JP2019084787A - Fiber-reinforced resin molding, and method for manufacturing fiber-reinforced resin molding - Google Patents

Abstract

To provide a fiber-reinforced resin molding having a structure which allows an uncured resin to be easily distributed in manufacture.SOLUTION: A fiber-reinforced resin molding 10 includes: a laminate X having a plate-like core material 11 formed of a foam resin and a pair of sheet-like reinforcement fiber base materials 12a and 12b overlapped on a front face 11a1 and a rear face 11b1 of the core material 11 respectively; and a resin part 13 obtained by curing an uncured resin R impregnating the laminate X. The core material 11 includes: a flow channel 110 that is formed on the front face 11a1 and the rear face 11b1 or inside and flows the uncured resin R in a plane direction; and a supply port 111 which is formed of a pore part connected with the flow channel 110 while penetrating in a thickness direction and supplies the uncured resin R from the outside through a reinforcement fiber base material 12a. The resin part 13 includes a flow channel resin part 130 filling the flow channel 110 and a supply port resin part 131 filling the supply port 111.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a fiber-reinforced resin molded article and a method for producing a fiber-reinforced resin molded article.

  Resin molded products reinforced with reinforcing fibers such as carbon fibers and glass fibers are widely used. As an example of such a resin molded product, one obtained by solidifying a laminate in which a sheet-like reinforcing fiber base material is superimposed on the front and back surfaces of a core material made of a foamed resin with a thermosetting resin (for example, , Patent Document 1). This type of resin molded product is molded using RTM (Resin Transfer Molding) method, and specifically, in a state where the above-mentioned laminate is set in the cavity of the mold, it is uncured in the cavity The resin molded product is manufactured by injecting a thermosetting resin having the fluidity of the state, and thermosetting the resin in a state in which the resin is impregnated in the reinforcing fiber base and the like of the laminate.

Unexamined-Japanese-Patent No. 04-224915 gazette

  If the thermosetting resin is supplied at high pressure into the mold cavity, the core material of the laminate may be crushed. Therefore, in the manufacturing process of this kind of molded product, there is a circumstance that it is desirable to keep the injection pressure of the resin as low as possible. However, if the injection pressure of the resin is set low, it takes a long time for the resin to spread throughout the laminate or in the cavity, which reduces the production efficiency. In particular, when the viscosity of the thermosetting resin is high, it takes time for the resin to spread throughout the laminate or in the cavity.

  An object of the present invention is to provide a fiber-reinforced resin molded article or the like having a structure in which uncured resin easily spreads during manufacture.

  The fiber-reinforced resin molded product according to the present invention comprises a laminate having a plate-like core material made of a foamed resin, and a pair of sheet-like reinforcing fiber substrates respectively superimposed on the front and back surfaces of the core material, It is a fiber reinforced resin molded article provided with the resin part by which the resin of the unhardened state by which the laminated body was impregnated is hardened | cured, Comprising: The said core material of the said laminated body is formed in the said surface and back, or inside. A flow path for flowing the uncured resin along the surface direction, and a hole connected to the flow path while penetrating in the thickness direction, the resin in the uncured state from the outside through the reinforcing fiber base material And the resin portion has a flow path resin portion filling the flow path and a supply port resin portion filling the supply port.

  In the fiber-reinforced resin molded product, the core members of the laminate are stacked on each other to form a gap used as the flow path, and each has a pair of unit core members in a plate shape. The resin portion may have, as the flow path resin portion, a gap resin portion filling the gap.

  In the fiber-reinforced resin molded product, preferably, the core material of the laminate is disposed between a pair of unit core materials and has a spacer portion for securing the gap.

  In the fiber-reinforced resin molded product, the core material of the laminate has at least a groove formed on the back surface and used as the flow path, and the resin portion is the groove as the flow path resin portion. The groove resin portion may be filled with the resin.

  In the fiber-reinforced resin molded product, the core material of the laminate has a hollow portion formed in the inside and used as the flow path, and the resin portion is the hollow portion as the flow path resin portion. It may have a hollow resin portion filling the portion.

  In the fiber-reinforced resin molded product, the core material of the laminate communicates the flow path with the surface side facing the one reinforcing fiber substrate or the other reinforcing fiber substrate, and is in an uncured state Preferably, the resin portion has a branch path resin portion filling the branch path.

  Further, a fiber-reinforced resin molded product according to the present invention comprises a laminate having a plate-like core material made of a foamed resin, and a pair of sheet-like reinforcing fiber substrates respectively superimposed on the surface and the back surface of the core material. A fiber-reinforced resin molded article comprising: a resin portion in which an uncured resin impregnated in the laminate is cured; and the core material of the laminate is between adjacent end faces, The resin portion has a pair of divided core members divided so as to form a longitudinal through channel extending along the surface direction and penetrating in the thickness direction, and the resin portion is formed of the longitudinal through channel. It has a through flow passage resin portion to be filled.

  In the fiber-reinforced resin molded product, the core material of the laminate is composed of a hole penetrating in the thickness direction, and the surface side facing one of the reinforcing fiber base and the other of the reinforcing fiber base are surfaced Preferably, the resin portion has a communication path resin portion filling the communication path.

