JP2020163674A - Fiber reinforced plastic molding - Google Patents

Abstract

To provide a fiber reinforced plastic molding having high appearance designability, having a small warp of the molding though an asymmetrically laminated structure and capable of achieving thinning, high strength and high rigidity.SOLUTION: A fiber reinforced plastic molding is constituted of a laminate (A)2 having a planar structure consisting of at least a fiber reinforced resin and a resin member (B)3 bonded to at least a part of the outer periphery of the laminate (A)2. The laminate (A)2 is formed by laminating a plate (C)4 and a plate (D)5; the flexural rigidity of the plate (D)5 is larger than that of the plate (C)4; when setting the amount of the resin member (B)3 existing in a region 13 on the side of the plate (C)4 rather than a center line 12 formed by dividing the laminate (A)2 into equal halves in the thick direction to Am1 and the amount of the resin member (B)3 existing in a region 14 on the side opposite thereto to Am2, Am2/Am1 is 2-25.SELECTED DRAWING: Figure 3

Description

The present invention relates to a fiber reinforced plastic molded product that is used as a component or housing portion of, for example, a personal computer, an OA device, a mobile phone, etc., and is suitable for applications requiring light weight, high strength, high rigidity, and thinning.

At present, as electric and electronic devices such as personal computers, OA devices, AV devices, mobile phones, telephones, facsimiles, home appliances, and toy supplies are becoming more portable, smaller size and lighter weight are required. In order to meet this requirement, the parts that make up the equipment, especially the housing, need to be prevented from bending significantly and coming into contact with or breaking the internal parts when an external load is applied. It is required to reduce the wall thickness while achieving high strength and high rigidity.

Further, since the housing for accommodating electronic devices such as notebook personal computers is a part that is exposed to the human eye and directly touched by the user's hand, the design and the appearance quality of the surface are important. Therefore, the housing is generally decorated by exterior painting, and the surface quality is controlled by strict appearance standards. In recent years, the diversification of designs such as clear metallic coating and pearl clear coating has progressed, and advanced coating technology is required to satisfy the surface quality, and the quality required for the surface of molded products is becoming stricter. .. In particular, it is considered to be an important factor for sales promotion to make the shape pattern of carbon fiber woven fabric, which is a fiber reinforced base material, stand out and to make a novel surface pattern a selling point.

In Patent Document 1, "at least, in a fiber reinforced plastic laminate in which a skin material made of reinforcing fibers and a matrix resin is laminated on a core material made of a resin foam having independent foam cells, a thin skin material is used. A unidirectional fiber reinforced plastic layer is arranged in at least one layer of the above, the thick skin material has a laminated structure, and a woven fiber reinforced plastic layer is arranged in at least one layer, and the upper surface skin material 3 is woven on the outermost layer. "Structure in which one layer of prepreg A composed of carbon fiber and epoxy resin and four layers of prepreg B composed of unidirectional carbon fiber and epoxy resin are laminated" is described, thereby providing rigidity and light weight. The effect of suppressing surface appearance defects due to the generation of bubble voids, so-called bubble voids, which are generated inside the structure while holding the structure, and maintaining a surface state having a good appearance with excellent design is disclosed.

Further, in Patent Document 2, a plate material (A) having a design surface on one side is arranged in a mold inside a member (B) having a frame shape with at least a part separated from the member (B). By injection molding the bonding resin (C) into the gap between the plate material (A) and the member (B), the plate material (A) and the member (B) are formed at least at the outer peripheral edge of the plate material (A). A configuration is described in which a plurality of structures are joined together with a high joining strength, the joining boundary portion has good smoothness, and the molded body has a constituent member of a plate material. However, the effect of reducing warpage and achieving weight reduction and thinning is disclosed.

Further, in Patent Document 3, "a composite molded product (I) in which a laminated member (II) having a sandwich structure and a resin member (III) are arranged at least a part around a plate end portion of the laminated member (II). The sandwich structure has a hard member layer (IIa) and a soft member layer (IIb), and the resin member (III) is a soft member layer (III) at the joint portion between the laminated member (II) and the resin member (III). A configuration in which at least a part of the convex shape is formed is described with respect to IIb), and the effect of being lightweight, having high rigidity and high strength, and being able to reduce the wall thickness is disclosed.

Further, in Patent Document 4, in a sandwich structure composed of a skin layer and a core layer including a fluid core layer composed of discontinuous fibers and a matrix resin (C), the skin layer is a continuous fiber and a matrix resin ( It is a fiber reinforced resin layer (X) composed of A), and a configuration in which one or more layers of a unidirectional fiber reinforced resin layer and one or more woven fiber reinforced resin layers are laminated is described, and it is lightweight, high strength, and high rigidity. , The effect that a standing portion having a complicated shape such as a rib having high strength in the out-of-plane direction of the skin layer can be obtained by a simple method such as one-shot molding is disclosed.

