JP2020023647A - Fiber reinforced resin molded body - Google Patents
Fiber reinforced resin molded body Download PDFInfo
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- JP2020023647A JP2020023647A JP2018149636A JP2018149636A JP2020023647A JP 2020023647 A JP2020023647 A JP 2020023647A JP 2018149636 A JP2018149636 A JP 2018149636A JP 2018149636 A JP2018149636 A JP 2018149636A JP 2020023647 A JP2020023647 A JP 2020023647A
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- fiber
- sheet
- thermosetting resin
- surface layer
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/20—Making multilayered or multicoloured articles
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/04—Layered products comprising a layer of synthetic resin as impregnant, bonding, or embedding substance
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/28—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer impregnated with or embedded in a plastic substance
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- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J5/00—Manufacture of articles or shaped materials containing macromolecular substances
- C08J5/04—Reinforcing macromolecular compounds with loose or coherent fibrous material
Abstract
Description
本開示は、熱硬化性樹脂と繊維を含む繊維強化樹脂成形体に関する。 The present disclosure relates to a fiber-reinforced resin molded article containing a thermosetting resin and fibers.
従来、基材としてのプリプレグにシートモールディングコンパウンドが積層されてなる繊維強化樹脂成形体が知られている（例えば、特許文献１参照）。このような繊維強化樹脂成形体では、シートモールディングコンパウンドによって、繊維強化樹脂成形体の表面に補強リブやボスのような局所的な突部等が形成される。 BACKGROUND ART Conventionally, a fiber-reinforced resin molded product in which a sheet molding compound is laminated on a prepreg as a base material is known (for example, see Patent Document 1). In such a fiber-reinforced resin molded body, local protrusions such as reinforcing ribs and bosses are formed on the surface of the fiber-reinforced resin molded body by the sheet molding compound.
上述した従来の繊維強化樹脂成形体において、シートモールディングコンパウンドからなる部位と基材との固定の安定化が望まれている。 In the above-mentioned conventional fiber-reinforced resin molded body, it is desired to stabilize the fixation between the portion formed of the sheet molding compound and the base material.
上記課題を解決するためになされた請求項１の発明は、板状の基材の表裏のうち少なくとも一方の面に、第１の熱硬化性樹脂を含むシートモールディングコンパウンドからなる表層構成部が部分的に積層されてなり、前記基材は、前記シートモールディングコンパウンドに含まれる繊維よりも繊維長の長い補強繊維と第２の熱硬化性樹脂とを含み、前記第１の熱硬化性樹脂と前記第２の熱硬化性樹脂とが硬化することにより、前記基材と前記表層構成部とが一体化した繊維強化樹脂成形体であって、前記表層構成部は、前記基材に埋め込まれ、前記基材と反対側を向く面に、突部又は凹部からなる賦形部を有し、前記表層構成部のうち前記賦形部以外の部分は、前記基材と略面一に配置され、前記第２の熱硬化性樹脂は、前記第１の熱硬化性樹脂に比べて、硬化温度が高い、又は、硬化時間が長い、繊維強化樹脂成形体である。 The invention of claim 1 made in order to solve the above-mentioned problem is characterized in that at least one of the front and back surfaces of a plate-like base material has a surface layer constituting part made of a sheet molding compound containing a first thermosetting resin. The base material comprises a reinforcing fiber having a longer fiber length than the fiber contained in the sheet molding compound and a second thermosetting resin, the first thermosetting resin and the By curing the second thermosetting resin, the substrate and the surface layer component is a fiber reinforced resin molded body integrated, wherein the surface layer component is embedded in the substrate, the On the surface facing the opposite side to the base material, has a shaping portion consisting of a protrusion or a concave portion, of the surface layer constituting portion other than the shaping portion is disposed substantially flush with the base material, The second thermosetting resin is the first thermosetting resin. Compared to fat, the curing temperature is high, or long curing time, a fiber-reinforced resin molded body.
ここで、硬化温度が高いとは、熱硬化性樹脂を一定時間で硬化させるために必要な温度が高い、という意味である。また、硬化時間が長いとは、熱硬化性樹脂を一定の温度で硬化させるために必要な時間が長い、という意味である。 Here, a high curing temperature means that a temperature necessary for curing the thermosetting resin in a certain time is high. Further, a long curing time means that the time required for curing the thermosetting resin at a certain temperature is long.
請求項２の発明は、前記基材は、熱硬化性樹脂発泡体からなり連続気泡を有する発泡シートの表裏のうち少なくとも一方の面に、前記補強繊維からなる１対の繊維シートが積層されると共に、前記発泡シートと前記１対の繊維シートとに前記第２の熱硬化性樹脂が含浸してなり、前記発泡シートのうち、厚み方向で前記表層構成部と重なる部分は、厚み方向で前記表層構成部と重ならない部分に比べて、厚み方向に圧縮されている、請求項１に記載の繊維強化樹脂成形体である。 In the invention according to claim 2, the pair of fiber sheets made of the reinforcing fibers are laminated on at least one of the front and back surfaces of the foamed sheet made of a thermosetting resin foam and having open cells. Along with this, the foam sheet and the pair of fiber sheets are impregnated with the second thermosetting resin, and a portion of the foam sheet that overlaps the surface layer component in the thickness direction is the thickness direction. The fiber-reinforced resin molded product according to claim 1, wherein the molded product is compressed in a thickness direction as compared with a portion not overlapping with the surface layer constituting portion.
請求項３の発明は、前記基材の前記少なくとも一方の面には、複数の前記表層構成部が互いに離れて設けられ、各表層構成部に前記賦形部が設けられている、請求項１又は２に記載の繊維強化樹脂成形体である。 The invention according to claim 3 is that, on the at least one surface of the base material, a plurality of the surface layer components are provided apart from each other, and the shaping portion is provided on each surface layer component. Or a fiber-reinforced resin molded product according to 2.
請求項４の発明は、第１の熱硬化性樹脂を含むシートモールディングコンパウンドと、前記シートモールディングコンパウンドに含まれる繊維よりも繊維長の長い補強繊維と第２の熱硬化性樹脂とを含む基材用シートと、を用意し、前記シートモールディングコンパウンドを前記基材用シートの表裏のうち少なくとも一方の面に部分的に重ね、加熱プレス成形により、前記第１の熱硬化性樹脂と前記第２の熱硬化性樹脂とを硬化させて、前記基材用シートから形成した基材と、前記シートモールディングコンパウンドから形成した表層構成部と、を一体化する繊維強化樹脂成形体の製造方法であって、前記表層構成部を形成する際に、前記表層構成部のうち前記基材と反対側を向く面に、突部又は凹部からなる賦形部を形成し、前記第２の熱硬化性樹脂として、前記第１の熱硬化性樹脂に比べて、前記加熱プレス成形の温度において硬化時間が長いものを用いる、繊維強化樹脂成形体の製造方法である。 The invention according to claim 4 is a substrate comprising: a sheet molding compound containing a first thermosetting resin; a reinforcing fiber having a longer fiber length than fibers contained in the sheet molding compound; and a second thermosetting resin. Sheet, the sheet molding compound is partially overlapped on at least one of the front and back surfaces of the base sheet, and the first thermosetting resin and the second By curing a thermosetting resin, a substrate formed from the base sheet, and a surface layer component formed from the sheet molding compound, a method for manufacturing a fiber-reinforced resin molded body, When forming the surface layer forming portion, a shaping portion including a protrusion or a concave portion is formed on a surface of the surface layer forming portion facing the side opposite to the base material, and the second heat As of resin, the than the first thermosetting resin, the use of heating as long curing time at a temperature of the press molding, a method for producing a fiber-reinforced resin molded body.