  The method for producing a fiber-reinforced resin molded article according to the present invention is the method for producing a fiber-reinforced resin molded article according to any one of the above, wherein the cavity of the mold in which the laminate is accommodated is not When the cured resin is supplied, the uncured resin is supplied to the supply port through the reinforcing fiber base material, and the resin flows along the flow path.

  The method for producing a fiber-reinforced resin molded article according to the present invention is the method for producing a fiber-reinforced resin molded article according to any one of the above, wherein the cavity of the mold in which the laminate is accommodated is not When the resin in the cured state is supplied, the resin in the uncured state is supplied to the through flow passage through the reinforcing fiber base material, and the resin supply process in which the resin flows along the through flow passage.

  ADVANTAGE OF THE INVENTION According to this invention, the fiber reinforced resin molded article etc. provided with the structure where resin of an unhardened state spreads easily at the time of manufacture can be provided.

Explanatory drawing which represented the cross-sectional structure of the fiber reinforced resin molded product typically Explanatory drawing which shows the process in which the laminated body which consists of a core material which consists of a pair of unit core material, and a pair of reinforcement fiber base materials is set to the fixed mold of a shaping | molding apparatus An explanatory view showing a movable mold approaching a fixed mold in a mold clamping process Explanatory drawing which shows the process in which uncured resin is inject | poured into the cavity of the clamped mold. An explanatory view showing a state in which the resin supplied from the injection hole spreads over the laminate in the cavity Explanatory drawing which shows the process in which a molded article is removed from a fixed mold Explanatory drawing which represented typically the cross-sectional structure of the molded article of Embodiment 2 Explanatory drawing which shows a mode that resin supplied from the injection hole spreads in the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 2. Explanatory drawing which represented typically the cross-sectional structure of the molded article of Embodiment 3 The perspective view of the core material of Embodiment 3 Explanatory drawing which shows a mode that resin supplied from the injection hole spreads in the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 3. Explanatory drawing which represented typically the cross-sectional structure of the molded article of Embodiment 4 Explanatory drawing which shows a mode that resin supplied from the injection hole spreads in the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 4. Explanatory drawing which represented the cross-sectional structure of the molded article of Embodiment 5 typically Top view of core material of Embodiment 5 Explanatory drawing which shows a mode that resin supplied from the injection hole spreads in the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 5.

First Embodiment
Hereinafter, Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 6. In the present embodiment, a fiber-reinforced resin molded product 10 and a method of manufacturing the same will be exemplified. First, a fiber-reinforced resin molded product 10 will be described with reference to FIG.

[Fiber-reinforced resin molded products]
FIG. 1 is an explanatory view schematically showing a cross-sectional configuration of a fiber-reinforced resin molded product (hereinafter, molded product) 10. As shown in FIG. The molded article 10 is lightweight and highly rigid, and is used as part of a vehicle seat (for example, a backboard). Such a molded article 10 is impregnated with the core material 11, a pair of sheet-like reinforcing fiber substrates 12a and 12b stacked on the front and back surfaces of the core material 11, and the reinforcing fiber substrates 12a and 12b, etc. And a resin portion 13 made of a thermosetting resin to be cured. Of the pair of reinforcing fiber bases 12a and 12b, the reinforcing fiber base 12a is disposed on the surface 11a1 side (upper side in FIG. 1), and the reinforcing fiber base 12b is on the rear surface 11b1 side (lower side in FIG. 1). Will be distributed).

  The core member 11 is a member made of a synthetic resin (so-called foamed resin) having a closed cell structure. The core member 11 of the present embodiment is formed by laminating a pair of unit core members 11 a and 11 b each having a plate shape. Of the pair of unit core members 11a and 11b, the unit core members 11a are disposed on the front side (the upper side in FIG. 1), and the unit core members 11b are disposed on the back side (the lower side in FIG. 1). The core material 11 is generally in the form of a plate (layered) having a thickness larger than that of each of the reinforcing fiber bases 12a and 12b. As a synthetic resin utilized for core material 11 (unit core materials 11a and 11b), an acrylic resin is mentioned, for example. Since unit core materials 11a and 11b are relatively thin, they can be manufactured by extrusion using a predetermined die (die), and are members excellent in cost.

  A very slight gap 110 is formed between the unit core members 11a and 11b overlapped in the thickness direction. The gap 110 is used as a flow path 110 for flowing the uncured resin R along the surface direction in the manufacturing process of the molded product 10 as described later. Then, in the state of the molded product 10, the gap (flow path) 110 is hardened by a thin spread in a planar shape, and a part of the resin portion 13 (gap resin portion which is an example of the flow path resin portion) 130 It will be buried.

  Moreover, the supply port 111 which consists of the hole 111 connected with the flow path (gap) 110 is provided in the unit core material 11a of front side, penetrating in the thickness direction. The supply port 111 is a portion to which the uncured resin R is supplied from the outside through one reinforcing fiber base 12a on the front side in the manufacturing process of the molded article 10, as described later. A filler 121 made of the same kind of material as the reinforcing fiber base 12a, 12b is filled in the supply port 111. Such a supply port (hole portion) 111 is filled with a part (supply port resin portion) 131 of the resin portion 13 cured in a state of being impregnated with the filler material 121 in the state of the molded product 10 Become.