Further, in Patent Document 5, "a skin is provided in a method for producing a sandwich panel composed of a core material and a skin material containing a fiber reinforced resin in which reinforcing fibers arranged on both sides of the core material are impregnated with a fiber reinforced resin. The material is a fiber reinforced resin having a one-layer structure or a plurality of laminated structures, and at least one layer in the fiber-reinforced resin is a fiber-reinforced resin layer containing continuous reinforcing fibers, and the continuous reinforcing fibers. "Structure in which the fiber reinforced plastic layer containing reinforced plastic contains a woven fabric of reinforced fibers" is described, whereby the skin material is made of a highly rigid fiber reinforced plastic and the core material is made of a resin having an apparent density lower than that of the skin material. Since the overall thickness is reduced, the effect of being excellent in lightness and X-ray transparency while maintaining rigidity is disclosed.

JP 2015-193119 International Publication No. 2018/110293 Pamphlet Japanese Unexamined Patent Publication No. 61-24439 International Publication 2017/1156040 Pamphlet Japanese Unexamined Patent Publication No. 2012-76464

The members that make up the housing used in electrical and electronic equipment are required to have good appearance design and smoothness, as well as high flexural rigidity. For example, attempts have been made to improve the appearance design by arranging a sheet-shaped fiber-reinforced base material such as a woven fabric on the surface of a fiber-reinforced plastic molded product to give it a unique surface morphology. However, in a fiber reinforced plastic molded body, if a sheet-shaped woven fiber reinforced base material such as a multi-axis woven fabric is used for the surface layer, a woven fabric pattern can be arranged on the surface, but the woven fabric is in a form in which carbon fibers are wavy. Therefore, the strength such as bending rigidity may decrease.

Therefore, it is necessary to secure a certain strength and rigidity by laminating a fiber-reinforced plastic molded body on a sheet-shaped woven fiber-reinforced base material such as a woven material to form a multi-layer structure. However, in that configuration, the molded body has an asymmetric laminated structure in which layers having different flexural rigidity are laminated, and the molded body itself may be warped due to the influence of heat shrinkage after molding. As described above, in the asymmetric laminated structure in which the base materials having different flexural rigidity are laminated, the molded body itself may be warped, and there is a problem in realizing smoothness.

Further, in order to solve this problem, a method of preliminarily forming the cavity of the mold into a shape that cancels the warp deformation of the fiber reinforced resin plate material caused by the difference in the coefficient of linear expansion is disclosed (for example, Japanese Patent Application Laid-Open No. 2015). -98173, JP2003-158143). However, it is necessary to make the mold as a custom-made mold, and it is necessary to perform a plurality of trial productions to confirm whether the shape is appropriate, which has been a factor that causes an increase in cost.

In response to such a problem, in Patent Document 1 described above, by arranging a unidirectionally reinforced fiber plastic skin material on both sides of the core material, it is possible to compensate for the decrease in rigidity, and the outermost layer of the skin material It is said that by arranging the woven fabric, it is possible to maintain high rigidity and improve the appearance design, but there is a problem in reducing the warp of the molded product that is likely to occur due to the asymmetric laminated structure. There was no suggestion regarding recognition or countermeasures, and there was room for improvement.

Further, in Patent Document 2, the bonding resin (C) injected into the outer peripheral edge portion of the plate material (A) is intended to bond the plate material (A) and the member (B) with high strength. Further, the description describes an asymmetric laminated structure in which a thermoplastic resin layer (D) is provided on the outer surface of the plate material (A), and the plate material (A) and the bonding resin (C) are bonded via the thermoplastic resin layer (D). However, there is room for improvement because there is no recognition of problems regarding warpage of the molded product that may occur when the thermoplastic resin layer (D) is provided and asymmetrical lamination is performed, and no suggestions regarding countermeasures thereof have been made.

Further, in Patent Document 3, the hard member layer (IIa) uses a sheet containing continuous reinforcing fibers arranged in one direction or a sheet containing continuous reinforcing fiber woven fabric, and a plate end portion of the laminated member (II). Although the configuration for injection molding the resin member (III) is described in the periphery, there is no description that the laminated member (II) has an asymmetric laminated structure, and the resin member (III) to be injection molded and the warp of the molded body are described. There was no description suggesting a relationship, and there was room for improvement as there was no recognition of issues regarding the warpage of the molded product or suggestions for countermeasures.

Further, in Patent Document 4, the skin layer is a fiber reinforced resin layer (X) composed of continuous fibers and a matrix resin (A), and one or more unidirectional fiber reinforced resin layers and one or more woven fiber reinforced resin layers are laminated. Although it is stated that lightweight, high-strength, and high-rigidity characteristics can be obtained by adopting the structure, when a woven fiber reinforced resin layer is arranged on the surface layer of the skin material to form an asymmetric laminated structure. There was no suggestion regarding the problem recognition and countermeasures related to the warpage of the molded body that may occur in the above, and there was room for improvement.

Further, Patent Document 5 states that the strength and elastic modulus can be designed more efficiently by having the fiber-reinforced resin layer containing the reinforcing fibers aligned in one direction and the reinforcing fibers of the woven fabric as the skin material. However, there is room for improvement as there is no recognition of issues related to warpage of the molded body that may occur when a woven fiber reinforced resin layer is arranged on the surface layer of the skin material to form an asymmetric laminated structure, and no suggestions regarding countermeasures have been made. It was.

