JP2018001464A - Fiber-reinforced resin member and method for producing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fiber-reinforced resin member having excellent rigidity and a method for producing the same.SOLUTION: There is provided a fiber-reinforced resin member which has a first fiber-reinforced member containing a woven fabric composed of a plurality of continuous fibers, a first resin part containing a first resin and a second resin part containing a second resin and comprises a resin base material for coating the fiber-reinforced member and a second fiber-reinforced member which is contained in the resin base material and is composed of a plurality of discontinuous fibers. In an interface between the first resin and the second resin, the first resin and the second resin are integrated by forming an irregular shape. A part of the woven fabric alternately penetrates the first resin and the second resin. A part of the plurality of discontinuous fibers intrudes both into the first resin and the second resin through an interface between the first resin and the second resin.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a fiber reinforced resin member and a method for manufacturing the same.

  Fiber reinforced resin (FRP) reinforced with glass fiber or carbon fiber with thermoplastic resin or thermosetting resin is a high strength of FRP in fields such as electrical industry, construction industry, sports industry, aviation industry, automobile industry, It is used by taking advantage of characteristics such as high rigidity and light weight. In particular, a fiber reinforced resin (CFRP) using carbon fibers has a high effect, and research and development has been actively conducted in recent years.

  Conventionally, an integrally molded product that can easily integrate a member made of FRP with another structural member and can be integrated with excellent bonding strength has been proposed.

  In this integrated molded product, a first member in which a group of reinforcing fibers composed of a large number of continuous filaments is arranged in a matrix resin and a second member composed of the thermoplastic resin composition (A) are bonded to each other. Being done. In this integrally molded product, the first member and the second member are bonded via the thermoplastic resin composition (B), and the thermoplastic resin compositions (A) and (B). The absolute value of the difference in the solubility parameter δ (SP value) of the thermoplastic resin constituting the is 1.2 or less.

  Moreover, a 1st member consists of a thermoplastic resin layer which consists of a thermosetting resin layer, a thermoplastic resin composition (B), and the reinforced fiber group which consists of many continuous filaments. Further, the first member includes a thermosetting resin layer and a thermoplastic resin layer, and at the interface between these layers, the resin of the thermosetting resin layer and the resin of the thermoplastic resin layer form an uneven shape and are integrated. It has become. In the first member, one group of filaments in the reinforcing fiber group is in contact with at least the resin of the thermosetting resin layer, and the remaining group of filaments in the reinforcing fiber group is at least the resin of the thermoplastic resin layer. Is a molded body in contact with Furthermore, the first member is a laminate in which the surface opposite to the interface of the thermoplastic resin layer is located on the surface of the molded body (see Patent Document 1).

JP 2006-44259 A

  However, the integrated molded product described in Patent Document 1 is only integrated by the compatibility of the resin at the interface and the formation of an uneven shape. At present, a fiber reinforced resin member having higher rigidity is desired, and there is a problem that the rigidity of the fiber reinforced resin member is not sufficient.

  The present invention has been made in view of such problems of the prior art. And an object of this invention is to provide the fiber reinforced resin member which has the outstanding rigidity, and its manufacturing method.

  The inventors of the present invention have made extensive studies in order to achieve the above object. As a result, the first resin and the second resin are integrated in a concavo-convex shape at the interface between the first resin and the second resin, and a part of the woven fabric composed of a plurality of continuous fibers is combined with the first resin. The second resin is alternately penetrated, and a part of the plurality of discontinuous fibers penetrates both the first resin and the second resin through the interface between the first resin and the second resin. It has been found that the above-described object can be achieved by adopting the configuration, and the present invention has been completed.

  ADVANTAGE OF THE INVENTION According to this invention, the fiber reinforced resin member which has the outstanding rigidity, and its manufacturing method can be provided.