  Further, the unit core material 11a on the front side includes a branch path 112a that communicates the gap (flow path) 110 with the surface 11a1 side facing the reinforcing fiber base 12a on the front side. The branch paths 112a are provided at a plurality of locations in the unit core material 11a, and each of the branch passages 112a is formed of a small diameter hole that penetrates the unit core material 11a in the thickness direction. On the other hand, the unit core material 11b on the back side is provided with the branch path 112b which connects the clearance gap (flow path) 110 and the back surface 11b side facing the other reinforcing fiber base 12b on the back side. The branch paths 112b are provided at a plurality of locations in the unit core material 11b, and each of the branch passages 112b is a small diameter hole that penetrates the unit core material 11b in the thickness direction. In the present specification, the branch paths 112a and 112b are collectively referred to as "branch path 112". In the state of the molded article 10, the branch path 112 is filled with a part of the resin portion 13 (branch path resin portion 132) which is hardened in a state of being elongated along the thickness direction.

  The reinforcing fiber base 12 is made of a woven fabric of carbon fibers (carbon fibers) processed into a sheet. As the reinforcing fiber base 12, in addition to carbon fibers, other fibers such as glass fibers may be used, but from the viewpoint of providing high strength, the reinforcing fiber base 12 made of carbon fibers is most preferable. In the case of the present embodiment, the reinforcing fiber base 12a on the front side and the reinforcing fiber base 12b on the rear side are made of carbon fiber woven fabric having the same thickness. In the present specification, the reinforcing fiber base 12a on the front side and the reinforcing fiber base 12b on the back side are collectively referred to as "the reinforcing fiber base 12".

  As shown in FIG. 1, the core material 11 is sandwiched from the front and back sides by a pair of reinforcing fiber bases 12a and 12b, and they have a so-called sandwich structure.

  As a thermosetting resin utilized for the resin part 13, what is generally used by RTM method (for example, two-liquid mixing type epoxy resin) is used. In addition, as a thermosetting resin, a colorless and transparent thing may be utilized and what a coloring agent is added may be utilized.

  In the molded product 10, the cured product of the thermosetting resin that constitutes the resin portion 13 is formed so as to cover the surface of the reinforcing fiber base 12 as well as the inside of the reinforcing fiber base 12. Therefore, in the molded article 10, the resin portion 13 is formed so as to wrap the entire laminate including the core material 11 and the pair of reinforcing fiber bases 12a and 12b.

  Since such a molded article 10 includes the core material 11, the amount of use of the relatively expensive reinforcing fiber base 12 (particularly, carbon fiber) is reduced while maintaining the lightness and high rigidity. Can. Further, since the core material 11 includes the flow path 110, the supply port 111, and the branch path 112, even in the process of manufacturing the molded product 10, even when the supply pressure (injection pressure) of the resin is relatively low, It is easy to distribute uncured resin to the details of the molded article 10.

[Method of producing fiber reinforced resin molded article]
Then, the manufacturing method of the molded article 10 using the shaping | molding apparatus 20 is demonstrated, referring FIGS. FIG. 2 shows a process of setting the laminate X composed of the core material 11 composed of the pair of unit core materials 11a and 11b and the pair of reinforcing fiber substrates 12a and 12b in the fixed mold 31 of the molding apparatus 20. FIG.

  The molding apparatus 20 includes a molding die 30 having a fixed die 31 which is one split die and a movable die 32 (see FIG. 3) which is the other split die. The fixed mold 31 is provided with a molding surface 31 a that forms the back side of the molded article 10. The molding surface 31a has a shape in which the center side is concavely recessed. FIG. 2 shows the mold 30 in the mold open state, and the fixed mold 31 is disposed on a horizontal floor surface so that the molding surface 31 a faces upward. In the mold open state, the movable mold 32 stands by above the fixed mold 31, but is omitted in FIG. On the molding surface 31a of the fixed mold 31 in such a mold-opened state, the laminate X composed of the core material 11 composed of the pair of unit core materials 11a and 11b and the pair of reinforcing fiber substrates 12a and 12b is placed ( Set process). The laminated body X is set to the fixed mold 31 in a state in which the shape of the molding surface 31 a is followed. In the case of the present embodiment, the laminated body X is placed on the molding surface 31 a of the fixed mold 31 with the peripheral edge rising. The laminate X may be preformed into a shape that conforms to the shape of the molding surface 31 a in advance. A binder (for example, a powdery adhesive) is applied in advance to the reinforcing fiber bases 12a and 12b constituting the laminate X, and the laminate X is maintained in a predetermined shape by the action of the binder. . The laminate X may be shaped using the molding surface 31 a by pressing the laminate X against the molding surface 31 a or the like.

  As shown in FIG. 2, the core material 11 of the laminate X is formed by stacking unit core materials 11 a and 11 b having a relatively small thickness. The core material 11 is smaller than the reinforcing fiber substrates 12a and 12b in a plan view, and the peripheral edges of the reinforcing fiber substrates 12a and 12b are arranged outside the peripheral edge of the core material 11. Then, the peripheral edges of the reinforcing fiber bases 12a and 12b are in a state where they are directly overlapped with each other without interposing the core material 11.