In view of the problems of the prior art, the subject of the present invention is to improve the appearance design in the asymmetric laminated structure in which the base materials having different bending rigidity are laminated, and to prevent the molded product from warping even though the structure is asymmetrical. It is an object of the present invention to provide a fiber reinforced plastic molded product which can suppress and realize smoothness, and can achieve thinning, high strength and high rigidity.

In order to solve the above problems, the present invention employs the following means. That is,
(1) A resin bonded to a laminated body (A) which is a planar structure made of at least a fiber reinforced resin and a part or all of the outer peripheral side surface portion and / or the outer peripheral peripheral portion of the laminated body (A). A fiber-reinforced plastic molded body composed of a member (B).
The laminated body (A) has a structure in which a plate material (C) and a plate material (D) having at least different bending rigidity are laminated, and the bending rigidity of the plate material (D) is larger than the bending rigidity of the plate material (C). , The laminated body (A) is divided into halves in the wall thickness direction, and the resin member (B) existing in the region (R1) on which the plate material (C) is laminated rather than the divided center line. Assuming that the amount of the resin member (B) existing in the region (R2) on which the plate material (C) is not laminated is Am2, Am2 / Am1 is in the range of 2 to 25. Characterized fiber reinforced plastic molded body.
(2) Assuming that the flexural modulus of the plate material (D) is Md (GPa) and the flexural modulus of the plate material (C) is Mc (GPa), Md / Mc is in the range of 1.2 to 17. The fiber-reinforced plastic molded product according to 1).
(3) The fiber-reinforced plastic according to (1) or (2), wherein the flexural modulus Md of the plate material (D) is in the range of 100 to 500 GPa, and the flexural modulus Mc of the plate material (C) is in the range of 30 to 80 GPa. Molded body.
(4) Assuming that the wall thickness of the plate material (D) is Td (mm) and the wall thickness of the plate material (C) is Tc (mm), Td / Tc is in the range of 1.2 to 40 (1). The fiber-reinforced plastic molded body according to any one of (3).
(5) Any of (1) to (4), wherein the wall thickness Td of the plate material (D) is in the range of 0.6 to 2 mm, and the wall thickness Tc of the plate material (C) is in the range of 0.05 to 0.5 mm. Fiber reinforced plastic molded body described in Crab.
(6) The plate material (C) is one layer or two or more layers of woven fiber reinforced resin composed of a woven fiber and a matrix resin, and the plate material (D) is made of a unidirectional continuous fiber and a matrix resin. The fiber-reinforced plastic molded body according to any one of (1) to (5), which is a unidirectional fiber-reinforced resin having one layer or two or more layers.
(7) The plate material (C) is one layer or two or more layers of woven fiber reinforced resin composed of a woven fiber and a matrix resin, and the plate material (D) is unidirectional on both surfaces of the core layer. One layer or two or more layers of unidirectional fiber reinforced resin composed of continuous fibers and matrix resin, or a sandwich structural member sandwiched between one layer or two or more layers of woven fiber reinforced resin composed of woven fibers and matrix resin. The fiber-reinforced plastic molded body according to any one of (1) to (5).
(8) The fiber-reinforced plastic molded product according to any one of (1) to (7), wherein the plate material (C) is arranged on the outermost layer on the design surface side of the fiber-reinforced plastic molded product.
(9) The method according to any one of (1) to (8), wherein the resin member (B) is joined and formed over the entire circumference of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A). Fiber reinforced plastic molded body.
(10) In the laminated body (A), the bonding layer (G) is arranged in a part or all of the flat surface portion of the outer peripheral edge portion of the plate material (D) on the side where the plate material (C) is not laminated. The fiber-reinforced plastic according to any one of (1) to (9), wherein the resin member (B) is bonded to the laminated body (A) via a bonding layer (G). Molded body.
(11) The fiber-reinforced plastic molded product according to any one of (1) to (10), wherein the warpage of the fiber-reinforced plastic molded product is 2% or less.

According to the fiber-reinforced plastic molded product of the present invention, in an asymmetric laminated structure in which base materials having different flexural rigidity are laminated, the occurrence of warpage of the molded product is suppressed and good smoothness is realized while having an asymmetric laminated structure. Moreover, it is possible to realize thinning and high strength and high rigidity.