FIG. 1 is a perspective view showing an outline of an example of a fiber-reinforced resin member according to the first embodiment of the present invention. FIG. 2 is a schematic cross-sectional view taken along line II-II of the fiber reinforced resin member shown in FIG. FIG. 3 is a flowchart showing an example of a method for manufacturing a fiber-reinforced resin member according to the second embodiment of the present invention. FIG. 4 is a schematic cross-sectional view showing an outline of an example of the injection molding shown in FIG. FIG. 5 is a schematic cross-sectional view showing an outline of an example of the injection molding shown in FIG. FIG. 6 is a perspective view showing an outline of a part of a fiber reinforced resin member obtained by an example of the injection molding shown in FIG. FIG. 7 is a schematic cross-sectional view showing an outline of another example of the injection molding shown in FIG. FIG. 8 is a schematic cross-sectional view showing an outline of another example of the injection molding shown in FIG. FIG. 9 is a perspective view schematically showing parts of a fiber reinforced resin member obtained by another example of the injection molding shown in FIG. FIG. 10 is a schematic perspective view illustrating an example of the outline of the bonding illustrated in FIG. 3. FIG. 11 is a schematic perspective view showing an example of the outline of adding the first fiber reinforcement shown in FIG. 3. FIG. 12 is a schematic perspective view showing an example of the outline of the resin transfer molding shown in FIG.

  Hereinafter, a fiber reinforced resin member and a manufacturing method thereof according to an embodiment of the present invention will be described in detail with reference to the drawings. In addition, the dimension ratio of drawing quoted by the following embodiment is exaggerated on account of description, and may differ from an actual ratio.

(First embodiment)
First, the fiber reinforced resin member according to the first embodiment of the present invention will be described. FIG. 1 is a perspective view showing an outline of an example of a fiber-reinforced resin member according to the first embodiment of the present invention. 2 is a schematic cross-sectional view taken along line II-II of the fiber reinforced resin member shown in FIG.

  As shown in FIGS. 1 and 2, the fiber reinforced resin member 1 of the present embodiment includes a first fiber reinforcing material 10, a resin base material 30, and a second fiber reinforcing material 20. The resin base material 30 includes a first resin portion 31 and a second resin portion 32 and covers the first fiber reinforcement 10. Further, the second fiber reinforcement 20 is contained in the resin base material 30. In addition, in the example of illustration, the 2nd fiber reinforcement 20 is contained in the state disperse | distributed to the whole 1st resin part 31. FIG.

  Here, the 1st fiber reinforcement 10 contains the textile fabric 111 which consists of a some continuous fiber. In addition, the fabric 111 in a figure also shows the fiber continuous in one direction which comprises the fabric 111, and description is abbreviate | omitted about the fiber continuous in the other direction. The first resin part 31 contains the first resin 311. Further, the second resin portion 32 contains a second resin 321. The second fiber reinforcement 20 is made of discontinuous fibers 201. Furthermore, in the illustrated example, the fabric 111 has a sheet shape, and these form a laminate. Further, the first resin 311 and the second resin 321 constituting the base material resin 30 are interposed between the fabrics 111 forming the laminated body.

  In addition, at the interface 30A between the first resin 311 and the second resin 321, the first resin 311 and the second resin 321 are integrated in an uneven shape.

  The interface between the first resin and the second resin can be confirmed by, for example, computer tomography (CT).

  Further, a part of the fabric 111 in the first fiber reinforcement 10 passes through the first resin 311 and the second resin 321 alternately. Furthermore, some of the plurality of discontinuous fibers 201 in the second fiber reinforcement 20 penetrate both the first resin 311 and the second resin 321 through the interface 30A.

  The structure as described above can also be confirmed by, for example, computer tomography (CT).

  Thus, by having the following configurations (1-1) to (1-3), a fiber-reinforced resin member having high rigidity, that is, excellent rigidity can be realized. As a result, a secondary effect that the weight reduction and cost reduction of the fiber reinforced resin member can be realized.

(1-1) At the interface between the first resin and the second resin, the first resin and the second resin are integrated in an uneven shape.
(1-2) A part of the woven fabric composed of a plurality of continuous fibers alternately penetrates the first resin and the second resin.
(1-3) A part of the plurality of discontinuous fibers penetrates both the first resin and the second resin through the interface between the first resin and the second resin.

  At present, it is considered that the fiber-reinforced resin member has high rigidity by the following mechanism.

  For example, in the case of being integrated without forming a concavo-convex shape, there is almost no resin that enters the facing resin side at the interface, and therefore, when stress is applied to the interface, destruction from the interface occurs. On the other hand, when the concave and convex shapes are integrated, the resin that enters the opposing resin side at the interface exhibits an anchor function for maintaining the integration. Therefore, even if stress is applied to the interface, it is difficult to break.