請求項５の発明は、前記基材用シートとして、熱硬化性樹脂発泡体からなり連続気泡を有する発泡シートの表裏のうち少なくとも一方の面に、前記補強繊維からなる繊維シートが積層され、前記第２の熱硬化性樹脂が含浸したものを用いる、請求項４に記載の繊維強化樹脂成形体の製造方法である。 The invention according to claim 5, wherein, as the base material sheet, a fiber sheet made of the reinforcing fiber is laminated on at least one of the front and back surfaces of a foamed sheet made of a thermosetting resin foam and having open cells, The method for producing a fiber-reinforced resin molded product according to claim 4, wherein a resin impregnated with a second thermosetting resin is used.
請求項６の発明は、前記加熱プレス成形を行うための成形金型の成形面に、前記表層構成部の前記賦形部を形成するための表面形成部を複数設けておき、前記加熱プレス成形を行うにあたって、前記シートモールディングコンパウンドを複数枚用意し、それら複数枚のシートモールディングコンパウンドを、互いに離して前記成形面の前記表面形成部に重ねる、請求項４又は５に記載の繊維強化樹脂成形体の製造方法である。 The invention according to claim 6 is characterized in that a plurality of surface forming portions for forming the shaping portion of the surface layer forming portion are provided on a molding surface of a molding die for performing the hot press molding, and the hot press molding is performed. When performing the above, a plurality of sheet molding compounds are prepared, and the plurality of sheet molding compounds are overlapped on the surface forming portion of the molding surface while being separated from each other, the fiber reinforced resin molded article according to claim 4 or 5. It is a manufacturing method of.
請求項１，４の発明では、基材に含まれる第２の熱硬化性樹脂が、シートモールディングコンパウンドに含まれる第１の熱硬化性樹脂よりも、硬化温度が高いか、又は、硬化時間が長くなっている。従って、繊維強化樹脂成形体の製造時に、第１の熱硬化性樹脂を硬化させてから、第２の熱硬化性樹脂を硬化させることができ、第１の熱硬化性樹脂が硬化して硬くなった表層構成部の形状に、基材を追従させた状態に形成することが容易となる。これにより、表層構成部が基材に埋め込まれて、シートモールディングコンパウンドからなる表層構成部と基材との固定の安定を図ることが可能となる。また、表層構成部のうち突部又は凹部からなる賦形部以外の部分を、基材と略面一に配置することで、突部の突出量又は凹部の深さについて寸法精度の安定化を図ることが可能となる。 According to the first and fourth aspects of the present invention, the second thermosetting resin contained in the base material has a higher curing temperature than the first thermosetting resin contained in the sheet molding compound, or the curing time is longer. It is getting longer. Therefore, at the time of manufacturing the fiber-reinforced resin molded body, the first thermosetting resin can be cured before the second thermosetting resin is cured, and the first thermosetting resin is cured and hardened. It becomes easy to form the substrate in a state in which the substrate follows the shape of the resulting surface layer constituting portion. Thereby, the surface layer component is embedded in the base material, and it is possible to stably fix the surface layer component made of the sheet molding compound to the substrate. In addition, by arranging a portion other than the shaping portion formed of the protrusion or the concave portion of the surface layer constituting portion substantially flush with the base material, stabilization of dimensional accuracy with respect to the protrusion amount of the protrusion or the depth of the concave portion is achieved. It becomes possible to plan.
請求項２の発明では、基材には、連続気泡を有する発泡シートが設けられる。そして、発泡シートのうち厚み方向で表層構成部と重なる部分は、厚み方向で表層構成部と重ならない部分に比べて、厚み方向に圧縮されている。本発明によれば、発泡シートのうち厚み方向で表層構成部と重なる部分が圧縮されることによって、表層構成部を基材に埋め込まれた状態に形成し易くすることができる。また、請求項５の発明によっても、発泡シートのうち厚み方向でシートモールディングコンパウンドと重なる部分を圧縮することにより、表層構成部を基材に埋め込まれた状態に形成し易くすることができる。 According to the second aspect of the present invention, the base material is provided with a foam sheet having open cells. The portion of the foam sheet that overlaps with the surface layer component in the thickness direction is compressed in the thickness direction as compared with the portion that does not overlap with the surface layer component in the thickness direction. ADVANTAGE OF THE INVENTION According to this invention, the part which overlaps with a surface layer component in a thickness direction among foamed sheets is compressed, and it can make it easy to form a surface layer component in the state embedded in the base material. According to the fifth aspect of the present invention, by compressing a portion of the foamed sheet that overlaps the sheet molding compound in the thickness direction, the surface layer constituting portion can be easily formed in a state embedded in the base material.
請求項３，６の発明では、突部又は凹部からなる賦形部が複数設けられる。本発明によれば、複数の賦形部全てに亘って１つのシートモールディングコンパウンドからなる表層構成部が形成される場合に比べて、表層構成部を形成するためのシートモールディングコンパウンドの使用量を少なくすることが可能となる。 According to the third and sixth aspects of the present invention, a plurality of shaping portions including protrusions or recesses are provided. ADVANTAGE OF THE INVENTION According to this invention, compared with the case where the surface layer component part which consists of one sheet molding compound is formed over all the several shaping parts, the usage of the sheet molding compound for forming a surface layer component part is reduced. It is possible to do.
図１には、本開示の一実施形態に係る繊維強化樹脂成形体１０が示されている。本実施形態の繊維強化樹脂成形体１０は、例えば、自転車の部品等に用いられる。繊維強化樹脂成形体１０は、板状の基材２０を有し、その基材２０の表裏の一方の面である第１面２０Ａから、突部（具体的には、補強リブ１３とボス１４）が突出した構成となっている。なお、本実施形態では、基材２０の他方の面である第２面２０Ｂ（図２参照）は、平坦面となっているが、第２面２０Ｂは、凹凸を有していてもよいし、湾曲面であってもよい。 FIG. 1 shows a fiber-reinforced resin molded body 10 according to an embodiment of the present disclosure. The fiber-reinforced resin molded body 10 of the present embodiment is used for, for example, bicycle parts. The fiber-reinforced resin molded body 10 has a plate-shaped base material 20, and a projection (specifically, a reinforcing rib 13 and a boss 14 ) Protrudes. In the present embodiment, the second surface 20B (see FIG. 2), which is the other surface of the substrate 20, is a flat surface, but the second surface 20B may have irregularities. It may be a curved surface.
具体的には、図２に示されるように、繊維強化樹脂成形体１０は、基材２０の第１面２０Ａに、補強リブ１３とボス１４を構成する表層構成部３０が部分的に積層されてなる。表層構成部３０は、繊維と第１の熱硬化性樹脂を含むシートモールディングコンパウンド（以下、ＳＭＣということとする。）からなる。 Specifically, as shown in FIG. 2, in the fiber-reinforced resin molded body 10, the surface layer constituting portion 30 constituting the reinforcing rib 13 and the boss 14 is partially laminated on the first surface 20 </ b> A of the base material 20. It becomes. The surface layer constituting section 30 is made of a sheet molding compound (hereinafter, referred to as SMC) containing fibers and a first thermosetting resin.
