer 26 bulges because the continuous fiber F2 which bulges is orientating along the extension direction of the convex part 22, it is with respect to the extension direction of the convex part 22. Thus, tension is unlikely to occur in the intersecting direction, and warping of the fiber reinforced resin structure 20 is suppressed.

  Further, continuous fibers F1a and F1b oriented along the direction intersecting the extending direction of the convex portion 22 are laminated on the surface of the root portion of the convex portion 22 along the rising direction of the convex portion 22. Is done. In the fiber reinforced resin material, since the rigidity and strength in the fiber orientation direction are high, the continuous fibers F1a and F1b at the base portion of the convex portion 22 are in a state of reinforcing the convex portion 22, and the convex portion 22 falls. It has become difficult.

  The height of the convex portion 22 can be set to a value in the range of 0.1 to 8.0 mm, for example. If the height of the convex portion 22 is too high, it may be difficult to form the convex portion 22 by cold pressing. If the height of the convex portion 22 is too low, the desired effect required for the convex portion 22 may not be obtained. Therefore, the height of the convex portion 22 is more preferably a value within the range of 0.5 to 5.0 mm, and still more preferably a value within the range of 1.0 to 3.0 mm.

  The first surface layer 24a and the second surface layer 24b include continuous fibers F1a and F1b oriented in a direction orthogonal to the extending direction of the convex portion 22, but at least one of the continuous fibers F1 and F1b. The orientation direction does not have to be orthogonal to the extending direction of the convex portion 22, and it is sufficient that it is at least crossed. Further, the entire inner layer 26 may not include the continuous fibers F2 oriented in the same direction. For example, in the inner layer 26, the layer region close to the first surface layer 24a includes the continuous fibers F2 oriented along the extending direction of the convex portion 22, and the other layer regions are oriented in different directions. Continuous fibers may be included.

  As described above, the fiber reinforced resin structure 20 according to the present embodiment is formed by projecting the continuous fibers F2 of the inner layer 26 through the slits SL formed along the orientation direction. Since it has the shape part 22, curvature is suppressed. Further, the surface of the root portion of the convex portion 22 is reinforced by the continuous fibers F1a of the first surface layer 24a oriented in a direction different from the orientation direction of the continuous fibers that stick out, and is not easily collapsed. Therefore, the rigidity and strength of the convex portion 22 are improved.

<2. Manufacturing method of fiber reinforced resin structure>
The manufacturing method of the fiber reinforced resin structure 20 according to the present embodiment will be specifically described. The manufacturing method of the fiber reinforced resin structure concerning this embodiment is a fiber reinforced resin structure by cold-pressing the fiber reinforced resin laminated body which laminated the fiber reinforced resin sheet which impregnated the matrix resin in the reinforced fiber. It is a manufacturing method of the fiber reinforced resin structure to shape | mold. In the present embodiment, the fiber reinforced resin sheet of the inner layer of the fiber reinforced resin laminate includes a unidirectional fiber reinforced resin sheet, and the surface layer is along the orientation direction of the reinforced fibers in the unidirectional fiber reinforced resin sheet of the inner layer. A slit is provided along the direction intersecting the reinforcing fibers in the fiber reinforced resin sheet, and press working is performed. Thereby, the reinforced fiber and matrix resin of the unidirectional fiber reinforced resin sheet of the inner layer are swelled from the surface layer through the slits, and a convex portion is formed on the surface of the fiber reinforced resin structure.

  FIG. 3 is an explanatory view schematically showing a process until the fiber reinforced resin structure 20 is obtained from the fiber reinforced resin sheets 10a, 10b, 10c, 10d, and 10e as the molding material. Such a manufacturing method includes a laminating step, a heating step, and a cold pressing step. Hereinafter, each step will be described in detail.