  For example, as a case where a part of the predetermined woven fabric contained in the first fiber reinforcement does not alternately penetrate the first resin and the second resin, for example, all of the first fiber reinforcement is The case where it is included in either the 1st resin or the 2nd resin is mentioned. In such a case, when stress is applied to the interface, destruction from the interface occurs. On the other hand, when a part of the predetermined fabric contained in the first fiber reinforcing material alternately penetrates the first resin and the second resin, the penetrating fibers are the first resin and the second resin. The anchor function that tries to maintain the integration of the is demonstrated. Therefore, even if stress is applied to the interface, it is difficult to break.

  Furthermore, for example, as a case where a part of the predetermined fiber that is the second fiber reinforcement does not enter both the first resin and the second resin via the interface, for example, the second fiber reinforcement is The case where it is not contained in the resin base material 30 is mentioned. In such a case, when stress is applied to the interface, destruction from the interface occurs. On the other hand, when a part of the predetermined fiber that is the second fiber reinforcing material has penetrated both the first resin and the second resin via the interface, the fiber is composed of the first resin and the second resin. The anchor function that tries to maintain the integration of the is demonstrated. Therefore, even if stress is applied to the interface, it is difficult to break.

  However, the above mechanism is based on estimation. Therefore, it goes without saying that even if the above-described effect is obtained by a mechanism other than the above-described mechanism, it is included in the scope of the present invention.

  The second fiber reinforcing material is particularly limited as long as it is contained in the resin base material and penetrates into both the first resin and the second resin via the interface between the first resin and the second resin. It is not a thing. Although not shown, for example, the second fiber reinforcement may be contained in a state of being dispersed throughout the second resin part, and the second fiber reinforcement may be included in both the first resin part and the second resin part. You may contain in the state disperse | distributed to the whole.

  Moreover, in the fiber reinforced resin member of this embodiment, it is preferable that at least one of the 1st resin part and the 2nd resin part contains 10-50 mass% of 2nd fiber reinforcement materials, and 15-40 mass. % Content is more preferable. When the content of the second fiber reinforcing material in at least one of the first resin portion and the second resin portion is 10% by mass or more, the rigidity is further improved. Further, when the content of the second fiber reinforcing material in at least one of the first resin portion and the second resin portion is 15 to 40% by mass, the rigidity is further improved. When the content of the second fiber reinforcing material in at least one of the first resin part and the second resin part is more than 50% by mass, the first resin and the second resin that form the first resin part and the second resin part The viscosity becomes higher. Therefore, there is a possibility that the first resin or the second resin is not sufficiently impregnated in the first fiber reinforcement.

  Here, each configuration will be described in more detail.

  For example, a carbon fiber woven fabric is preferably used as the woven fabric 111 described above. As such a woven fabric, for example, a plain woven fabric or a twill woven fabric can be used. From the viewpoint of strength, it is preferable to use a plain woven fabric.

  However, it is not limited to these, As a textile fabric, the textile fabric used as glass fiber and another conventionally well-known fiber reinforcement material can also be used, for example. Further, a carbon fiber woven fabric and other conventionally known woven fabric used as a fiber reinforcing material may be used in combination. Furthermore, a woven fabric combining carbon fibers and other conventionally known fiber reinforcements can also be used.

  Moreover, as the above-mentioned discontinuous fiber 201, for example, it is preferable to use carbon fiber. Moreover, as carbon fiber, it is suitable to use the carbon fiber whose fiber length is 0.1-12 mm, for example.

  However, it is not limited to these, As a discontinuous fiber, the fiber used as a glass fiber and another conventionally well-known fiber reinforcement can also be used, for example. Also, carbon fibers and other conventionally known fiber reinforcements can be used in combination.

  Furthermore, as the first resin 311 described above, for example, a thermoplastic resin can be used. As the thermoplastic resin, for example, polypropylene (PP), polyamide (PA), acrylonitrile butadiene styrene copolymer (ABS), polyphenylene sulfide (PPS), or the like can be used. Specific examples of polyamide include nylon 6 and nylon 66. These may be used individually by 1 type and may be used in combination of 2 or more type. As described above, the first resin may include discontinuous fibers.