  FIG. 3 is an explanatory view showing the movable mold 32 approaching the fixed mold 31 in the mold clamping process. As shown in FIG. 3, the movable mold 32 waiting above the fixed mold 31 descends so as to approach the fixed mold 31, whereby the mold clamping of the mold 30 is performed. (Clamping process). The movable mold 32 is driven to move up and down using a known lifting mechanism (reciprocation mechanism) (not shown) provided with a hydraulic cylinder or the like. Such a movable mold 32 is provided with a molding surface 32 a that forms the front side of the molded article 10. The molding surface 32a has a shape in which the center side is convexly raised. The molding surface 32 a is provided on the inner side (inner surface side) of the movable mold 32 facing the fixed mold 31. As described later, in the mold 30 in the mold clamped state, a space surrounded by the molding surface 32 a of the movable mold 32 and the molding surface 31 a of the fixed mold 31 becomes the cavity C of the mold 30.

  The movable mold 32 generally has a lid shape so as to cover the concave molding surface 31 a of the fixed mold 31. An injection hole (sprue) 33 for injecting a resin into the mold 30 is provided in the central portion of such a movable mold 32. The injection hole 33 is provided so as to penetrate the movable mold 32 and is in communication with the cavity C of the mold 30. The nozzle 41 of the resin supply device 40 is connected to such an injection hole 33.

  The resin supply device 40 is a device for supplying the uncured thermosetting resin to the cavity C of the mold 30. The resin supply device 40 of the present embodiment supplies a two-component mixed epoxy resin (resin R) composed of a main agent and a curing agent into the mold 30. The resin supply device 40 includes a mixing head which discharges the main agent and the curing agent toward the forming die 30 while causing collision mixing. The main agent and the curing agent are respectively contained in predetermined tanks, and are sent to the mixing head at the correct blending ratio by the respective pressure pumps. Then, the main agent and the curing agent collide and mix in the mixing head, and an uncured epoxy resin composed of the mixture is discharged from the nozzle 41 at the tip of the mixing head. The resin discharged from the nozzle 41 is injected into the cavity C via the injection hole 33.

  A seal member 34 surrounding the periphery of the cavity C is provided on the inner peripheral side (inner surface side) of the movable mold 32. When such a seal member 34 is sandwiched between the fixed mold 31 and the movable mold 32 at the time of mold clamping, the gap between the movable mold 32 and the fixed mold 31 around the cavity C is sealed. Be done.

  FIG. 4 is an explanatory view showing a process of injecting the uncured resin R into the cavity C of the clamped mold 30. As shown in FIG. 4, when the mold 30 is clamped, a space surrounded by the molding surface 31 a of the fixed mold 31 and the molding surface 32 a of the movable mold 32 is formed as one cavity C. Ru. The laminated body X is accommodated in the cavity C of the mold 30 which is clamped.

  After clamping, the gas in the cavity C is discharged to the outside by using a negative pressure application mechanism (not shown) provided in the molding apparatus 20, and the inside of the cavity C is brought into a negative pressure state (negative pressure application step). The movable mold 32 of the mold 30 is provided with an exhaust hole (not shown) in the form of a through hole, and the gas in the cavity C is exhausted to the outside by the vacuum pump through the exhaust hole.

  When the negative pressure in the cavity C reaches a predetermined value, a predetermined valve device (not shown) is activated to stop the discharge of gas from the exhaust hole. Then, the inside of the cavity C is kept airtight. After that, the uncured resin (epoxy resin) is injected into the cavity C in such a state by using the resin supply device 40. In the case of the present embodiment, the injection pressure of the resin supply device 40 is relatively low (for example, 0.3 MPa to 5 MPa, preferably 1 MPa or less) in order to suppress the core material 11 of the laminate X from being crushed or the like. Set to).

  The resin supply device 40 injects into the cavity C the collision mixing of the two-component mixed epoxy resin (resin R) composed of the main agent and the curing agent (resin supply step). FIG. 5 is an explanatory view showing how the resin R supplied from the injection holes 33 spreads over the laminate X in the cavity C. As shown in FIG. As shown in FIG. 5, the laminate X is set in the cavity C such that the injection hole 33 is disposed right above the supply port 111. The supply port 111 includes a hole penetrating the unit core material 11 a on the front side, and has a circular shape smaller than the injection hole 33 in a plan view. The supply port 111 is filled with a filler 121 made of carbon fiber woven fabric, and formation of a large void in the unit core material 11 a is suppressed.

  In the cavity C, the resin R supplied from the injection hole 33 is supplied to the supply port 111 of the core material 11 through the reinforcing fiber base 12a on the front side. Since the reinforcing fiber base 12a is made of carbon fiber woven fabric, it is porous and can be easily impregnated with the uncured resin R, and can easily pass the resin R. A part of the resin R supplied from the injection hole 33 moves along the surface of the core material 11 so as to spread in the surface direction inside the reinforcing fiber base 11 on the front side.