It is a perspective view of the fiber reinforced plastic molded article which concerns on one Embodiment of this invention. (A) A cross-sectional view showing an example of a laminated body (A) in which a plate material (C) and a plate material (D) according to the present invention are laminated, and (B) after press molding of the laminated body (A), warpage occurs due to heat shrinkage. It is sectional drawing which shows an example of the state. It is sectional drawing which shows an example of the fiber reinforced plastic molded article which concerns on this invention which showed the state which the resin member (B) was bonded to the outer peripheral side surface portion of the laminated body (A). The present invention shows an example of a state in which the resin member (B) is bonded to the outer peripheral side surface portion and the outer peripheral edge portion of the laminated body (A) in which the bonding layer (G) is formed on one surface of the plate material (D). It is sectional drawing of the fiber-reinforced plastic molded article. (A) A cross-sectional view showing an example of a laminated body (A) using a sandwich structural member in which a skin layer is sandwiched between a core layer as a plate material (D) in the present invention, and (B) after press molding of the laminated body (A). It is sectional drawing which shows an example of the state which warped by heat shrinkage. It is sectional drawing of the fiber reinforced plastic molded article which concerns on this invention which shows an example of the state in which the resin member (B) is bonded to the outer peripheral side surface portion of the laminated body (A) shown in FIG. The present invention shows an example of a state in which the resin member (B) is bonded to the outer peripheral side surface portion and the outer peripheral edge portion of the laminated body (A) in which the bonding layer (G) is formed on one surface of the plate material (D). It is sectional drawing of the fiber-reinforced plastic molded article. It is sectional drawing of the fiber reinforced plastic molded article which concerns on this invention which shows an example of the state in which the resin member (B) is bonded to the outer peripheral side surface portion of the laminated body (A) of another form. The present invention shows an example of a state in which the resin member (B) is bonded to the outer peripheral side surface portion and the outer peripheral edge portion of the laminated body (A) in which the bonding layer (G) is formed on one surface of the plate material (D). It is sectional drawing of the fiber-reinforced plastic molded article. 6 is a cross-sectional view showing a state before arranging each member constituting the laminated body (A) in the press-molded lower die in the manufacturing process of the laminated body (A) shown in FIG. It is sectional drawing of the laminated body (A) formed by the press molding by closing the press forming lower die and the press forming upper die. It is a process drawing which shows the manufacturing process of a molded body, (A) the cross-sectional view which shows the state which the laminated body (A) shown in FIG. 11 is arranged in the injection molding die, (B) the resin member (B). It is sectional drawing of the fiber-reinforced plastic molded article which concerns on this invention which was molded by injection injection from an injection gate opening. FIG. 5 is a cross-sectional view showing a state before arranging each member constituting the laminated body (A) in the press-molded lower die in the manufacturing process of the laminated body (A) shown in FIG. 7. It is sectional drawing of the laminated body (A) formed by the press molding by closing the press forming lower die and the press forming upper die. It is a process drawing which shows the manufacturing process of a molded body, (A) the cross-sectional view which shows the state which the laminated body (A) shown in FIG. 14 is arranged in the injection molding die, (B) the resin member (B). It is sectional drawing of the fiber-reinforced plastic molded article which concerns on this invention which was molded by injection injection from an injection gate opening. It is the schematic which shows the method of measuring the warp of a fiber reinforced plastic molded article.

Hereinafter, the present invention will be described in detail together with embodiments with reference to the drawings. The present invention is not limited to the drawings and the examples described later.

With reference to FIGS. 1 to 4, the fiber reinforced plastic molded body 1 of the present invention has a laminated body (A) 2 which is a planar structure made of at least a fiber reinforced resin and an outer peripheral side surface of the laminated body (A) 2. A fiber-reinforced plastic molded body 1 in which a resin member (B) 3 is bonded to a part or all of a part and / or an outer peripheral edge portion, and the laminated body (A) 2 is a plate material having at least a different bending rigidity. It has a structure in which (C) 4 and plate material (D) 5 are laminated, and the bending rigidity of plate material (D) 5 is larger than the bending rigidity of plate material (C) 4, and the laminated body (A) 2 is formed in the wall thickness direction. The amount of the resin member (B) 3 existing in the region (R1) 13 on which the plate material (C) 4 is laminated is larger than that of the divided central line 12, and the amount of the resin member (B) 3 is Am1 and the plate material (C) 4 is divided into halves. Assuming that the amount of the resin member (B) 3 existing in the region (R2) 14 on which the layers are not laminated is Am2, Am2 / Am1 is in the range of 2 to 25.

As shown in FIG. 1, the fiber-reinforced plastic molded product 1 of the present invention includes the laminated body (A) 2 and a part or all of the outer peripheral side surface portion and / or the outer peripheral peripheral portion of the laminated body (A) 2. The resin member (B) 3 is joined to the resin member (B) 3.

Further, as shown in FIG. 2, the laminated body (A) 2 has a configuration in which at least a plate material (C) 4 and a plate material (D) 5 having a flexural rigidity higher than that of the plate material (C) 4 are laminated.

In a molded body composed of only the plate material (C) 4, the strength and rigidity of the molded body may not be sufficiently obtained. Therefore, the molded body is formed by laminating the plate material (D) 5 having a large bending rigidity. High strength and rigidity can be ensured.