  However, it is not limited to these, As a 1st resin, a thermosetting resin can also be used, for example. In addition, when using a thermosetting resin, it is preferable to use what is easy to impregnate textiles, such as a resin monomer, at the time of manufacture.

  Moreover, as the above-mentioned second resin 321, for example, a thermoplastic resin can be used. As the thermoplastic resin, for example, polypropylene (PP), polyamide (PA), acrylonitrile butadiene styrene copolymer (ABS), polyphenylene sulfide (PPS), or the like can be used. These may be used individually by 1 type and may be used in combination of 2 or more type. Note that the first resin and the second resin may be the same or different. Further, as described above, the second resin may include discontinuous fibers.

  Furthermore, although mentioned later in detail, when the above-mentioned 1st resin is previously impregnated at the time of manufacture, it is not necessarily easy to impregnate a 2nd resin further to a textile. For example, when the fabric is impregnated with the second resin, it is preferable that the molding temperature of the second resin is set higher than the molding temperature of the first resin to lower the viscosity of the second resin and the fabric is impregnated. For example, as the second resin, it is also preferable to use a resin monomer having a low viscosity, which is impregnated into a fabric and polymerized. Furthermore, for example, as the second resin, it is also preferable to use a resin in which the molding temperature of the second resin is lower than the molding temperature of the first resin and the viscosity of the second resin at the molding temperature is lower than the viscosity of the first resin.

  However, it is not limited to these, As a 2nd resin, a thermosetting resin can also be used, for example. In addition, when using a thermosetting resin, it is preferable to use what is easy to impregnate textiles, such as a resin monomer, at the time of manufacture.

(Second Embodiment)
Next, the manufacturing method of the fiber reinforced resin member which concerns on the 2nd Embodiment of this invention is demonstrated. In addition, it cannot be overemphasized that the fiber reinforced resin member of this invention is not limited to what was obtained by the manufacturing method of the fiber reinforced resin member of this invention.

  FIG. 3 is a flowchart showing an example of a method for manufacturing a fiber-reinforced resin member according to the second embodiment of the present invention. As shown in FIG. 3, the manufacturing method of the fiber reinforced resin member of this embodiment includes the following steps (A) to (D). In the figure, step (A) is abbreviated as S-A (the same applies hereinafter).

  In the step (A), a first fiber reinforcing material containing a woven fabric made of a plurality of continuous fibers is formed on the second fiber made of a plurality of discontinuous fibers forming either the first resin portion or the second resin portion. This is a step of impregnating a molten resin containing a fiber reinforcement from one side of the first fiber reinforcement by injection molding. Thereby, the component of a fiber reinforced resin member is produced. This step corresponds to an example of step (1) described later.

  And a process (B) is a process of joining by combining the components of the some fiber reinforced resin member produced at the process (A), for example using an adhesive agent. Thereby, the component of a fiber reinforced resin member is produced. In addition, this process is a process added as needed.

  Moreover, a process (C) is a process of adding a 1st fiber reinforcement to the components of the fiber reinforced resin member produced at the process (B). Thereby, the component of a fiber reinforced resin member is produced. In addition, this process is a process added as needed.

  Further, in the step (D), a resin monomer that forms one of the first resin portion and the second resin portion is formed on the part of the fiber reinforced resin member produced in the step (C) by resin transfer molding (C ) Is impregnated from the other side of the first fiber reinforcement of the fiber reinforced resin member produced in step) and polymerized. Thereby, a fiber reinforced resin member is produced. This step corresponds to an example of step (2) described later.

  If there is no step (C), the component of the fiber reinforced resin member produced in the step (B) is applied in the step (D) instead of the component of the fiber reinforced resin member produced in the step (C). That's fine. In addition, when there is no step (B) and step (C), in step (D), the fiber reinforced resin member produced in step (A) instead of the fiber reinforced resin member produced in step (C) These parts can be applied. If there is no step (B), the component of the fiber reinforced resin member produced in the step (A) is applied instead of the component of the fiber reinforced resin member produced in the step (B) in the step (C). That's fine.

  Thus, the fiber reinforced resin member which can manufacture efficiently the fiber reinforced resin member which has high rigidity, ie, the outstanding rigidity, by having the structure of the following (2-1) and (2-2). This manufacturing method can be realized.