図２及び図３に示されるように、表層構成部３０は、基材２０と反対側を向く面に、賦形部を有する構成となっている。具体的には、表層構成部３０は、薄板状をなして基材２０に重ねられるベース部３１と、そのベース部３１のうち基材２０と反対側を向く露出面３１Ａから突出する上述の賦形部としての表面突部３２と、からなる。また、本実施形態では、補強リブ１３を構成する表層構成部３０と、ボス１４を構成する表層構成部３０とが、別に設けられ、互いに離れて配置されている。そして、各表層構成部３０の表面突部３２が、それぞれ補強リブ１３とボス１４を構成している。 As shown in FIGS. 2 and 3, the surface layer forming section 30 has a configuration in which a shaping section is provided on a surface facing the side opposite to the base material 20. Specifically, the surface layer constituting portion 30 is formed of a base portion 31 which is formed on the base material 20 in the form of a thin plate, and the above-described additional portion projecting from the exposed surface 31A of the base portion 31 facing the opposite side to the base material 20. And a surface projection 32 as a shape part. Further, in the present embodiment, the surface layer constituting section 30 constituting the reinforcing rib 13 and the surface layer constituting section 30 constituting the boss 14 are separately provided and arranged apart from each other. The surface protrusions 32 of each surface layer constituting portion 30 constitute the reinforcing rib 13 and the boss 14, respectively.
基材２０は、発泡シート２１の表裏の両面に、１対の繊維シート２２，２２が積層された構成を有する。発泡シート２１は、熱硬化性樹脂からなる連続気泡発泡体で構成され、発泡シート２１には第２の熱硬化性樹脂が含浸している。また、本実施形態では、繊維シート２２は、表層構成部３０を構成するＳＭＣの繊維よりも繊維長が長い補強繊維から構成されていると共に、繊維シート２２にも第２の熱硬化性樹脂が含浸している。そして、発泡シート２１と１対の繊維シート２２，２２に含浸した第２の熱硬化性樹脂が硬化することによって発泡シート２１と１対の繊維シート２２，２２とが一体化されている。 The base material 20 has a configuration in which a pair of fiber sheets 22, 22 are laminated on both front and back surfaces of a foam sheet 21. The foam sheet 21 is formed of an open-cell foam made of a thermosetting resin, and the foam sheet 21 is impregnated with a second thermosetting resin. In the present embodiment, the fiber sheet 22 is made of a reinforcing fiber having a longer fiber length than the fiber of the SMC forming the surface layer forming portion 30, and the second thermosetting resin is also applied to the fiber sheet 22. Impregnated. Then, the foam sheet 21 and the pair of fiber sheets 22, 22 are integrated by curing the second thermosetting resin impregnated in the foam sheet 21 and the pair of fiber sheets 22, 22.
ここで、表層構成部３０のベース部３１は、基材２０に埋め込まれていて、基材２０に密着している。表層構成部３０のうち表面突部３２以外の部分は、基材２０と略面一に配置されている。具体的には、表層構成部３０のベース部３１の露出面３１Ａと基材２０の第１面２０Ａとが略面一となっている。 Here, the base portion 31 of the surface layer constituting portion 30 is embedded in the base material 20 and is in close contact with the base material 20. Portions of the surface layer constituting portion 30 other than the surface protrusions 32 are arranged substantially flush with the base material 20. Specifically, the exposed surface 31A of the base portion 31 of the surface layer constituting portion 30 and the first surface 20A of the base material 20 are substantially flush.
また、基材２０の発泡シート２１のうち、厚み方向で表層構成部３０と重なる部分は、厚み方向で表層構成部３０と重ならない部分に比べて、ベース部３１の厚みと略同じ分だけ圧縮されて薄くなっている。 Further, in the foamed sheet 21 of the base material 20, a portion overlapping the surface layer component 30 in the thickness direction is compressed by substantially the same thickness as the base portion 31 in comparison with a portion not overlapping the surface layer component 30 in the thickness direction. Being thinner.
繊維強化樹脂成形体１０では、表層構成部３０に含まれる第１の熱硬化性樹脂と、基材２０に含浸された第２の熱硬化性樹脂とが硬化することにより、表層構成部３０と基材２０とが一体化している。ここで、第２の熱硬化性樹脂は、第１の熱硬化性樹脂よりも、熱硬化し難くなっている。即ち、第２の熱硬化性樹脂は、第１の熱硬化性樹脂よりも、一定の温度で硬化するために必要な時間である硬化時間が長いか、又は、一定時間で硬化するために必要な温度である硬化温度が高くなっている。 In the fiber-reinforced resin molded body 10, the first thermosetting resin included in the surface layer forming section 30 and the second thermosetting resin impregnated in the base material 20 are cured, so that the surface layer forming section 30 The substrate 20 is integrated. Here, the second thermosetting resin is harder to thermoset than the first thermosetting resin. That is, the second thermosetting resin has a longer curing time, which is a time required for curing at a constant temperature, or a longer curing time than the first thermosetting resin. The curing temperature, which is a high temperature, is high.
繊維強化樹脂成形体１０の各構成要素、即ち、発泡シート２１、繊維シート２２、第１の熱硬化性樹脂、第２の熱硬化性樹脂、及び、ＳＭＣの詳細については、以下のようになっている。 Details of each component of the fiber-reinforced resin molded body 10, that is, the foam sheet 21, the fiber sheet 22, the first thermosetting resin, the second thermosetting resin, and the SMC are as follows. ing.
発泡シート２１を構成する発泡体としては、例えば、ウレタン樹脂発泡体、メラミン樹脂発泡体等が挙げられる。また、発泡シート２１の厚みは、例えば、基材２０の厚み０．５〜３０ｍｍに対して、０．１〜２９．５ｍｍとなっている。 Examples of the foam constituting the foam sheet 21 include a urethane resin foam and a melamine resin foam. The thickness of the foam sheet 21 is, for example, 0.1 to 29.5 mm with respect to the thickness of the base material 20 of 0.5 to 30 mm.
繊維シート２２としては、例えば、炭素繊維、ガラス繊維、アラミド繊維等の繊維によって構成されたものを用いることができる。また、繊維シート２２は、例えば、織物、編み物、不織布等の形態であってもよい。織物の織り方としては、平織、綾織、朱子織、三軸織等が挙げられる。また、繊維シート２２は、一方向又は複数方向に配向した繊維から構成されていてもよい。なお、軽量化と剛性向上の観点から、繊維シート２２を構成する繊維としては、炭素繊維が好ましい。また、剛性向上の観点から、繊維シート２２は、繊維織物から構成されることが好ましい。熱硬化性樹脂が含浸した繊維シート２２としては、例えば、プリプレグが挙げられる。 As the fiber sheet 22, for example, a sheet made of fibers such as carbon fiber, glass fiber, and aramid fiber can be used. Further, the fiber sheet 22 may be in the form of, for example, a woven fabric, a knitted fabric, or a nonwoven fabric. Examples of the weaving method of the woven fabric include plain weave, twill weave, satin weave, and triaxial weave. Further, the fiber sheet 22 may be composed of fibers oriented in one direction or a plurality of directions. From the viewpoint of weight reduction and improvement in rigidity, carbon fibers are preferable as the fibers constituting the fiber sheet 22. Further, from the viewpoint of improving rigidity, the fiber sheet 22 is preferably made of a fiber fabric. Examples of the fiber sheet 22 impregnated with a thermosetting resin include prepreg.
また、繊維シート２２を構成する繊維としては、ＳＭＣの繊維より繊維長が長いものが好ましく、例えば、ＳＭＣの繊維よりも数平均繊維長が長いものが挙げられる。また、繊維シート２２としては、例えば、連続繊維又は不連続繊維からなるものが挙げられる。繊維シート２２は、剛性の観点から、５ｍｍ以上の繊維長のものが好ましい。また、繊維シート２２は、剛性、第２の熱硬化性樹脂の含浸性、軽量性の観点から、目付量が９０〜４００ｇ／ｍ２のものが好ましい。 The fibers constituting the fiber sheet 22 preferably have a fiber length longer than that of the SMC fibers, and include, for example, fibers having a number average fiber length longer than that of the SMC fibers. Examples of the fiber sheet 22 include those made of continuous fibers or discontinuous fibers. The fiber sheet 22 preferably has a fiber length of 5 mm or more from the viewpoint of rigidity. The fiber sheet 22 preferably has a basis weight of 90 to 400 g / m 2 from the viewpoint of rigidity, impregnation of the second thermosetting resin, and lightness.