  The resin R supplied to the supply port 111 is supplied to the gap (flow path) 110 between the unit core members 11 a and 11 b connected to the supply port 111. The resin R supplied to the gap 110 moves in the gap 110 so as to spread in a plane. When moving in the gap 110, a part of the resin R infiltrates into the branch paths 112 (112a and 112b) provided in the unit core members 11a and 11b, and the reinforcing fiber base 12a on the front side and the back side Are respectively supplied to the reinforcing fiber base 12a. When the resin R is continuously supplied to the injection hole 33 and the cavity C is filled with the resin, the reinforcing fiber base 12a on the front side of the laminate X and the reinforcing fiber base 12b on the rear side are impregnated with the resin R, respectively. It becomes a state. In addition, the gap 110, the supply port 111, and the branch path 112 of the core material 11, which are used as a flow path for spreading the resin R in the laminate X, are all filled with the resin R. .

  Since the core material 11 of the laminate X is made of a foamed resin having a closed cell structure, although the core material 11 can not be positively impregnated with the uncured resin R, as described above, the supply port 111 is provided. By providing the gap (flow passage) 110 and the branch passage 112, the resin R can be efficiently spread between the core material 11 and the respective reinforcing fiber bases 12a and 12b.

  The uncured liquid resin R (epoxy resin) is easily impregnated with the laminate X even if the injection pressure of the resin is low because the viscosity is low (for example, about several mPa · s to several 100 mPa · s) . That is, the epoxy resin can move even in a small space such as the gap 110 or the branch passage 112.

  After the inside of the cavity C of the mold 30 is filled with the resin R, the discharge of the resin R is stopped, and thereafter, the inside of the cavity C is held (pressure holding process). Then, in a state where the pressure in the cavity C is held, curing of the resin R in the mold 30 is performed (curing step). The mold 30 is provided with a heating device (a heater or the like) not shown, and the resin R in the cavity C is cured by heating the mold 30 by the heating device.

  When the resin R in the gap 110 is cured, it becomes a gap resin portion 130 (an example of a flow path resin portion, see FIG. 1), and when the resin R in the supply port 111 cures, it becomes a supply port resin portion 131 (see FIG. 1). When the resin R in the branch passage 112 is cured, it becomes a branch passage resin portion 132 (see FIG. 1). Thereafter, the mold 30 is opened (mold opening process). At the time of mold opening, the movable mold 32 ascends away from the fixed mold 31.

  FIG. 6 is an explanatory view showing a process (demolding process) in which the molded product 10 is demolded from the fixed mold 31. As shown in FIG. After the mold is opened, the molded product 10 left on the molding surface 31 a of the fixed mold 31 is removed from the molding surface 31 a. Thus, the molded article 10 is manufactured using the molding apparatus 20.

  As described above, by forming the flow path (the gap 110) for passing the uncured resin R in the planar direction inside the core material 11, the inside of the cavity C is not affected without affecting the appearance of the molded article 10. And the resin R can be distributed in the laminate X. Even when the injection pressure of the resin R is low or the viscosity of the resin R is high, it is possible to spread the resin R in the cavity C of the mold in a short time.

Second Embodiment
Next, Embodiment 2 of the present invention will be described with reference to FIGS. 7 and 8. FIG. 7 is an explanatory view schematically showing the cross-sectional configuration of the molded article 10A of the second embodiment. FIG. 8 is a view showing the laminate XA in the cavity C in the manufacturing process of the molded article 10A of the second embodiment. It is explanatory drawing which shows a mode that resin R supplied from the injection hole 33 spreads. In the second and subsequent embodiments, the same components as those of the molded article 10 of the first embodiment are given the same reference numerals as the first embodiment, and the detailed description thereof will be omitted as appropriate.

  The molded article 10A of this embodiment, as shown in FIG. 7, includes a core material 11A, a pair of reinforcing fiber substrates 12a and 12b stacked on the surface 11Aa1 and the back surface 11Ab of the core material 11A, and a reinforcing fiber substrate 12a. , 12b, and the like, and is provided with a resin portion 13A made of a thermosetting resin (epoxy resin) to be cured. The core member 11A is formed by overlapping a pair of unit core members 11Aa and 11Ab, and a gap 110A between them is a flow path through which the uncured resin R is passed.

  In the case of the present embodiment, a plurality of spacer portions 113A are provided on the inner surface side (surface side facing the reinforcing fiber base 12b on the back side) of the unit core member 11Aa on the front side. The spacer portion 113A has a convex shape protruding from the inner surface of the unit core member 11a, and the gap 110A is easily formed between the unit core members 11Aa and 11Ab by such a spacer portion 113A. . Such a gap 110A is filled with a gap resin portion (an example of a flow path resin portion) 130A which is a part of the resin portion 13A.

  As in the first embodiment, a supply port 111A filled with a filler material 121A is formed in the unit core member 11Aa on the front side of the core material 11A. The supply port 111A is filled with a supply port resin portion 131A which is a part of the resin portion 13A. Further, as in the first embodiment, a plurality of branch paths 112A are formed in each unit core member 11Aa and 11Ab. Each branch path 112A is filled with a branch path resin portion 132A which is a part of the resin portion 13A.

  As shown in FIG. 8, when the resin R in the uncured state (liquid state) is supplied from the injection hole 33 into the cavity C of the mold in which the laminate XA is set, the resin R is manufactured according to the first embodiment. Similarly to the above, it is supplied into the laminate XA through the reinforcing fiber base 12a on the front side. Then, the resin R supplied to the supply port 111A through the reinforcing fiber base 12a moves in a planar manner in the gap 110A, and is distributed to the branch paths 112A in the middle thereof. In particular, in the case of the present embodiment, since the gap 110A is reliably secured by the spacer portion 113A, the resin R easily moves so as to spread in a planar manner in the gap 110A. Therefore, in the present embodiment, the resin R in the uncured state can be efficiently spread in the cavity C and in the laminate XA (in particular, each reinforcing fiber base 12a, 12b, etc.).