When the plate material (D) 5 having a higher bending rigidity than the plate material (C) 4 is laminated on the plate material (C) 4 and the laminated body (A) 2 which is a planar structure is produced by press molding, press molding is performed. Immediately after completion, as shown in FIG. 2 (A), the laminated body (A) 2 has a substantially flat shape without warping, but after that, due to heat shrinkage due to cooling, the laminated body (A) 2 becomes as shown in FIG. 2 (B). The center may be dented and deformed downward. This is because the laminated body (A) 2 has an asymmetric laminated structure, so it is considered that the laminated body (A) 2 is affected by the heat shrinkage of the plate material (C) 4 and warps downward in a convex shape. If it is used in the housing of an electric device or the like in this state, it may come into contact with an internal electronic component or the like and cause a problem.

Therefore, in order to suppress such deformation, in the present invention, as shown in FIG. 3, a part or all of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A) 2 produced by press molding. The resin member (B) 3 is joined to the region. At this time, the laminated body (A) 2 is divided into half equal parts in the wall thickness direction, and is present in the region (R2) 14 on which the plate material (C) 4 is not laminated than the divided center line 12. The amount of the resin member (B) 3 is made larger than the amount of the resin member (B) 3 existing in the region (R1) 13 on which the plate material (C) 4 is laminated at a constant ratio. By giving a bias in the joining amount of the resin member (B) 3 to be joined to the outer peripheral edge portion and / or the outer peripheral side surface portion of the molded body 1 in this way, the shrinkage of the resin member (B) 3 causes the laminated body (A). ) A stress is generated in the direction opposite to the warp of 2, and the warp is canceled as a whole. As a result, it is possible to suppress the occurrence of warpage during molding even with asymmetric lamination. In FIGS. 3, 4, 6, 7, 8 and 9, the center line 12 is a line indicating the central portion of the laminated body (A) 2 having a wall thickness of 11 in half.

Flexural rigidity is expressed by rigidity = elastic modulus × moment of inertia of area, and represents the difficulty of deformation of a member with respect to bending or torsion. Therefore, by defining the flexural rigidity, the relationship with the warp can be expressed in consideration of the thickness and shape of the base material.

If Am2 / Am1 is less than 2, it may be difficult to exert the effect of canceling the warp. If Am2 / Am1 exceeds 25, the thickness of the molded product itself becomes thick, and it may be difficult to realize thinning. Am2 / Am1 is preferably 5 to 22, more preferably Am2 / Am1 is 8 to 20, and even more preferably 10 to 18. The amount of the resin member (B) 3 is specified by volume.

The outer peripheral edge portion of the laminated body (A) 2 is a flat portion region near the outer peripheral portion of the laminated body (A) 2 of the planar structure, and is relative to the length of one side of the laminated body (A) 2. It is preferably within the range of 0 to 15% from the outer peripheral edge. The outer peripheral side surface portion is an end portion having a plane perpendicular to the plane portion of the outer peripheral portion of the laminated body (A) 2 of the planar structure.

Further, it is preferable that the resin member (B) 3 is arranged so as to be joined to a part or all of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A) 2. FIG. 3 shows a state in which a part of the resin member (B) 3 is joined to the outer peripheral side surface portion of the laminated body (A) 2, and FIG. 4 shows a part of the resin member (B) 3 of the laminated body (A) 2. It shows a state of being joined to a part of the outer peripheral side surface portion and the outer peripheral edge portion.

It is preferable that the resin member (B) 3 is joined to a part or all of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A) 2 by injection molding.

Further, in the present invention, assuming that the flexural modulus of the plate material (D) 5 is Md (GPa) and the flexural modulus of the plate material (C) 4 is Mc (GPa), Md / Mc is 1.2 to 17. Is preferable. As a result, the strength of the molded product can be ensured, and the effect of canceling the warp can be obtained.

If Md / Mc is less than 1.2, the effect of warpage reduction may be weakened. If Md / Mc exceeds 17, the effect of warpage reduction may be weakened. Md / Mc is preferably 3 to 16, more preferably 5 to 15, and even more preferably 7-14.

Further, in the present invention, it is preferable that the flexural modulus Md of the plate material (D) 5 is 100 to 500 GPa and the flexural modulus Mc of the plate material (C) 4 is 30 to 80 GPa.

If Md is less than 100 GPa, the laminated body (A) 2 may warp too much, and when the resin member (B) 3 is injection-molded, the bonding with the resin member (B) 3 may be insufficient. .. If Md exceeds 500 GPa, it may be difficult to handle as a base material, and the material cost may affect the product competitiveness.

If Mc is less than 30 GPa, the strength of the molded product 1 may not be sufficiently secured. If Mc exceeds 80 GPa, the laminated body (A) 2 may warp too much, and when the resin member (B) 3 is injection-molded, the bonding with the resin member (B) 3 may be insufficient.

Md is preferably 120 to 480 GPa, more preferably 180 to 400 GPa, and even more preferably 220 to 320 GPa. The Mc is preferably 35 to 75 GPa, more preferably 45 to 65 GPa, and even more preferably 50 to 60 GPa.

Further, in the present invention, assuming that the wall thickness of the plate material (D) 5 is Td (mm) and the wall thickness of the plate material (C) 4 is Tc (mm), Td / Tc is preferably 1.2 to 40. .. By increasing the wall thickness of the plate material (D) 5 with respect to the wall thickness of the plate material (C) 4, the influence of heat shrinkage of the plate material (C) 4 can be reduced.