ＳＭＣとしては、例えば、炭素繊維、ガラス繊維等の繊維を含むものを用いることができる。なお、軽量化と剛性向上の観点から、ＳＭＣを構成する繊維としては、炭素繊維が好ましい。ＳＭＣを構成する繊維としては、３０ｍｍ以下の繊維長のものが好ましい。 As the SMC, for example, those containing fibers such as carbon fiber and glass fiber can be used. From the viewpoint of weight reduction and improvement in rigidity, carbon fibers are preferable as the fibers constituting the SMC. The fiber constituting the SMC preferably has a fiber length of 30 mm or less.
ＳＭＣの第１の熱硬化性樹脂としては、例えば、エポキシ樹脂、ビニールエステル樹脂、不飽和ポリエステル樹脂、フェノール樹脂、エポキシアクリレート樹脂、又は、これらの樹脂のうち２種類以上の樹脂の混合樹脂、等が挙げられる。 Examples of the first thermosetting resin of the SMC include an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, a phenol resin, an epoxy acrylate resin, or a mixed resin of two or more of these resins. Is mentioned.
なお、表層構成部３０に設けられる補強リブ１３としては、例えば、突出量が０．１〜３０ｍｍで、最小幅が０．５〜１０ｍｍであるものが挙げられる。また、ボス１４としては、例えば、突出量が０．１〜３０ｍｍで、内径と外径の差が０．５〜１０．０ｍｍのものが挙げられる。 In addition, as the reinforcing rib 13 provided in the surface layer constituting portion 30, for example, a rib having a protrusion amount of 0.1 to 30 mm and a minimum width of 0.5 to 10 mm is exemplified. The boss 14 has a protrusion amount of, for example, 0.1 to 30 mm and a difference between the inner diameter and the outer diameter of 0.5 to 10.0 mm.
基材２０の第２の熱硬化性樹脂としては、例えば、エポキシ樹脂、フェノール樹脂、又は、これらの樹脂の混合樹脂、等が挙げられる。これらの樹脂を用いることにより、剛性の向上が図られる。 Examples of the second thermosetting resin of the base material 20 include an epoxy resin, a phenol resin, and a mixed resin of these resins. By using these resins, the rigidity can be improved.
繊維強化樹脂成形体１０は、以下のようにして製造される。まず、複数のシートが用意される。具体的には、連続気泡を有する発泡シート２１、１対の繊維シート２２，２２、及び、第１の熱硬化性樹脂を含むＳＭＣ３０Ｓ、が用意される。発泡シート２１と各繊維シート２２には、第２の熱硬化性樹脂を含浸させておく。第２の硬化性樹脂としては、第１の硬化性樹脂に比べて、硬化温度が高いか、又は、硬化時間が長いものを用いればよい。なお、第２の熱硬化性樹脂は、発泡シート２１と繊維シート２２のうち一方にのみ含浸させておいてもよい。また、発泡シート２１としては、後述する加熱プレス成形での圧縮容易性、第２の熱硬化性樹脂の含浸性、軽量性、剛性の観点から、密度が５〜８０ｋｇ／ｍ３のものを用いるのが好ましい。 The fiber-reinforced resin molded body 10 is manufactured as follows. First, a plurality of sheets are prepared. Specifically, a foam sheet 21 having open cells, a pair of fiber sheets 22, 22, and an SMC 30S including a first thermosetting resin are prepared. The foam sheet 21 and each fiber sheet 22 are impregnated with a second thermosetting resin. As the second curable resin, a resin having a higher curing temperature or a longer curing time than the first curable resin may be used. Note that the second thermosetting resin may be impregnated into only one of the foam sheet 21 and the fiber sheet 22. Further, as the foamed sheet 21, one having a density of 5 to 80 kg / m 3 is used from the viewpoint of ease of compression in hot press molding described later, impregnation of the second thermosetting resin, light weight, and rigidity. Is preferred.
本実施形態の例では、第１の熱硬化性樹脂としてビニールエステル樹脂とエポキシアクリレート樹脂との混合樹脂を用い、第２の熱硬化性樹脂として第１の熱硬化性樹脂よりも硬化時間が高く且つ硬化時間も長いフェノール樹脂を用いた。また、発泡シート２１としてウレタン樹脂発泡体からなるものを用い、繊維シート２２として炭素繊維織物からなるプリプレグ、ＳＭＣとして炭素繊維を有するものを用いた。 In the example of the present embodiment, a mixed resin of a vinyl ester resin and an epoxy acrylate resin is used as the first thermosetting resin, and the curing time is higher than that of the first thermosetting resin as the second thermosetting resin. A phenol resin having a long curing time was used. Further, a foam sheet 21 made of urethane resin foam was used, a fiber sheet 22 was made of a prepreg made of carbon fiber fabric, and an SMC having carbon fibers was used.
次いで、発泡シート２１と繊維シート２２とＳＭＣ３０Ｓとが重ねられて、成形金型７０によって加熱プレス成形される。 Next, the foam sheet 21, the fiber sheet 22, and the SMC 30 </ b> S are superimposed on each other and are hot-pressed by a molding die 70.
図４には、成形金型７０が示されている。同図に示されるように、成形金型７０は、上型７１と下型７２とから構成される。本実施形態では、上型７１の成形面は、平坦となっている一方、下型７２の成形面には、補強リブ１３とボス１４をそれぞれ形成するための表面形成部として成形凹部７３，７４が設けられている。詳細には、成形凹部７３は、溝状となっていると共に、成形凹部７４は、円筒状の凹部となっている。なお、下型７２の成形面のうち成形凹部７３，７４が設けられた部分以外は、平坦になっている。 FIG. 4 shows a molding die 70. As shown in the figure, the molding die 70 includes an upper die 71 and a lower die 72. In the present embodiment, the molding surface of the upper mold 71 is flat, while the molding surface of the lower mold 72 is formed as molding concave portions 73, 74 as surface forming portions for forming the reinforcing ribs 13 and the bosses 14, respectively. Is provided. Specifically, the molding recess 73 has a groove shape, and the molding recess 74 has a cylindrical recess. It should be noted that the molding surface of the lower mold 72 is flat except for the portions where the molding recesses 73 and 74 are provided.
加熱プレス成形を行うにあたっては、まず、成形金型７０が型開き状態にされて、ＳＭＣ３０Ｓが、下型７２の成形凹部７３，７４を覆うように下型７２の成形面に部分的に重ねられる（図４及び図６（Ａ）参照）。本実施形態では、成形凹部７３を覆うＳＭＣ３０Ｓと成形凹部７４を覆うＳＭＣ３０Ｓとは、別に設けられ、互いに離れて配置される。また、各ＳＭＣ３０Ｓは、各成形凹部７３，７４を満たすのに必要な量、即ち、補強リブ１３、ボス１４の形成に必要な量、よりも多い量となっている。 In performing the heat press molding, first, the molding die 70 is opened, and the SMC 30S is partially overlapped with the molding surface of the lower die 72 so as to cover the molding recesses 73 and 74 of the lower die 72. (See FIGS. 4 and 6A). In the present embodiment, the SMC 30S that covers the molding concave portion 73 and the SMC 30S that covers the molding concave portion 74 are provided separately and are separated from each other. Further, the amount of each SMC 30S is larger than the amount required to fill each of the molding recesses 73 and 74, that is, the amount required to form the reinforcing ribs 13 and the bosses 14.