Embodiment 3
Next, Embodiment 3 of the present invention will be described with reference to FIGS. 9 to 11. FIG. 9 is an explanatory view schematically showing a cross-sectional configuration of a molded article 10B of the third embodiment, FIG. 10 is a perspective view of a core material 11B of the third embodiment, and FIG. It is an explanatory view showing signs that resin R supplied from injection hole 33 spreads over layered product XB in cavity C in a manufacturing process of molded article 10B.

  As shown in FIG. 9, a molded article 10B according to the present embodiment includes a core 11B, a pair of reinforcing fiber bases 12a and 12b stacked on a front surface 11B1 and a back surface 11B2 of the core 11B, and a reinforcing fiber base 12a. , 12b and the like, and is provided with a resin portion 13B made of a thermosetting resin (epoxy resin) to be cured. The core material 11B is made of a sheet of foam resin. The core material 11B is provided with a through-hole-shaped supply port 111B through which the uncured resin R is supplied through the reinforcing fiber base 12a on the front side. In the supply port 111B, as shown in FIG. 9, a filler 121B made of carbon fiber woven fabric is filled as in the first embodiment and the like. Then, in the state of the molded product 10B, the inside of the supply port 111B filled with the filler 121B is filled with the supply port resin portion 131B which is a part of the resin portion 13B. Further, on the back surface 11B2 of the core member 11B, a plurality of grooves 110B are provided so as to extend along the surface direction while being connected to the supply port 11B. The groove 110B is a flow path through which the resin R in the uncured state passes, and in particular, the resin R is provided on the back surface 11B2 of the core material 11B so as to easily spread.

  Further, in the state of the molded product 10B, the groove 110B is filled with the groove resin portion 130B which is a part of the resin portion 13B. Further, the core member 11B is provided with a plurality of branch paths 112B provided to penetrate in the thickness direction. Each branch path 112B communicates the groove 110B on the back surface 11B2 side with the surface 11B1 side. Then, in the state of the molded product 10B, each branch path 112B is filled with a branch path resin portion 132B which is a part of the resin portion 13B.

  As shown in FIG. 11, when the resin R in the uncured state (liquid state) is supplied from the injection hole 33 into the cavity C of the mold in which the laminate XB is set, the resin R is manufactured according to the first embodiment. Similarly to the above, it is supplied into the laminate XB through the reinforcing fiber base 12a on the front side. Then, the resin R supplied to the supply port 111B through the reinforcing fiber base 12a is introduced to the groove 110B while being impregnated into the reinforcing fiber base 12b on the back side so as to cover the back surface 11B2 of the core material 11B. Spread in a plane. Further, a part of the resin R supplied from the injection hole 33 spreads in a planar manner while being impregnated in the reinforcing fiber base 12a on the front side in a form along the surface 11B1 of the core material 11B.

  As in the present embodiment, by providing the supply port 111B, the groove 110B, and the branch path 112B in the core material 11B, the resin R in an uncured state can be contained in the cavity C and in the laminate XB (in particular, each reinforcing fiber group Material (12a, 12b, etc.) can be efficiently distributed.

Fourth Embodiment
Next, Embodiment 4 of the present invention will be described with reference to FIGS. 12 and 13. FIG. 12 is an explanatory view schematically showing a cross-sectional configuration of a molded article 10C of the fourth embodiment, and FIG. 13 is a manufacturing process of the molded article 10C of the fourth embodiment. It is explanatory drawing which shows a mode that resin R supplied from the injection hole 33 spreads.

  Molded article 10C of this embodiment, as shown in FIG. 12, includes core material 11C, a pair of reinforcing fiber substrates 12a and 12b stacked on surface 11C1 and back surface 11C2 of core material 11C, and reinforcing fiber substrate 12a. , 12b and the like, and is provided with a resin portion 13C made of a thermosetting resin (epoxy resin) to be cured. The core material 11C is formed of a sheet of foamed resin plate material, and the core material 11C is provided with a through hole-like supply port 111C to which uncured resin is supplied through the reinforcing fiber base 12a on the front side. ing. In the supply port 111C, as shown in FIG. 12, a filler 121C made of carbon fiber woven fabric is filled as in the first embodiment and the like. The inside of the supply port 111C in which the filler 121C is filled is filled with the supply port resin portion 131C which is a part of the resin portion 13C.

  Inside the core material 11C, a hollow portion 110C extending along the surface direction is provided while being connected to the supply port 11B. The hollow portion 110C is a flow path through which the resin R in an uncured state passes, and a plurality of hollow portions 110C are provided in the core material 11C. Further, the core member 11C is provided with a plurality of branch paths 112C that connect the hollow portion 110C and the surface 11C1 side or the back surface 11C2 side of the core member 11C and branch the flow of the resin R flowing in the hollow portion 10C. There is. In the state of the molded product 10C, the inside of the hollow portion 110C is filled with the hollow resin portion 130C which is a part of the resin portion 13C, and the inside of each branch path 112C is a branch path resin portion which is a part of the resin portion 13C. Filled with 132C.