(2-1) A second fiber composed of a plurality of discontinuous fibers forming one of the first resin part and the second resin part in the first fiber reinforcement containing a woven fabric composed of a plurality of continuous fibers. A step (1) of impregnating a molten resin containing a reinforcing material from one side of the first fiber reinforcing material by injection molding is included.
(2-2) Resin monomer which is executed after step (1) and forms one of the first resin part and the second resin part on the first fiber reinforcing material containing a woven fabric composed of a plurality of continuous fibers. Is impregnated from the other side of the first fiber reinforcing material by resin transfer molding, and is reacted (2).

  At present, it is considered that a fiber-reinforced resin member having high rigidity can be efficiently manufactured by the following mechanism.

  For example, the impregnation state in the first fiber reinforcement is more uneven when the first fiber reinforcement is impregnated by injection molding than when the resin monomer is impregnated in the first fiber reinforcement by resin transfer molding. Easy to do. That is, in the step (1), when the molten resin is impregnated into the first fiber reinforcement by injection molding, it is easier to form an uneven shape at the interface between the first resin and the second resin. It is preferable because the two resins are easily integrated into a concave-convex shape.

  Also, for example, the first fiber reinforcement is impregnated with the resin when the resin monomer is impregnated with the first fiber reinforcement by resin transfer molding than when the molten resin is impregnated with the first fiber reinforcement. Easy to make. That is, in the step (2), it is easier to integrate the first resin and the second resin when the resin monomer is impregnated into the first fiber reinforcement by resin transfer molding. Is preferable because it can be easily integrated into a concave-convex shape. Further, in the step (2), when the first fiber reinforcement is impregnated with the resin monomer by resin transfer molding, a part of the predetermined fabric contained in the first fiber reinforcement is the first resin and the first resin. Since it is easy to make it the state which penetrated 2 resin alternately, it is preferable.

  Furthermore, for example, by causing the molten resin in the step (1) to contain the predetermined fiber that is the second fiber reinforcing material, a part of the predetermined fiber that is the second fiber reinforcing material passes through the interface via the first fiber. A structure penetrating both the resin and the second resin can be more reliably formed.

  However, the above mechanism is based on estimation. Therefore, it goes without saying that even if the above-described effect is obtained by a mechanism other than the above-described mechanism, it is included in the scope of the present invention.

  Here, each step will be described in more detail with reference to the drawings.

  FIG. 4 is a schematic cross-sectional view showing an outline of an example of the injection molding shown in FIG. FIG. 5 is a schematic cross-sectional view showing an outline of an example of the injection molding shown in FIG. Further, FIG. 6 is a perspective view showing an outline of a part of the fiber reinforced resin member obtained by the example of injection molding shown in FIG. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 4, the molds 51 and 52 are opened, and a laminate 112 of carbon fiber fabrics (for example, seven sheets) is prepared in the molds 51 and 52.

  Next, as shown in FIG. 5, the carbon fiber woven laminate 112 is placed in the molds 51 and 52, the molds 51 and 52 are closed, and the molten resin 60 is injected into the carbon fiber woven laminate 112 by injection molding. Impregnation from one side. At this time, the amount of impregnation of the molten resin 60 is not particularly limited as long as an uneven-shaped interface (not shown) is formed and the shape of the member is formed. For example, it may be impregnated to about half as in the illustrated example. Although not shown, this molten resin contains discontinuous carbon fibers.

  In this way, a fiber reinforced resin member part 3 as shown in FIG. 6 is obtained. In the component 3, a part of the laminated body 112 of the first fiber reinforcing material is covered with the first resin 311.

  FIG. 7 is a schematic cross-sectional view showing an outline of another example of the injection molding shown in FIG. FIG. 8 is a schematic cross-sectional view showing an outline of another example of the injection molding shown in FIG. Furthermore, FIG. 9 is a perspective view showing an outline of parts of a fiber reinforced resin member obtained by another example of the injection molding shown in FIG. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 7, the molds 53 and 54 are opened, and a laminate 113 of carbon fiber fabrics (for example, seven sheets) is prepared in the molds 53 and 54.