そして、発泡シート２１の両面に１対の繊維シート２２，２２が重ねられた基材用シート２０Ｓが、ＳＭＣ３０Ｓの上に重ねられ、成形金型７０が型閉じされる。すると、図５及び図６（Ｂ）に示されるように、加熱されて流動性が生じたＳＭＣ３０Ｓが、成形凹部７３，７４に流れ込む。また、ＳＭＣ３０Ｓのうち成形凹部７３，７４に入りきれなかった余剰部分は、薄板状となって成形凹部７３，７４の上に残る。一方、基材用シート２０Ｓ（特に、発泡シート２１）は、成形金型７０に加熱プレスされることにより圧縮される。 Then, the base sheet 20S in which the pair of fiber sheets 22 and 22 are overlapped on both sides of the foam sheet 21 is overlapped on the SMC 30S, and the molding die 70 is closed. Then, as shown in FIG. 5 and FIG. 6 (B), the SMC 30 </ b> S that has been heated and has flowability flows into the molding recesses 73 and 74. The surplus portion of the SMC 30S that could not be accommodated in the molding recesses 73 and 74 remains in the shape of a thin plate on the molding recesses 73 and 74. On the other hand, the base material sheet 20S (particularly, the foamed sheet 21) is compressed by being hot-pressed in the molding die 70.
ここで、上述のように、基材用シート２０Ｓの第２の熱硬化性樹脂は、ＳＭＣ３０Ｓの第１の熱硬化性樹脂よりも、硬化時間が長くなっている。従って、図６（Ｂ）に示されるように、成形金型７０内で、ＳＭＣ３０Ｓの第１の熱硬化性樹脂が、第２の熱硬化性樹脂よりも先に硬化することとなる（図６（Ｂ）、図７（Ａ）及び図７（Ｂ）では、第１と第２の熱硬化性樹脂のうち硬化しきった熱硬化性樹脂を含む部分が灰色で示されている）。なお、ここで、図８には、成形金型７０内での一定の加熱温度における、第１及び第２の熱硬化性樹脂の硬化度と加熱時間との関係が概念的に示されていて、図７において第１と第２の熱硬化性樹脂がそれぞれ硬化しきったタイミングＴ１、Ｔ２のときが、それぞれ図６（Ｂ）、図７（Ｂ）に示す状態である。 Here, as described above, the curing time of the second thermosetting resin of the base sheet 20S is longer than that of the first thermosetting resin of the SMC 30S. Therefore, as shown in FIG. 6 (B), the first thermosetting resin of the SMC 30S is cured before the second thermosetting resin in the molding die 70 (FIG. 6). (B), FIG. 7 (A) and FIG. 7 (B), the portion including the completely cured thermosetting resin among the first and second thermosetting resins is shown in gray). Here, FIG. 8 conceptually shows the relationship between the degree of curing of the first and second thermosetting resins and the heating time at a constant heating temperature in the molding die 70. In FIG. 7, timings T1 and T2 at which the first and second thermosetting resins are completely cured are the states shown in FIGS. 6B and 7B, respectively.
第１の熱硬化性樹脂が硬化すると、ＳＭＣ３０Ｓから表層構成部３０が形成される。このとき、ＳＭＣ３０Ｓのうち成形凹部７３，７４に入り込んだ部分により、それぞれ補強リブ１３とボス１４（即ち、各表面突部３２）が形成されると共に、ＳＭＣ３０Ｓのうち成形凹部７３，７４に入りきらなかった薄板状の余剰部分により、ベース部３１が形成される。 When the first thermosetting resin cures, the surface layer constituting section 30 is formed from the SMC 30S. At this time, the reinforcing ribs 13 and the bosses 14 (that is, the respective surface projections 32) are respectively formed by the portions of the SMC 30S that have entered the forming recesses 73 and 74, and the portions of the SMC 30S that have entered the forming recesses 73 and 74 are completely removed. The base part 31 is formed by the thin plate-shaped surplus part.
ここで、図８に示されるように、第１の熱硬化性樹脂が硬化しきってからもタイミングＴ２までは、第２の熱硬化性樹脂は硬化しきっていないので、基材用シート２０Ｓが硬化しきっておらず、図６（Ｂ）から図７（Ａ）への変化に示されるように、基材用シート２０Ｓを変形させて表層構成部３０の形状に追従させることができる。これにより、ベース部３１を基材用シート２０Ｓに埋め込んで、ベース部３１と基材用シート２０Ｓとのうち下型７２と対向する部分同士を略面一にすることができる。また、このとき、基材用シート２０Ｓの発泡シート２１のうち、厚み方向で表層構成部３０のベース部３１と重なる部分は、厚み方向でベース部３１と重ならない部分に比べて、ベース部３１の厚みと略同じ分だけ圧縮されることとなる。 Here, as shown in FIG. 8, since the second thermosetting resin is not completely cured until timing T2 even after the first thermosetting resin is completely cured, the base material sheet 20S is cured. As shown in the change from FIG. 6 (B) to FIG. 7 (A), the base sheet 20S can be deformed to conform to the shape of the surface layer constituting portion 30. Thereby, the base part 31 is embedded in the base material sheet 20S, and the portions of the base part 31 and the base material sheet 20S facing the lower mold 72 can be made substantially flush. At this time, in the foamed sheet 21 of the base material sheet 20S, a portion overlapping the base portion 31 of the surface layer constituting portion 30 in the thickness direction is compared with a portion not overlapping the base portion 31 in the thickness direction. Will be compressed by approximately the same thickness as the thickness.
図７（Ｂ）に示されるように、基材用シート２０Ｓの第２の熱硬化性樹脂が硬化しきると、基材用シート２０Ｓが硬化する。このとき、発泡シート２１と１対の繊維シート２２，２２とが一体化して基材２０が形成されると共に、基材２０と表層構成部３０とが一体化する（図５参照）。 As shown in FIG. 7B, when the second thermosetting resin of the base sheet 20S is completely cured, the base sheet 20S is cured. At this time, the base sheet 20 is formed by integrating the foam sheet 21 and the pair of fiber sheets 22, 22, and the base layer 20 and the surface layer forming section 30 are integrated (see FIG. 5).
次いで、成形金型７０が型開きされて、基材２０と表層構成部３０が成形金型７０から外され、図２に示される繊維強化樹脂成形体１０が完成する。 Next, the molding die 70 is opened, and the base material 20 and the surface layer constituting portion 30 are removed from the molding die 70, and the fiber-reinforced resin molded body 10 shown in FIG. 2 is completed.
本実施形態に係る繊維強化樹脂成形体１０の構成及び繊維強化樹脂成形体１０の製造方法に関する説明は以上である。次に、繊維強化樹脂成形体１０及びその製造方法の作用効果について説明する。 The description of the configuration of the fiber-reinforced resin molded body 10 and the method of manufacturing the fiber-reinforced resin molded body 10 according to the embodiment has been described above. Next, the function and effect of the fiber-reinforced resin molded body 10 and the method of manufacturing the same will be described.