  As shown in FIG. 13, when the resin R in the uncured state (liquid state) is supplied from the injection hole 33 into the cavity C of the mold in which the laminate XC is set, the resin R is manufactured according to the first embodiment. Similarly to the above, it is supplied to the supply port 111C in the laminate XC through the reinforcing fiber base 12a on the front side. Then, a part of the resin R supplied to the supply port 111C through the reinforcing fiber base 12a intrudes into the hollow portion 130C, and further moves in the surface direction along the hollow portion 130C. Since the resin R flowing in the hollow portion 130C is appropriately branched at the branch path 112C, the resin R spreads on the surface 11C1 side and the back surface 11C2 side of the core material 11C. Further, the resin R supplied from the supply port 111C to the reinforcing fiber base 11b on the back side spreads in a planar manner while being impregnated in the reinforcing fiber base 12b on the back side along the back surface 11C2 of the core material 11C. In addition, a part of the resin R supplied from the injection hole 33 spreads in a planar manner while being impregnated into the reinforcing fiber base 12a on the front side, along the surface 11C1 of the core material 11C.

  As in the present embodiment, by providing the supply port 11C, the hollow portion 110C, and the branch path 112C in the core member 11C, the resin R in an uncured state is placed in the cavity C and in the laminate XC (in particular, each reinforcing fiber It can be efficiently distributed to the base materials 12a, 12b, etc.).

Fifth Embodiment
Next, a fifth embodiment of the present invention will be described with reference to FIGS. FIG. 14 is an explanatory view schematically showing a cross-sectional configuration of a molded article 10D of the fifth embodiment, FIG. 15 is a plan view of a core member 14D of the fifth embodiment, and FIG. It is an explanatory view showing signs that resin R supplied from injection hole 33 spreads over layered product XD in cavity C in a manufacturing process of molded article 10D.

  As shown in FIG. 14, a molded article 10D of the present embodiment includes a core 11D, a pair of reinforcing fiber bases 12a and 12b stacked on the surface 11D1 and the back 11D2 of the core 11D, and a reinforcing fiber base 12a. , 12b, and the like, and is provided with a resin portion 13D made of a thermosetting resin (epoxy resin) to be cured. Core material 11D consists of a pair of division core materials 11Da and 11Db divided in the surface direction. Each of the divided core members 11Da and 11Db is a plate made of a foamed resin, and is a longitudinal through flow passage extending along the surface direction and penetrating in the thickness direction between the end surfaces 11D3 and 11D4 adjacent to each other. 113D is formed. The through flow passage 113D is a flow passage for passing the uncured resin R along the surface direction in the manufacturing process. Each of the end surfaces 11D3 and 11D4 has a longitudinal shape, and a convex portion 115D protruding from each of the end surfaces 11D3 and 11D4 is provided at each end of the end surfaces 11D3 and 11D4. The through flow passage 113D is composed of a portion surrounded by the end surfaces 11D3 and 11D4 and the convex portions 114D.

  In the through flow passage 113D, as shown in FIGS. 14 and 15, a filler 123D made of a woven fabric of carbon fibers is filled. The inside of the through flow passage 113D filled with the filler 123D is filled with the through flow passage resin portion 133D which is a part of the resin portion 13D. Further, in the core member 11D (the divided core members 11Da and 11Db), a communication passage 114D is formed which is a hole penetrating in the thickness direction and which communicates the surface 11D1 side and the back surface 11D2 side. A plurality of communication paths 114D are provided in each of the divided core members 11Da and 11Db. In the state of the molded product 10D, the divided core members 11Da and 11Db are filled with the communication passage resin portion 134D which is a part of the resin portion 13D.

  As shown in FIG. 16, when the resin R in the uncured state (liquid state) is supplied from the injection hole 33 into the cavity C of the mold in which the laminate XD is set, the resin R is reinforced on the front side. It supplies to penetration channel 113D in layered product XD through textiles substrate 12a. Then, the resin R supplied to the through flow passage 113D moves along the longitudinal direction and the like of the through flow passage 113D. A part of the resin R that has infiltrated into the through flow passage 113D spreads in a planar manner in a state in which the reinforcing fiber base 12b on the back side is impregnated along the back surface 11D2 of the core material 11D. A part of the resin R supplied from the injection hole 33 spreads in a planar manner while being impregnated into the reinforcing fiber base 12a on the front side, along the surface 11D1 of the core material 11D. In addition, a part of the resin R on the surface 11D1 side of the core material 11D moves to the back surface side 11D2 through the communication passage 114D. In some cases, part of the resin R on the back surface 11D2 side moves to the front surface 11D1 side.

  As in the present embodiment, by forming the through flow passage 113D in the core member 11D by combining the divided core members 11Da and 11Db, the resin R in an uncured state can be formed in the cavity C and in the laminate XD (in particular, The reinforcing fiber base 12a, 12b, etc.) can be efficiently distributed. In particular, by forming the plurality of communication paths 114D in the core material 11D (the divided core materials 11Da and 11Db), the resin R can be efficiently spread further.

Other Embodiments
The present invention is not limited to the embodiments described above with reference to the drawings. For example, the following embodiments are also included in the technical scope of the present invention.