  Next, as shown in FIG. 8, the carbon fiber woven laminate 113 is placed in the molds 53 and 54, the molds 53 and 54 are closed, and the molten resin 60 is injected into the carbon fiber woven laminate 113 by injection molding. Impregnation from one side. At this time, the amount of impregnation of the molten resin 60 is not particularly limited as long as an uneven-shaped interface (not shown) is formed and the shape of the member is formed. For example, it may be impregnated to about half as in the illustrated example. Although not shown, this molten resin contains discontinuous carbon fibers.

  In this way, a fiber reinforced resin member part 4 as shown in FIG. 9 is obtained. In the component 4, a part of the first fiber reinforcement laminated body 113 is covered with the first resin 311.

  FIG. 10 is a schematic perspective view illustrating an example of the outline of the bonding illustrated in FIG. 3. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  As shown in FIG. 10, an adhesive is applied to a portion where the component 3 and the component 4 are in contact with each other, and the components 3 and 4 are combined and pressed together in the direction indicated by the arrow Z in the drawing.

  FIG. 11 is a schematic perspective view showing an example of the outline of adding the first fiber reinforcement shown in FIG. 3. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

  A laminate of carbon fiber woven fabrics (for example, 7 sheets) is added, and further, a carbon fiber woven fabric is added to the side surfaces of the joining portions of the parts 3 and 4, and the fiber reinforced resin member as shown in FIG. Part 2 is obtained. In the component 2, a part (inner side) of the laminated body 114 of the first fiber reinforcing material is covered with the first resin 311.

  FIG. 12 is a schematic perspective view showing an example of the outline of the resin transfer molding shown in FIG. In the present embodiment, the same components as those in the first embodiment are denoted by the same reference numerals, and detailed description thereof is omitted.

As shown in FIG. 12, the molds 55 and 56 are opened, and the component 2 is placed in the molds 55 and 56.
Although not shown, after the mold is closed, the resin monomer that forms the second resin portion is formed on the outside of the first fiber reinforcement not impregnated with the first resin by resin transfer molding of the first fiber reinforcement. It is impregnated from the outside and polymerized. Thereby, the outside of the component is covered with the second resin. As a result, the fiber reinforced resin member 1 covered with the base material resin 30 as shown in FIG. 1 is obtained.

  When impregnating the resin monomer, the mold may be evacuated. Moreover, you may add suitably the catalyst which accelerates | stimulates polymerization reaction to the resin monomer to be used. Furthermore, when making it polymerize, you may heat suitably.

  Although not shown, when impregnating the first resin, there is no need for injection molding. For example, a resin film sheet may be placed in a mold, and the first fiber reinforcement may be impregnated with a hot press. In addition, when impregnating the second resin, there is no need for resin transfer molding using a resin monomer.

  EXAMPLES Hereinafter, although an Example demonstrates this invention further in detail, this invention is not limited to such an Example.

Example 1
The following materials were used.
<Material>
First fiber reinforcement raw material: Carbon fiber fabric (Toray Industries, Ltd., trading card cloth (CO6343B))
First resin and second fiber reinforcing material: Carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (a pellet of 12 mm nylon 6 containing 40 mass% carbon fiber having a fiber length of 12 mm) is there.)
Second resin: Nylon 6 activator-containing nylon 6 monomer (manufactured by Nagase ChemteX Corporation, DENITEITE)

<Preparation>
Carbon fiber fabric was cut into 310 mm length and 130 mm width to prepare 14 sheets. The cut carbon fiber fabric was placed in an aluminum tray filled with general-purpose pure acetone and left overnight. After standing, it was washed with pure acetone, and a carbon fiber fabric was placed on a net and allowed to air dry. After drying, it was trimmed to a length of 300 mm and a width of 120 mm.

<Injection molding (introduction of the first resin)>
A mold having a plate part cavity of 310 mm in length, 130 mm in width, and 2 mm in thickness is attached to a general-purpose injection molding machine (Siyo 180III, manufactured by Toyo Machine Metal Co., Ltd.) with a mold clamping of 180 tons. Set to 90 ° C. The mold was opened, seven carbon fiber fabrics were placed in the mold and dried at the mold temperature, and then a carbon fiber-containing nylon pellet plastron was injection molded at a resin temperature of 280 ° C.