本実施形態の繊維強化樹脂成形体１０及びその製造方法では、基材２０に含まれる第２の熱硬化性樹脂が、ＳＭＣに含まれる第１の熱硬化性樹脂よりも、硬化温度が高いか、又は、硬化時間が長くなっている。従って、繊維強化樹脂成形体１０の製造時に、ＳＭＣの第１の熱硬化性樹脂を硬化させてから、基材用シート２０Ｓの第２の熱硬化性樹脂を硬化させることができ、第１の熱硬化性樹脂が硬化して硬くなった表層構成部３０の形状に、基材２０を追従させた状態に形成することが容易となる。これにより、表層構成部３０が基材２０に埋め込まれて、ＳＭＣからなる表層構成部３０と基材２０との固定の安定を図ることが可能となる。また、表層構成部３０のベース部３１を、基材と略面一に配置することで、表面突部３２の突出量について寸法精度の安定化を図ることが可能となる。しかも、ベース部３１が基材２０の第１面２０Ａと略面一になることにより、下型７２と基材用シート２０Ｓとの間に、ベース部３１の略厚み分のスペースが生じることを防ぐことができ、基材２０の厚み精度の向上が図られると共に、基材２０の設計において設計自由度の向上を図ることができる。 In the fiber-reinforced resin molded body 10 and the method of manufacturing the same according to the present embodiment, the second thermosetting resin contained in the base material 20 has a higher curing temperature than the first thermosetting resin contained in the SMC. Or, the curing time is long. Therefore, at the time of manufacturing the fiber-reinforced resin molded body 10, the first thermosetting resin of the SMC can be cured, and then the second thermosetting resin of the base sheet 20S can be cured. It becomes easy to form the base layer 20 in a state where the base layer 20 follows the shape of the surface layer constituting section 30 in which the thermosetting resin is hardened by hardening. Thereby, the surface layer component 30 is embedded in the base material 20, and the fixing between the surface layer component 30 made of SMC and the substrate 20 can be stabilized. In addition, by arranging the base portion 31 of the surface layer forming portion 30 substantially flush with the base material, it is possible to stabilize the dimensional accuracy of the protrusion amount of the surface protrusion 32. In addition, since the base portion 31 is substantially flush with the first surface 20A of the base material 20, a space corresponding to the thickness of the base portion 31 is generated between the lower mold 72 and the base material sheet 20S. Thus, the thickness accuracy of the base member 20 can be improved, and the design flexibility of the base member 20 can be improved.
本実施形態の繊維強化樹脂成形体１０では、基材２０には、連続気泡を有する発泡シート２１が設けられる。そして、発泡シート２１のうち厚み方向で表層構成部３０と重なる部分は、厚み方向で表層構成部３０と重ならない部分に比べて、厚み方向に圧縮されている。本実施形態の繊維強化樹脂成形体１０によれば、発泡シート２１のうち厚み方向で表層構成部３０と重なる部分を圧縮することによって、表層構成部３０を基材２０に埋め込まれた状態に形成し易くすることができ、ベース部３１と基材２０の第１面２０Ａとを略面一に配置し易くすることができる。また、本実施形態の繊維強化樹脂成形体１０の製造方法によっても、発泡シート２１のうち厚み方向でＳＭＣ３０Ｓと重なる部分を圧縮することにより、表層構成部３０を基材２０に埋め込まれた状態に形成し易くすることができる。しかも、本実施形態によれば、発泡シート２１によって加熱プレス成形時の歪みを吸収し、基材２０の第２面２０Ｂにおいて厚み方向で表層構成部３０と重なる部分に、ヒケ等が発生することを抑制可能となり、第２面２０Ｂが不均一な外観になることを抑制可能となる。 In the fiber-reinforced resin molded body 10 of the present embodiment, the base material 20 is provided with a foam sheet 21 having open cells. The portion of the foam sheet 21 that overlaps with the surface layer component 30 in the thickness direction is compressed in the thickness direction as compared with the portion that does not overlap with the surface layer component 30 in the thickness direction. According to the fiber-reinforced resin molded body 10 of the present embodiment, the portion of the foam sheet 21 that overlaps with the surface layer component 30 in the thickness direction is formed so that the surface layer component 30 is embedded in the base material 20. And the base portion 31 and the first surface 20A of the base member 20 can be easily arranged substantially flush with each other. Also, according to the method for manufacturing the fiber-reinforced resin molded body 10 of the present embodiment, the surface layer constituting portion 30 is embedded in the base material 20 by compressing the portion of the foam sheet 21 that overlaps the SMC 30S in the thickness direction. It can be easily formed. Moreover, according to the present embodiment, the foam sheet 21 absorbs the distortion at the time of hot press molding, and causes sink marks or the like in a portion of the second surface 20B of the base material 20 that overlaps the surface layer constituting portion 30 in the thickness direction. Can be suppressed, and it can be suppressed that the second surface 20B has an uneven appearance.
本実施形態では、表面突部３２が設けられる表層構成部３０が複数設けられ、それら複数の表層構成部３０が互いに離れて配置される。本実施形態によれば、複数の表面突部３２全てに亘って１つのＳＭＣからなる表層構成部３０が形成される場合に比べて、表層構成部３０を形成するためのＳＭＣの使用量を少なくすることが可能となる。 In the present embodiment, a plurality of surface layer components 30 provided with the surface protrusions 32 are provided, and the plurality of surface layer components 30 are arranged apart from each other. According to the present embodiment, the amount of SMC used to form the surface layer component 30 is reduced as compared with the case where the surface layer component 30 including one SMC is formed over all of the plurality of surface protrusions 32. It is possible to do.
［確認実験］
以下、繊維強化樹脂成形体１０を上述の製造方法で製造した実験例について説明する。
[Confirmation experiment]
Hereinafter, an experimental example in which the fiber-reinforced resin molded body 10 is manufactured by the above-described manufacturing method will be described.
＜材料＞
本実験例では、繊維強化樹脂成形体１０を構成する各構成要素について、以下の材料を用いた。
発泡シート２１：株式会社イノアックコーポレーション製の「バソテクト（登録商標）Ｇ＋」（密度：９．２ｋｇ／ｍ３、厚み５．０ｍｍで、２００ｍｍ×２００ｍｍのサイズにカットしたものを用いた。）
繊維シート２２：東邦テナックス株式会社製の「Ｗ−３１６１−Ｌ」（連続繊維からなる炭素繊維織物で、目付量が２００ｇ／ｍ２。発泡シート２１と同様のサイズにカットしたものを用いた。）
第２の熱硬化性樹脂：住友ベークライト株式会社製の「スミライトレジン（登録商標）ＰＲ−５５７９１」（フェノール樹脂。ガラス転移温度：１５１℃）
シートモールディングコンパウンド（ＳＭＣ）：三菱ケミカル株式会社製の「パイロフィル（登録商標） ＳＴＲ１２０Ｎ１３１」（厚み２．０ｍｍ、繊維長２５．４ｍｍ。第１の熱硬化性樹脂としてビニールエステル樹脂とエポキシアクリレート樹脂の混合樹脂を含有。ガラス転移温度：１３０℃）
<Material>
In this experimental example, the following materials were used for each component constituting the fiber-reinforced resin molded body 10.
Foam sheet 21: Inoac Corporation manufactured "Basotect (R) G +" (Density: 9.2 kg / m 3, a thickness 5.0 mm, was used which was cut to a size of 200 mm × 200 mm.)
Fiber sheet 22: “W-3161-L” (manufactured by Toho Tenax Co., Ltd.) (a carbon fiber woven fabric composed of continuous fibers, having a basis weight of 200 g / m 2. Cut into the same size as the foam sheet 21 was used. )
Second thermosetting resin: Sumitomo Bakelite Co., Ltd. "Sumilite Resin (registered trademark) PR-55791" (phenol resin; glass transition temperature: 151 ° C)
Sheet molding compound (SMC): “Pyrofil (registered trademark) STR120N131” (manufactured by Mitsubishi Chemical Corporation) (2.0 mm thick, 25.4 mm fiber length. Mixing of vinyl ester resin and epoxy acrylate resin as first thermosetting resin) Contains resin, glass transition temperature: 130 ° C)
＜成形条件＞
本実験例の加熱プレス成形の成形条件としては、成形温度を１５０℃、成形圧力を２０ＭＰａ、成形時間を１０分とした。
<Molding conditions>
The molding conditions of the heat press molding of this experimental example were a molding temperature of 150 ° C., a molding pressure of 20 MPa, and a molding time of 10 minutes.