(2-1. Lamination process)
The lamination step is a step of forming a fiber reinforced resin laminate 12 by laminating a plurality of fiber reinforced resin sheets 10. In the present embodiment, five unidirectional fiber reinforced resin sheets 10a, 10b, 10c, 10d, and 10e each having continuous fibers oriented in one direction are used. At this time, the orientation direction D1 of the continuous fibers of the unidirectional fiber reinforced resin sheets 10a, 10e located in the uppermost layer and the lowermost layer of the fiber reinforced resin laminate 12, and the unidirectional fiber reinforced resin sheets 10b, 10c, located therein, Lamination is performed so that the orientation direction D2 of 10d continuous fibers intersects. In the present embodiment, the continuous fiber orientation direction D1 of the unidirectional fiber reinforced resin sheets 10a and 10e and the continuous fiber orientation direction D2 of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d are orthogonal to each other.

  In the present embodiment, the slits SL are provided in advance in the unidirectional fiber-reinforced resin sheet 10a located in the uppermost layer. The slit SL is along the orientation direction of the continuous fibers of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d located inside, and intersects the orientation direction of the continuous fibers of the unidirectional fiber reinforced resin sheet 10a provided with the slit SL. Are arranged. The slit SL only needs to be formed along the orientation direction of the continuous fibers of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d inside, and in the orientation direction of the continuous fibers of the surface unidirectional fiber reinforced resin sheet 10a. It does not need to be orthogonal.

  The width of the slit SL can be set to a value of 5.0 mm or less, for example. However, if the width of the slit SL is too large, the continuous fibers around the slit SL may not be dragged in when the continuous fibers and the matrix resin inside are bulged. Therefore, the width of the slit SL is more preferably a value of 4.0 mm or less, and further preferably a value of 3.0 mm or less.

  In FIG. 3, the slit SL is formed in the unidirectional fiber reinforced resin sheet 10a using the cutter blade 5, but two unidirectional fiber reinforced resin sheets are arranged side by side with a predetermined gap therebetween. You may form slit SL by. In addition, the slit SL may not be provided before the formation of the fiber reinforced resin laminate 12, and the slit SL may be provided by a cutter blade or the like after the fiber reinforced resin laminate 12 is formed.

  As described above, the fiber reinforced resin sheet 10 as a molding material may be obtained by cutting a fiber reinforced resin sheet into a desired size, and an end in the width direction of the fiber reinforced resin sheet cut into a desired size. They may be joined together to have a desired width. The number of fiber reinforced resin sheets 10 to be laminated and the size in plan view can be appropriately selected according to the thickness and size of the fiber reinforced resin structure 20 to be manufactured.

(2-2. Heating step)
The heating step is a step of heating the fiber reinforced resin laminate 12. In the heating step, for example, the fiber reinforced resin laminate 12 is put into the heating device 40. The fiber reinforced resin laminate 12 is heated from the upper surface side and the lower surface side by heating means 41 and 43 such as a heating wire and a far infrared heater. The temperature of the heating device 40 is set to be equal to or higher than the melting point of the matrix resin. In the heating step, the fiber reinforced resin laminate 12 is brought into a molten state so that the matrix resin is not decomposed. The heating device used is not particularly limited.

(2-3. Cold pressing process)
The cold pressing step is a step of cold-pressing the molten fiber reinforced resin laminate 12 to form a fiber reinforced resin structure 20 having a desired shape having the convex portions 22. In the cold pressing process, the temperature of the first mold 51 and the second mold 53 of the cold pressing apparatus 50 is set to be lower than the melting point of the matrix resin. In the cold pressing step, after the molten fiber reinforced resin laminate 12 is placed on the second mold 53, the opposing first mold 51 and second mold 53 are brought close to each other. Thus, the fiber reinforced resin laminate 12 is pressed. Thereby, the fiber reinforced resin laminate 12 is cured, and the fiber reinforced resin structure 20 having a desired shape is obtained.

  Here, in the manufacturing method of the fiber reinforced resin structure 20 according to the present embodiment, through the slit SL provided in the unidirectional fiber reinforced resin sheet 10a of the surface layer of the fiber reinforced resin laminate 12 during the cold press processing, Part of the internal unidirectional fiber reinforced resin sheets 10b, 10c, and 10d is expanded. Thereby, the convex part 22 is formed in the fiber reinforced resin structure 20.