  (1) In the first embodiment, the core material is a stack of a pair of (two) unit core materials. However, the present invention is not limited thereto. For example, three or more unit core materials may be used. A pile may be used as a core material.

  (2) Although the unit core material of comparable thickness was used in the said Embodiment 1, as long as the objective of this invention is not impaired, unit core materials from which thickness mutually differs may be used.

  (3) In the second embodiment, the spacer portion is formed of a part of the unit core material on the front side, but in another embodiment, even if a part of the unit core material on the back side is used as a spacer portion Alternatively, part of both unit core materials may be used as the spacer portion. Also, in some cases, a member other than the unit core material may be used as the spacer portion.

  (4) In the third embodiment, the groove is provided on the back surface side of the core material, but in another embodiment, the groove may be further provided on the surface side of the core material. Preferably, the groove is formed at least on the back surface of the core material.

  (5) In the fifth embodiment, the convex portion for forming the through flow passage may be formed only in one of the divided core members of the pair of adjacent divided core members, and the through flow passage is formed. There is no particular limitation if it is done.

  (6) In another embodiment, a molded article may be manufactured using a thermosetting resin such as a urethane resin or a phenol resin.

  DESCRIPTION OF SYMBOLS 10 ... Fiber reinforced resin molded product (molded product), 11 ... Core material, 110 ... Flow path (gap), 111 ... Supply port, 112 ... Branch path, 12a, 12b ... Reinforcing fiber base material, 13 ... Resin part, 130 ... flow path resin portion (gap resin portion), 131 ... supply port resin portion, 132 ... branch path resin portion, 20 ... molding apparatus, 30 ... molding mold, 31 ... fixed mold (division mold), 31 a ... molding surface , 32: movable mold (divided mold), 32a: molding surface, 40: resin supply device, C: cavity, R: uncured resin, X: laminate

Claims (10)

A laminate having a plate-like core material made of a foamed resin, and a pair of sheet-like reinforcing fiber substrates respectively superimposed on the front and back surfaces of the core material;
It is a fiber reinforced resin molded article provided with the resin part by which the resin of the unhardened state by which the said laminated body was impregnated are hardened | cured,
The core material of the laminate is formed on the front surface and the back surface, or in the inside, and is connected to the flow path while passing through the flow path of the uncured resin along the surface direction and in the thickness direction And a supply port which comprises a hole and through which the uncured resin is supplied from the outside through the reinforcing fiber base,
The said resin part is a fiber reinforced resin molded article which has the flow-path resin part which fills the said flow path, and the supply port resin part which fills the said supply port. The core members of the laminate are stacked on each other so as to form a gap used as the flow path, and each of the core members has a pair of unit core members in a plate shape,
The fiber reinforced resin molded article according to claim 1, wherein the resin portion has a gap resin portion filling the gap as the flow path resin portion.   The fiber reinforced resin molded article according to claim 2, wherein the core material of the laminate is disposed between a pair of the unit core materials and has a spacer portion for securing the gap. The core material of the laminate has at least a groove formed on the back surface and used as the flow path,
The fiber reinforced resin molded article according to claim 1, wherein the resin portion has a groove resin portion filling the groove as the flow path resin portion. The core material of the laminate has a hollow portion formed in the interior and used as the flow path,
The fiber reinforced resin molded article according to claim 1, wherein the resin portion has a hollow resin portion filling the hollow portion as the flow path resin portion. The core material of the laminate connects the flow path and the surface side facing the reinforcing fiber base on one side or the other reinforcing fiber base, and branches the flow of the uncured resin. With a fork
The fiber reinforced resin molded article according to any one of claims 1 to 5, wherein the resin portion has a branch path resin portion filling the branch path. A laminate having a plate-like core material made of a foamed resin, and a pair of sheet-like reinforcing fiber substrates respectively superimposed on the front and back surfaces of the core material;
A fiber reinforced resin molded article comprising: a resin portion obtained by curing an uncured resin impregnated in the laminate while wrapping the laminate.
The core material of the laminated body is a pair of divided cores divided such that a longitudinal through channel extending along the surface direction and penetrating in the thickness direction is formed between the adjacent end faces. Have material,
The said resin part is a fiber reinforced resin molded article which has a penetration flow path resin part which fills the longitudinal-like said penetration flow path. The core material of the laminate includes a hole penetrating in the thickness direction, and a series connecting the surface side facing one of the reinforcing fiber base and the back side facing the other reinforcing fiber base Have a passage,
The fiber reinforced resin molded article according to claim 7, wherein the resin portion has a communication path resin portion filling the communication path. A method of producing a fiber-reinforced resin molded article according to any one of claims 1 to 6,
When an uncured resin is supplied from the outside to the cavity of the mold in which the laminate is accommodated, the uncured resin is supplied to the supply port through the reinforcing fiber substrate, and the resin is And a resin supply step flowing along the flow path. A method of producing a fiber-reinforced resin molded article according to claim 7 or 8, wherein
When the uncured resin is supplied from the outside to the cavity of the mold in which the laminate is accommodated, the uncured resin is supplied to the through flow path through the reinforcing fiber base material, and the resin And a resin supply step of flowing along the through flow passage.

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