＜実験結果＞
上記の材料及び成形条件で、加熱プレス成形を行ったところ、補強リブ１３とボス１４が形成される共に、表層構成部３０のベース部３１と基材２０の第１面２０Ａとが面一となった繊維強化樹脂成形体１０が得られた。具体的には、繊維強化樹脂成形体１０において、補強リブ１３とボス１４（即ち、表面突部３２）を除いた部分の厚みは、１．０ｍｍとなった。詳細には、繊維強化樹脂成形体１０において基材２０と表層構成部３０が厚み方向で重なっていない部分では、発泡シート２１が０．５０ｍｍ、各繊維シート２２が０．２５ｍｍであった。また、繊維強化樹脂成形体１０において基材２０と表層構成部３０が厚み方向で重なっている部分では、発泡シート２１が０．１０ｍｍ、各繊維シート２２が０．２５ｍｍ、表層構成部３０のベース部３１が０．４０ｍｍであった。
<Experimental results>
When heat press molding was performed using the above materials and molding conditions, the reinforcing ribs 13 and the bosses 14 were formed, and the base portion 31 of the surface layer forming portion 30 and the first surface 20A of the base material 20 were flush with each other. The resulting fiber-reinforced resin molded body 10 was obtained. Specifically, in the fiber-reinforced resin molded body 10, the thickness of the portion excluding the reinforcing rib 13 and the boss 14 (that is, the surface protrusion 32) was 1.0 mm. Specifically, in the portion where the base material 20 and the surface layer constituting portion 30 do not overlap in the thickness direction in the fiber-reinforced resin molded body 10, the foam sheet 21 is 0.50 mm, and each fiber sheet 22 is 0.25 mm. In the portion where the base material 20 and the surface layer component 30 overlap in the thickness direction in the fiber-reinforced resin molded body 10, the foam sheet 21 is 0.10 mm, each fiber sheet 22 is 0.25 mm, and the base of the surface layer component 30 is The portion 31 was 0.40 mm.
この繊維強化樹脂成形体１０では、基材２０とＳＭＣからなる表層構成部３０とが十分に固定されていることが確認できたと共に、寸法精度が良好であった。さらに、基材２０の第２面２０Ｂにおいて厚み方向で表層構成部３０と重なる部分は、ヒケ等が生じて不均一な外観になることもなく、良好な外観であった。 In this fiber-reinforced resin molded body 10, it was confirmed that the base material 20 and the surface layer constituting portion 30 made of SMC were sufficiently fixed, and the dimensional accuracy was good. Further, the portion of the second surface 20B of the base material 20 that overlaps with the surface layer constituting portion 30 in the thickness direction did not have a sink mark or the like to give an uneven appearance, and had a good appearance.
なお、上記同様の成形温度及び成形圧で、加熱プレス成形の成形時間を３分とした場合、ＳＭＣの第１の熱硬化性樹脂が硬化していることが確認できた一方で、第２の熱硬化性樹脂が硬化しきっておらず、成形金型７０から基材２０を外す際に、基材２０が変形した。即ち、成形時間が３分経ったタイミングは、図８に示すタイミングＴ１以降で、タイミングＴ２の前であると考えられる。成形時間が１０分の場合、図８に示すタイミングＴ２を経過するため、ＳＭＣの第１の熱硬化性樹脂と、発泡シート２１及び繊維シート２２に含浸した第２の熱硬化性樹脂と、の両方が硬化しきり、上述のような良好な状態の繊維強化樹脂成形体１０を製造することができる。 When the molding time of the hot press molding was set to 3 minutes at the same molding temperature and molding pressure as above, while it was confirmed that the first thermosetting resin of the SMC was cured, the second The thermosetting resin was not completely cured, and the base material 20 was deformed when the base material 20 was removed from the molding die 70. That is, the timing at which the molding time has passed for 3 minutes is considered to be after the timing T1 shown in FIG. 8 and before the timing T2. When the molding time is 10 minutes, since the timing T2 shown in FIG. 8 elapses, the first thermosetting resin of the SMC and the second thermosetting resin impregnated in the foam sheet 21 and the fiber sheet 22 are mixed. Both are completely cured, and the fiber-reinforced resin molded body 10 in the favorable state as described above can be manufactured.
［他の実施形態］
（１）上記実施形態では、表層構成部３０のうち基材２０と反対側を向く面に、賦形部として、表面突部３２が設けられていたが、図９及び図１０に示されるように、凹部３２Ｖが設けられていてもよい。この場合においても、表層構成部３０のベース部３１を、基材２０と略面一に配置することで、凹部３２Ｖの深さについて寸法精度の安定化を図ることが可能となる。なお、このような凹部３２Ｖは、溝であってもよいし、穴であってもよい。
[Other embodiments]
(1) In the above embodiment, the surface protrusions 32 are provided as shaping portions on the surface of the surface layer constituting portion 30 facing the side opposite to the base material 20, as shown in FIGS. 9 and 10. May be provided with a concave portion 32V. Also in this case, by arranging the base portion 31 of the surface layer forming portion 30 substantially flush with the base material 20, it is possible to stabilize the dimensional accuracy of the depth of the concave portion 32V. In addition, such a concave portion 32V may be a groove or a hole.
（２）上記実施形態において、補強リブ１３とボス１４とをそれぞれ構成する２つの表面突部３２，３２同士が、１つの表層構成部３０に設けられていてもよい（即ち、１枚のＳＭＣから形成されてもよい）。 (2) In the above embodiment, the two surface protrusions 32, 32 constituting the reinforcing rib 13 and the boss 14, respectively, may be provided in one surface layer component 30 (that is, one sheet of SMC). May be formed).
（３）上記実施形態では、基材２０が、繊維シート２２を発泡シート２１の表裏の両面に積層した構成であったが、繊維シート２２を発泡シート２１の表裏の一方の面のみに積層した構成であってもよい。この場合、表層構成部３０は、基材２０に対して、繊維シート２２側から積層されていてもよいし、図１１に示されるように発泡シート２１側から積層されていてもよい。 (3) In the above embodiment, the base material 20 is configured such that the fiber sheet 22 is laminated on both the front and back surfaces of the foam sheet 21. However, the fiber sheet 22 is laminated on only one of the front and back surfaces of the foam sheet 21. It may be a configuration. In this case, the surface layer constituting portion 30 may be laminated on the base material 20 from the fiber sheet 22 side, or may be laminated on the foam sheet 21 side as shown in FIG.
（４）上記実施形態において、発泡シート２１と繊維シート２２が積層された基材２０の構成として、発泡シート２１が２枚以上設けられる構成であってもよいし、繊維シート２２が３枚以上設けられる構成であってもよい。これらの場合、基材２０が、発泡シート２１と繊維シート２２を一枚ずつ交互に積層した構成であってもよいし、隣り合う発泡シート２１同士又は隣り合う繊維シート２２同士を含む構成であってもよい。また、これらの場合、基材２０のうち表層構成部３０が積層される最外層は、発泡シート２１によって構成されていてもよいし、繊維シート２２によって構成されていてもよい。 (4) In the above embodiment, as a configuration of the base material 20 on which the foam sheet 21 and the fiber sheet 22 are laminated, a configuration in which two or more foam sheets 21 are provided, or three or more fiber sheets 22 may be provided. A configuration may be provided. In these cases, the base material 20 may have a configuration in which the foam sheet 21 and the fiber sheet 22 are alternately laminated one by one, or a configuration including adjacent foam sheets 21 or adjacent fiber sheets 22. You may. In these cases, the outermost layer of the base material 20 on which the surface layer constituting portion 30 is laminated may be constituted by the foam sheet 21 or may be constituted by the fiber sheet 22.