If Td / Tc is less than 1.2, it may be difficult to exert the effect of offsetting the warp. If Td / Tc exceeds 40, the thickness of the molded product itself becomes thick, and it may be difficult to realize thinning. Td / Tc is preferably 2-35, more preferably 5-3, and even more preferably 8-30.

Further, in the present invention, it is preferable that the wall thickness Td of the plate material (D) 5 is 0.6 to 2 mm and the wall thickness Tc of the plate material (C) 4 is 0.05 to 0.5 mm. It is a range that can achieve both the effect of offsetting the warp and the realization of thinning.

If Td is less than 0.6 mm, the strength of the molded product itself may decrease. If Td exceeds 2 mm, the thickness of the molded product itself becomes thick, and it may be difficult to realize thinning. If Tc is less than 0.05 mm, poor appearance may occur. If the Tc exceeds 0.5 mm, the thickness of the molded product itself becomes thick, and it may be difficult to realize thinning.

Preferably, Td is 0.7 to 1.8 mm, Tc is 0.06 to 0.4 mm, more preferably Td is 0.9 to 1.6 mm, Tc is 0.08 to 0.3 mm, and even more preferably. , Td is 1 to 1.4 mm, and Tc is 0.1 to 0.2 mm.

Further, in the present invention, the plate material (C) 4 is a woven fabric fiber reinforced resin having one or more layers composed of a woven fabric fiber and a matrix resin, and the plate material (D) 5 is a unidirectional continuous fiber and a matrix resin. It is preferably a unidirectional fiber reinforced resin having one layer or two or more layers composed of.

As shown in FIG. 3, the laminated body (A) 2 has a configuration in which a unidirectional fiber reinforced resin is used as the plate material (D) 5 and a woven fiber reinforced resin is used as the plate material (C) 4. By arranging the woven fiber reinforced resin on the surface layer of either one of the laminated body (A) 2, the shape pattern of the carbon fiber woven fabric can be made conspicuous, and a unique surface morphology can be imparted to enhance the appearance design. it can. Further, by using the unidirectional fiber reinforced resin for the plate material (D) 5, the strength of the laminated body (A) 2 can be ensured. Further, as described above, the resin member (B) is joined by joining the resin member (B) 3 to the outer peripheral edge portion and / or the outer peripheral side surface portion of the laminated body (A) 2 with a bias. ) 3 causes stress in the direction opposite to the warp of the laminated body (A) 2, and even in an asymmetric laminated structure, the warpage of the molded body 1 can be suppressed.

Further, in the present invention, as shown in FIGS. 5 to 9, the plate material (C) 4 is a woven fabric fiber reinforced resin having one or more layers composed of a woven fabric fiber and a matrix resin, and the plate material (D). Reference numeral 5 denotes a sandwich structural member in which both surfaces of the core layer 7 are sandwiched between one layer or two or more layers of unidirectional fiber reinforced plastic composed of unidirectional continuous fibers and matrix resin as the skin layer 6. Is preferable. As a result, the surface morphology of the woven fabric can be imparted to enhance the appearance design, and the sandwich structural member using the unidirectional fiber reinforced resin is laminated and arranged as the skin layer 6, thereby making the skin lightweight and thin. Along with this, it is possible to secure a certain level of strength and rigidity.

As shown in FIGS. 5 (A) and 5 (B), the laminate (A) 2 is composed of a woven fiber reinforced resin on the surface of any one of the plate members (D) 5 composed of sandwich structural members. When the laminated body (A) 2 which is a planar structure is produced by laminating the plate material (C) 4 by press molding, immediately after the completion of press molding, as shown in FIG. 2 described above. As shown in FIG. 5 (A), the laminated body (A) 2 has a substantially flat shape without warping, but after that, due to heat shrinkage due to cooling, the laminated body (A) 2 has a dent in the center as shown in FIG. 5 (B). It may be deformed in a convex shape downward.

Therefore, as shown in FIGS. 6 and 7, the resin member is made to have a bias in the joining amount of the resin member (B) 3 to be joined to the outer peripheral edge portion and / or the outer peripheral side surface portion of the laminated body (A) 2. Due to the shrinkage of (B) 3, stress is generated in the direction opposite to the warp of the laminated body (A) 2, and the warp is canceled out as a whole. Reference numerals 11 to 14 displayed in FIGS. 6 and 7 have the same meanings as those in FIGS. 3 or 4 described above, and thus the description thereof will be omitted.

Further, in the present invention, as shown in FIGS. 8 and 9, the plate material (C) 4 is a woven fabric fiber reinforced resin having one or more layers composed of the woven fabric fiber and the matrix resin, and the plate material (D). It is also preferable that reference numeral 5 denotes a sandwich structure member in which both surfaces of the core layer 7 are sandwiched between one layer or two or more layers of woven fiber reinforced resin composed of woven fibers and matrix resin as the skin layer 6.