  4-6 is explanatory drawing which shows a mode that the cold press process is implemented. FIG. 4 shows a state at the start of pressing, FIG. 5 shows a state during pressing, and FIG. 6 shows a state at the end of pressing. 4 and FIG. 5 and the upper part of FIG. 6 show cross-sectional views of the first mold 51, the second mold 53, and the fiber reinforced resin laminate 12, respectively. The lower part of FIG. 5 and the lower part of FIG. 6 are partially enlarged views of the upper part of FIG. 5 and the upper part of FIG.

  As shown in FIG. 4, the slit provided in the unidirectional fiber reinforced resin sheet 10a in the state which the fiber reinforced resin laminated body 12 was installed in the cold press apparatus 50 in the press surface of the 1st metal mold | die 51. As shown in FIG. A recess 51a is provided at a position facing the SL. The concave portion 51a is for receiving the continuous fibers and the matrix resin of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d that bulge through the slit SL, and molding the convex portion 22. The shape of the concave portion 51a is designed according to the shape of the convex portion 22 to be formed.

  When the fiber reinforced resin laminate 12 is pressed by bringing the first mold 51 and the second mold 53 close to each other, the slit SL provided in the unidirectional fiber reinforced resin sheet 10a is formed as shown in FIG. Accordingly, a part of the unidirectional fiber reinforced resin sheet 10b bulges into the recess 51a. The fiber reinforced resin laminate 12 starts to harden quickly from the portion in contact with the first mold 51 and the second mold 53 that are set to a temperature lower than the melting point, but the periphery of the slit SL faces the recess 51a. The timing to start curing is delayed. Therefore, a part of the internal unidirectional fiber reinforced resin sheet 10b can bulge through the slit SL, and the unidirectional fiber reinforced around the slit SL as the unidirectional fiber reinforced resin sheet 10b bulges. The continuous fibers of the resin sheet 10a are pulled up and started up.

  At this time, since the continuous fibers of the unidirectional fiber reinforced resin sheet 10b are oriented along the extending direction of the slit SL, the continuous fibers and the matrix resin of the unidirectional fiber reinforced resin sheet 10b flow out through the slit SL. It is easy to do. Further, when the continuous fiber flows out, the continuous fiber is not pulled inside. On the other hand, continuous fibers in the surface layer that are dragged as the internal unidirectional fiber-reinforced resin sheet 10 b bulges are laminated along the rising direction of the convex portion 22. Therefore, the fiber of the direction different from the extending direction of the convex part 22 is laminated | stacked on the root part of the convex part 22. FIG.

  Further, when the pressing of the fiber reinforced resin laminate 12 is continued, as shown in FIG. 6, the recess 51a is filled with the continuous fibers and the matrix resin of the unidirectional fiber reinforced resin sheet 10b. And the inside of the fiber reinforced resin laminated body 12 is also cooled gradually, and the fiber reinforced resin structure 20 is shape | molded.

  Since the fiber reinforced resin structure 20 has a property of increasing physical properties such as rigidity and strength along the fiber orientation direction, the root portion of the convex portion 22 is reinforced by continuous fibers of the unidirectional fiber reinforced resin sheet 10a. It becomes a state. Therefore, the convex portion 22 is increased in strength and is difficult to fall down. Moreover, since the continuous fiber is not pulled inside when the continuous fiber of the internal unidirectional fiber reinforced resin sheet 10b flows out, the warp of the fiber reinforced resin structure 20 is suppressed.

  As described above, according to the method for manufacturing the fiber reinforced resin structure 20 according to the present embodiment, when the fiber reinforced resin structure 20 is manufactured by cold pressing, the internal unidirectional fiber reinforced resin sheet 10b The convex portions 22 are formed by bulging the continuous fibers and the matrix resin through the slits SL. Since the continuous fibers that bulge are oriented along the direction of the slit SL, in the fiber reinforced resin structure 20, the occurrence of warpage due to the continuous fibers being pulled is suppressed.

  Further, when the continuous fibers and the matrix resin of the internal unidirectional fiber reinforced resin sheet 10 b bulge out from the slit SL, the continuous fibers around the slit SL are dragged and laminated on the root portion of the convex portion 22. . Since the continuous fibers are oriented in a direction different from the orientation direction of the continuous fibers bulged from the inside, the convex portion 22 is reinforced. Therefore, according to the manufacturing method of the fiber reinforced resin structure 20 according to the present embodiment, physical properties such as rigidity and strength of the convex portion 22 can be improved.