<Resin transfer molding (introduction of second resin)>
After completion of the injection molding, the piping was replaced, the mold temperature was set to 150 ° C., and the thickness of the cavity was changed to 3 mm by changing the spacer, and preparation for resin transfer molding was performed. The mold was opened, seven carbon fiber fabrics were added, and the mold was closed. After the inside of the mold was evacuated and dried, nylon 6 monomer containing nylon 6 activator was fed into the mold at 1.0 MPa. Two minutes after the completion of liquid feeding, the fiber reinforced resin member of this example as shown in FIG. 2 was obtained from the mold.

(Example 2)
As the first resin and the second fiber reinforcement, carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (a pellet of 12 mm nylon 6 pellets containing 40 mass% carbon fiber having a fiber length of 12 mm) In place of carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (pellet length 12 mm nylon 6 pellets, carbon fiber having a fiber length of 12 mm is contained in 30% by mass). ) Was used, and the same operation as in Example 1 was repeated to obtain a fiber-reinforced resin member of this example as shown in FIG.

(Example 3)
As the first resin and the second fiber reinforcement, carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (a pellet of 12 mm nylon 6 pellets containing 40 mass% carbon fiber having a fiber length of 12 mm) Instead of carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (pellet length 12 mm nylon 6 pellets, carbon fiber having a fiber length of 12 mm is contained in 20% by mass). ) Was used, and the same operation as in Example 1 was repeated to obtain a fiber-reinforced resin member of this example as shown in FIG.

Example 4
As the first resin and the second fiber reinforcement, carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (a pellet of 12 mm nylon 6 pellets containing 40 mass% carbon fiber having a fiber length of 12 mm) In place of carbon fiber-containing nylon pellets (Daicel Polymer Co., Ltd., Plastron (pellet length 12 mm nylon 6 pellets containing 10 mass% carbon fiber having a fiber length of 12 mm). ) Was used, and the same operation as in Example 1 was repeated to obtain a fiber-reinforced resin member of this example as shown in FIG.

(Comparative Example 1)
The following materials were used.
<Material>
First fiber reinforcement raw material: Carbon fiber fabric (Toray Industries, Ltd., trading card cloth (CO6343B))
First resin: Nylon (Nylon for Plastron dilution, manufactured by Daicel Polymer Co., Ltd.)
Second resin: Nylon 6 activator-containing nylon 6 monomer (manufactured by Nagase ChemteX Corporation, DENITEITE)

<Preparation>
Carbon fiber fabric was cut into 310 mm length and 130 mm width to prepare 14 sheets. The cut carbon fiber fabric was placed in an aluminum tray filled with general-purpose pure acetone and left overnight. After standing, it was washed with pure acetone, and a carbon fiber fabric was placed on a net and allowed to air dry. After drying, it was trimmed to a length of 300 mm and a width of 120 mm.

<Injection molding (introduction of the first resin)>
A mold having a plate part cavity of 310 mm in length, 130 mm in width, and 2 mm in thickness is attached to a general-purpose injection molding machine (Siyo 180III, manufactured by Toyo Machine Metal Co., Ltd.) with a mold clamping of 180 tons. Set to 90 ° C. The mold was opened, and seven carbon fiber fabrics were placed in the mold and dried at the mold temperature, and then the first resin nylon was injection molded at a resin temperature of 270 ° C.

<Resin transfer molding (introduction of second resin)>
After completion of the injection molding, the piping was replaced, the mold temperature was set to 150 ° C., and the thickness of the cavity was changed to 3 mm by changing the spacer, and preparation for resin transfer molding was performed. The mold was opened, seven carbon fiber fabrics were added, and the mold was closed. After the inside of the mold was evacuated and dried, nylon 6 monomer containing nylon 6 activator was fed into the mold at 1.0 MPa. Two minutes after the completion of liquid feeding, the fiber-reinforced resin member of this example was obtained from the mold.