As a result, the surface morphology of the woven fabric shape pattern can be imparted to enhance the appearance design, and by using the woven fabric fiber reinforced resin as the skin layer 6, the molded body 1 can be made into a complicated shape such as a three-dimensional shape. Can be easily shaped, and the strength and rigidity of the molded body 1 can be ensured. Further, as shown in FIG. 8 or 9, the laminated body is formed by giving a bias to the joining amount of the resin member (B) 3 to be joined to the outer peripheral edge portion and / or the outer peripheral side surface portion of the laminated body (A) 2. (A) Stress is generated in the direction opposite to the warp of 2, and the warp is canceled out as a whole.

Examples of the reinforcing fibers used for the unidirectional fiber reinforced plastic and the woven fiber reinforced resin include high strength and high elasticity fibers such as carbon fiber, glass fiber, alumina fiber, silicon carbide fiber, boron fiber and silicon carbide fiber. Be done. In order to ensure light weight while maintaining high rigidity, it is preferable to use carbon fiber having a high specific elastic modulus, which is a ratio of elastic modulus to density, for example, polyacrylonitrile (PAN) type, pitch type, and cellulose type. , Gastric growth carbon fiber by hydrocarbon, graphite fiber and the like can be used, and two or more of these may be used in combination. Preferably, PAN-based carbon fiber having an excellent balance between rigidity and price is preferable.

Further, as the unidirectional fiber of the unidirectional fiber reinforced resin, it is preferable to have a structure in which two or more layers of continuous fiber base materials having different fiber orientation angles of 45 degrees or 90 degrees are laminated, whereby the molded body is thin and lightweight. Along with this, it is possible to impart a certain degree of rigidity and strength.

Further, in the present invention, the plate material (C) 4 is preferably arranged on the outermost layer on the design surface side of the fiber reinforced plastic molded body 1. By using the woven fiber reinforced resin having a characteristic fiber pattern as the plate material (C) 4, since the fiber pattern is characteristic, the characteristic fiber pattern can be made to stand out and can be differentiated in the design appearance. By using a woven fiber base material for the outermost layer, the shape pattern of the carbon fiber woven fabric can be made conspicuous and a novel surface pattern can be expressed.

Further, in the present invention, it is preferable that the resin member (B) 3 is joined and formed over the entire circumference of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A) 2. As shown in FIGS. 1, 3, 6 or 8, the molded product is joined to the resin member (B) 3 over the entire circumference of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A) 2. 1 As a whole, high bonding strength and thinning can be realized.

Further, in the present invention, the laminated body (A) 2 has a bonding layer (G) in a part or all of the flat surface portion of the outer peripheral edge portion of the plate material (D) 5 on the side where the plate material (C) 4 is not laminated. ) 8 is arranged, and it is preferable that the resin member (B) 3 is bonded to the laminated body (A) 2 via the bonding layer (G) 8.

As shown in FIGS. 4, 7 or 9, the bonding layer (G) 8 is previously attached to the surface opposite to the surface on which the plate material (C) 4 is laminated, and then the resin member (B) is attached. 3 is injection molded. As a result, the laminated body (A) 2 can be bonded to the molten resin member (B) 3 via the bonding layer (G) 8 to realize a higher bonding strength as the molded body 1. As the bonding layer (G) 8, a thermoplastic resin film or a non-woven fabric of a thermoplastic resin can be appropriately used.

Further, in the present invention, it is preferable that the core layer 7 is made of a resin foam or a porous base material made of a discontinuous fiber and a thermoplastic resin. Since the core layer 7 is porous and has voids, it is possible to realize weight reduction and high rigidity of the molded body 1.

Examples of the foam include polyurethane resin, phenol resin, melamine resin, acrylic resin, polyethylene resin, polypropylene resin, polyvinyl chloride resin, polystyrene resin, acrylonitrile-butadiene-styrene (ABS) resin, polyetherimide resin or polymethacrylicimide resin. Can be preferably used. Specifically, in order to ensure light weight, it is preferable to use a resin having an apparent density lower than that of the skin layer, and in particular, a polyurethane resin, an acrylic resin, a polyethylene resin, a polypropylene resin, a polyetherimide resin or a polymethacrylicimide resin is used. It can be preferably used.

When a composite composed of a thermoplastic resin and a discontinuous fiber is used as the core layer 7, a core layer precursor composed of the discontinuous fiber and the thermoplastic resin is prepared, and is equal to or higher than the softening point or the melting point of the thermoplastic resin. After heating and pressurizing, the pressurization is released, and the restoring force that tries to return to the original state when the residual stress of the discontinuous fiber is released, so-called springback, expands in the thickness direction to form voids with the composite. It is preferable to do so.

As the discontinuous fiber used for the core layer 7, the same kind of reinforcing fiber as the above-mentioned continuous fiber can be used. The fiber length of the discontinuous fiber is preferably 1 mm or more and less than 150 mm. If it is less than 1 mm, it is difficult to use the discontinuous fiber as a base material, while if the fiber length is 150 mm or more, the plate thickness of the molded product 1 may vary widely. As the thermoplastic resin used for the core layer 7, the same type of resin as the above-mentioned thermoplastic resin can be used.