  The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious that a person having ordinary knowledge in the technical field to which the present invention pertains can come up with various changes or modifications within the scope of the technical idea described in the claims. Of course, it is understood that these also belong to the technical scope of the present invention.

DESCRIPTION OF SYMBOLS 10 Fiber reinforced resin sheet 10a, 10b, 10c, 10d, 10e Unidirectional fiber reinforced resin sheet 12 Fiber reinforced resin laminated body 16 Slit 18 Layer thickness increase material 20 Fiber reinforced resin structure 22 Convex part 24a 1st surface layer 24b 1st 2 surface layers 26 inner layer 40 heating device 50 cold press device 51 first mold 51a recess 53 second mold SL slit

Claims (10)

A fiber reinforced resin structure formed by cold pressing a plurality of laminated fiber reinforced resin sheets,
An inner layer including a unidirectional fiber reinforced resin sheet in which reinforcing fibers are oriented along one direction;
A surface layer containing reinforcing fibers oriented along a direction intersecting the orientation direction of the reinforcing fibers of the inner layer;
A convex portion formed by the inner layer bulging out from a slit provided in the surface layer along the orientation direction of the reinforcing fibers of the inner layer;
A fiber reinforced resin structure.   The fiber-reinforced resin structure according to claim 1, wherein a part of the surface layer is raised along the convex portion.   The fiber reinforced resin sheet of the surface layer is composed of the unidirectional fiber reinforced resin sheet, and the orientation direction of the reinforcing fibers of the unidirectional fiber reinforced resin sheet of the surface layer intersects with the orientation direction of the reinforcing fibers of the inner layer. The fiber-reinforced resin structure according to claim 1 or 2.   The fiber-reinforced resin sheet of the surface layer is the fiber-reinforced resin sheet in which the reinforcing fibers are oriented along at least two directions, and the at least two directions intersect with the orientation directions of the reinforcing fibers of the inner layer. The fiber-reinforced resin structure according to claim 1 or 2.   The fiber-reinforced resin structure according to any one of claims 1 to 4, wherein a height of the convex portion is a value within a range of 0.1 to 5.0 mm. A step of forming a fiber reinforced resin laminate by laminating a plurality of fiber reinforced resin sheets impregnated with a matrix resin into reinforced fibers;
Heating the fiber-reinforced resin laminate,
A step of pressing the heated fiber reinforced resin laminate using a cold press device to form a fiber reinforced resin structure, and
The fiber reinforced resin sheet of the inner layer of the fiber reinforced resin laminate includes a unidirectional fiber reinforced resin sheet in which the reinforced fibers are oriented along one direction,
While pressing along the orientation direction of the reinforcing fiber in the unidirectional fiber reinforced resin sheet of the inner layer, a slit is provided along the direction intersecting the reinforcing fiber in the fiber reinforced resin sheet of the surface layer, and the pressing is performed. Thus, the reinforcing fiber and the matrix resin of the unidirectional fiber reinforced resin sheet of the inner layer are swelled from the surface layer through the slit, and a convex portion is formed on the surface of the fiber reinforced resin structure. The manufacturing method of the fiber reinforced resin structure to form. In the press surface of the die of the cold press device, a recess is provided at a position facing the slit,
The manufacturing method of the fiber reinforced resin structure according to claim 6, wherein the reinforced fiber and the matrix resin of the unidirectional fiber reinforced resin sheet bulged from the slit are made to enter the concave portion to form the convex portion. .   The manufacturing method of the fiber reinforced resin structure of Claim 6 or 7 whose width | variety of the said slit is a value of 5.0 mm or less.   The manufacturing method of the fiber reinforced resin structure of any one of Claims 6-8 which arrange | positions the said fiber reinforced resin sheet which provided the said slit previously in a surface layer, and forms the said fiber reinforced resin laminated body. After forming the said fiber reinforced resin laminated body, the said slit is formed from the said surface layer side, and the said fiber reinforced resin laminated body is installed in the said cold press apparatus of any one of Claims 6-8. Manufacturing method of fiber reinforced resin structure.

Images