（５）上記実施形態では、基材２０を構成するシートが、発泡シート２１と繊維シート２２であったが、繊維シート２２のみであってもよい。この構成として、例えば、基材２０がプリプレグからなる構成が挙げられる。 (5) In the above embodiment, the sheets constituting the base material 20 are the foam sheet 21 and the fiber sheet 22, but may be only the fiber sheet 22. As this configuration, for example, a configuration in which the base material 20 is made of a prepreg is given.
（６）上記実施形態において、表層構成部３０が、基材２０の表裏の両面に設けられていてもよい。この場合、繊維強化樹脂成形体１０を製造する際に、基材用シート２０Ｓの表裏の両面にＳＭＣ３０Ｓが重ねられる。 (6) In the above embodiment, the surface layer constituting section 30 may be provided on both the front and back surfaces of the base material 20. In this case, when manufacturing the fiber-reinforced resin molded body 10, the SMC 30S is overlapped on both the front and back surfaces of the base sheet 20S.
（７）上記実施形態では、発泡シート２１と繊維シート２２とに含浸する熱硬化性樹脂が同じであったが、異なっていてもよい。この場合、発泡シート２１に含浸する熱硬化性樹脂と、繊維シート２２に含浸する熱硬化性樹脂とは、それぞれ、ＳＭＣを構成する第１の熱硬化性樹脂に比べて、硬化温度が高いか、又は、硬化時間が長いものが用いられる。 (7) In the above embodiment, the thermosetting resin impregnated in the foam sheet 21 and the fiber sheet 22 is the same, but may be different. In this case, the thermosetting resin impregnating the foam sheet 21 and the thermosetting resin impregnating the fiber sheet 22 each have a higher curing temperature than the first thermosetting resin constituting the SMC. Alternatively, one having a long curing time is used.
（８）上記実施形態において、表層構成部３０の表面突部３２は、例えば、突条、突壁、棒状の突部であってもよい。 (8) In the above embodiment, the surface projection 32 of the surface layer constituting section 30 may be, for example, a ridge, a projection wall, or a rod-like projection.
１０ 繊維強化樹脂成形体
２０ 基材
３０ 表層構成部
DESCRIPTION OF SYMBOLS 10 Fiber-reinforced resin molded body 20 Substrate 30 Surface layer component
Claims (6)
前記基材は、前記シートモールディングコンパウンドに含まれる繊維よりも繊維長の長い補強繊維と第２の熱硬化性樹脂とを含み、
前記第１の熱硬化性樹脂と前記第２の熱硬化性樹脂とが硬化することにより、前記基材と前記表層構成部とが一体化した繊維強化樹脂成形体であって、
前記表層構成部は、前記基材に埋め込まれ、前記基材と反対側を向く面に、突部又は凹部からなる賦形部を有し、
前記表層構成部のうち前記賦形部以外の部分は、前記基材と略面一に配置され、
前記第２の熱硬化性樹脂は、前記第１の熱硬化性樹脂に比べて、硬化温度が高い、又は、硬化時間が長い、繊維強化樹脂成形体。 On at least one of the front and back surfaces of the plate-shaped base material, the surface layer constituting portion made of the sheet molding compound containing the first thermosetting resin is partially laminated,
The base material includes a reinforcing fiber and a second thermosetting resin having a fiber length longer than a fiber included in the sheet molding compound,
By curing the first thermosetting resin and the second thermosetting resin, a fiber-reinforced resin molded body in which the base material and the surface layer component are integrated,
The surface layer constituting portion is embedded in the base material, and on a surface facing the opposite side to the base material, has a shaping portion including a protrusion or a concave portion,
The portion of the surface layer constituting portion other than the shaping portion is disposed substantially flush with the base material,
The second thermosetting resin has a higher curing temperature or a longer curing time than the first thermosetting resin.
前記発泡シートのうち、厚み方向で前記表層構成部と重なる部分は、厚み方向で前記表層構成部と重ならない部分に比べて、厚み方向に圧縮されている、請求項１に記載の繊維強化樹脂成形体。 The substrate is a thermosetting resin foam, and at least one of the front and back surfaces of a foam sheet having open cells, a fiber sheet made of the reinforcing fiber is laminated, and the foam sheet and the fiber sheet Impregnated with the second thermosetting resin,
2. The fiber-reinforced resin according to claim 1, wherein a portion of the foam sheet that overlaps with the surface layer in the thickness direction is compressed in a thickness direction as compared with a portion that does not overlap with the surface layer in the thickness direction. Molded body.
前記シートモールディングコンパウンドを前記基材用シートの表裏のうち少なくとも一方の面に部分的に重ね、
加熱プレス成形により、前記第１の熱硬化性樹脂と前記第２の熱硬化性樹脂とを硬化させて、前記基材用シートから形成した基材と、前記シートモールディングコンパウンドから形成した表層構成部と、を一体化する繊維強化樹脂成形体の製造方法であって、
前記表層構成部を形成する際に、前記表層構成部のうち前記基材と反対側を向く面に、突部又は凹部からなる賦形部を形成し、
前記第２の熱硬化性樹脂として、前記第１の熱硬化性樹脂に比べて、前記加熱プレス成形の温度において硬化時間が長いものを用いる、繊維強化樹脂成形体の製造方法。 A sheet molding compound including a first thermosetting resin, a base sheet including a reinforcing fiber having a longer fiber length than a fiber included in the sheet molding compound and a second thermosetting resin are prepared. ,
The sheet molding compound partially overlaps at least one of the front and back surfaces of the base sheet,
The first thermosetting resin and the second thermosetting resin are cured by hot press molding to form a base material formed from the base material sheet, and a surface layer component formed from the sheet molding compound. And a method for producing a fiber-reinforced resin molded body that integrates
When forming the surface layer component, on the surface of the surface layer component facing the opposite side to the base material, forming a shaping portion consisting of a protrusion or a recess,
A method for producing a fiber-reinforced resin molded article, wherein a resin having a longer curing time at the temperature of the hot press molding than the first thermosetting resin is used as the second thermosetting resin.
前記加熱プレス成形を行うにあたって、前記シートモールディングコンパウンドを複数枚用意し、それら複数枚のシートモールディングコンパウンドを、互いに離して前記成形面の前記表面形成部に重ねる、請求項４又は５に記載の繊維強化樹脂成形体の製造方法。 On a molding surface of a molding die for performing the hot press molding, a plurality of surface forming portions for forming the shaping portion of the surface layer constituting portion are provided,
6. The fiber according to claim 4, wherein in performing the hot press molding, a plurality of the sheet molding compounds are prepared, and the plurality of sheet molding compounds are separated from each other and overlap with the surface forming portion of the molding surface. 7. A method for producing a reinforced resin molded article.
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| PCT/JP2019/030586 WO2020031919A1 (en) | 2018-08-08 | 2019-08-02 | Fiber-reinforced resin molded article and method for manufacturing same |
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| JP2022171921A (en) | 2022-11-11 |
| JP7403931B2 (en) | 2023-12-25 |
| JP7146519B2 (en) | 2022-10-04 |
| WO2020031919A1 (en) | 2020-02-13 |
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