[Performance evaluation]
(Rigidity evaluation)
After the fiber reinforced resin member of each example taken out was sufficiently cooled, it was cut into a length of 100 mm and a width of 15 mm, and these were used as test pieces. These test pieces were subjected to a three-point bending test at a temperature of 25 ° C., a fulcrum distance of 80 mm, and a test speed of 5 mm / min. The obtained results are shown in Table 1. In addition, “◯” in “existence of uneven shape” in Table 1 indicates a structure in which the first resin and the second resin are integrated in an uneven shape at the interface between the first resin and the second resin. It has what has. “X” in “Existence of uneven shape” in Table 1 has a structure in which the first resin and the second resin are integrated in an uneven shape at the interface between the first resin and the second resin. Indicates what is not. In Table 1, “◯” in “Presence / absence of penetrating structure” indicates that a part of the fabric has a structure in which the first resin and the second resin are alternately passed through. “X” in “Possibility of penetration structure” in Table 1 indicates that a part of the woven fabric does not have a structure that alternately penetrates the first resin and the second resin. Furthermore, “◯” in “Intrusion structure presence / absence” in Table 1 indicates that a part of the plurality of discontinuous fibers passes through the interface between the first resin and the second resin. The thing which has the structure which has penetrate | invaded both is shown. “X” in “Intrusion structure presence / absence” in Table 1 indicates that a part of the plurality of discontinuous fibers is in both the first resin and the second resin via the interface between the first resin and the second resin. The one without the invading structure is shown.

  From Table 1, it can be seen that Examples 1 to 4 belonging to the scope of the present invention have a higher flexural modulus than Comparative Example 1 outside the present invention. That is, it can be seen that Examples 1 to 4 have high rigidity, that is, excellent rigidity. This is considered because it has the structure of (1-1)-(1-3) mentioned above.

  Moreover, it is also considered that Example 1-Example 4 has the outstanding rigidity because the 1st resin part contains 10-50 mass% of 2nd fiber reinforcements.

  Furthermore, it can be seen that, among Examples 1 to 4, Examples 1 to 3 have particularly high rigidity, that is, excellent rigidity. This is considered because the 1st resin part contains the 2nd fiber reinforcement material 15-40 mass%.

  From the results in Table 1, it is considered that Example 1 is most excellent at the present time.

  In addition, Examples 1 to 4 belonging to the scope of the present invention have the above-described configurations (2-1) and (2-2), so that the fiber-reinforced resin having high rigidity, that is, excellent rigidity. It turns out that a member can be manufactured efficiently.

  As mentioned above, although this invention was demonstrated with some embodiment and an Example, this invention is not limited to these, A various deformation | transformation is possible within the range of the summary of this invention.

DESCRIPTION OF SYMBOLS 1 Fiber reinforced resin member 2,3,4 parts 10 1st fiber reinforcement 111 Woven fabric 112,113,114 Laminated body
20 second fiber reinforcement 201 discontinuous fiber 30 base resin 30A interface 31 first resin part 311 first resin 32 second resin part 321 second resin 51, 52, 53, 54, 55, 56 mold 60 melting resin

Claims (4)

A first fiber reinforcement containing a fabric composed of a plurality of continuous fibers;
A resin base material having a first resin part containing a first resin and a second resin part containing a second resin, and covering the first fiber reinforcement;
A second fiber reinforcing material contained in the resin base material and comprising a plurality of discontinuous fibers, and
In the interface between the first resin and the second resin, the first resin and the second resin are integrated in a concavo-convex shape,
A part of the fabric passes through the first resin and the second resin alternately;
A part of the plurality of discontinuous fibers penetrates both the first resin and the second resin through the interface. A fiber-reinforced resin member, wherein:   2. The fiber-reinforced resin member according to claim 1, wherein at least one of the first resin portion and the second resin portion contains 10 to 50 mass% of the second fiber reinforcing material.   The fiber-reinforced resin member according to claim 1, wherein at least one of the first resin portion and the second resin portion contains 15 to 40% by mass of the second fiber reinforcing material. It is a manufacturing method of the fiber reinforced resin member as described in any one of Claims 1-3, Comprising: The following process (1) and (2)
Step (1): a second fiber composed of a plurality of discontinuous fibers forming one of the first resin portion and the second resin portion on a first fiber reinforcement containing a woven fabric composed of a plurality of continuous fibers. Impregnating a molten resin containing a reinforcing material from one side of the first fiber reinforcing material by injection molding;
Step (2): After the step (1), one of the first resin portion and the second resin portion is added to the first fiber reinforcement containing the woven fabric composed of the plurality of continuous fibers. A method for producing a fiber reinforced resin member, comprising: impregnating a resin monomer to be formed from the other side of the first fiber reinforcing material by resin transfer molding and reacting the resin monomer.

Images