Further, in the present invention, the warpage of the fiber reinforced plastic molded product 1 is preferably 2.0% or less. As a result, when the molded body 1 according to the present invention is used as a housing of an electronic device, high flatness can be maintained, and thinning and high strength can be realized without contacting internal electronic parts. it can.

Further, in the present invention, since the unidirectional fiber reinforced resin and the woven fiber reinforced resin ensure high rigidity, the tensile elastic modulus of the reinforced fiber is preferably in the range of 200 to 850 GPa from the viewpoint of the rigidity of the molded body 1. It is preferable to use the one that is inside. If the tensile elastic modulus of the reinforcing fiber is smaller than 200 GPa, it may not be possible to secure the required high rigidity while maintaining the light weight, and if it is larger than 850 GPa, the compressive strength of the reinforcing fiber is weak. Since it is easily broken, it is difficult to impregnate the reinforcing fibers with a matrix resin to form the fiber reinforced resin. When the tensile elastic modulus of the reinforcing fiber is within the above range, it is preferable in terms of further improving the rigidity of the laminated body and improving the manufacturability of the reinforcing fiber.

Further, in the present invention, from the viewpoint of moldability and strength of the laminate (A) 2, the weight fiber content of the unidirectional fiber reinforced resin is 50 to 80% by weight, and the weight fiber content of the woven fiber reinforced resin is 40. It is preferably ~ 70% by weight.

If the weight fiber content of the unidirectional fiber reinforced resin is less than 50% by weight, it may be difficult to develop the strength of the laminate (A) 2. If the weight fiber content of the unidirectional fiber reinforced resin exceeds 80% by weight, it may be difficult to handle as a prepreg because the amount of fibers is too large. It is preferably 55 to 75% by weight, more preferably 60 to 70% by weight.

If the weight fiber content of the woven fiber reinforced resin is less than 40% by weight, it may be difficult to develop the strength of the laminate (A) 2. If the weight fiber content of the woven fiber reinforced resin exceeds 70% by weight, the resin may be insufficient and the design after molding may be impaired. It is preferably 45 to 65% by weight, more preferably 50 to 60% by weight.

Further, in the present invention, the fiber woven fabric contained in the woven fiber reinforced resin is preferably at least one woven fabric selected from plain weave, twill weave, satin weave and satin weave.

Further, in the present invention, it is preferable that the matrix resin of the unidirectional fiber reinforced resin or the woven fiber reinforced resin is made of a thermosetting resin.

As the thermosetting resin, a thermosetting resin such as an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, a phenol (resole type) resin, a urea-melamine resin, a polyimide resin, a maleimide resin, or a benzoxazine resin is preferably used. be able to. In particular, epoxy resin is preferable from the viewpoint of mechanical properties of the molded product and heat resistance. The epoxy resin is preferably contained as a main component of the resin to be used in order to exhibit its excellent mechanical properties, and specifically, it is preferably contained in an amount of 60% by weight or more per resin composition.

Further, in the present invention, it is also preferable that the unidirectional fiber reinforced resin or the matrix resin of the woven fiber reinforced resin is made of a thermoplastic resin.

The thermoplastic resin is preferably at least one thermoplastic resin selected from polystyrene resin, polyamide resin, polycarbonate resin, polyester resin, polyethylene terephthalate resin, polyethylene resin and polypropylene resin, and the resin components are melted and laminated. The body (A) can be integrated, and a strong bonding strength with the resin member can be obtained.

Further, other thermoplastic resins can also be preferably used. For example, polyester resins such as polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, and liquid crystal polyester resin, polyolefin resins such as polybutylene resin, polyoxymethylene (POM) resin, and polyphenylene sulfide (PPS) resin. Polyarylene sulfide resin, polymethylmethacrylate (PMMA) resin, polyvinyl chloride (PVC) resin, polyphenylene ether (PPE) resin, polyimide (PI) resin, polyamideimide (PAI) resin, polyetherimide (PEI) resin, etc. , Polysulfone (PSU) resin, polyether sulfone resin, polyarylate (PAR) resin and other amorphous resins, other phenol-based resins, phenoxy resins, polystyrene-based resins, polyolefin-based resins, polyurethane-based resins, polyester-based Examples thereof include thermoplastic elastomers such as resins, polyamide-based resins, polybutadiene-based resins, polyisoprene-based resins, fluorine-based resins, and acrylonitrile-based resins, and thermoplastic resins selected from copolymers and modified products thereof. Among them, a polyolefin resin is preferable from the viewpoint of lightness of the obtained molded product, a polyamide resin is preferable from the viewpoint of strength, and amorphous such as a polycarbonate resin, a styrene resin, and a modified polyphenylene ether resin from the viewpoint of surface appearance. A sex resin is preferable.

Further, in the present invention, it is preferable that the resin member (B) 3 is composed of discontinuous carbon fiber or glass fiber and a thermoplastic resin. As a result, the laminated body (A) 2 constituting the molded body 1 and the resin member (B) 3 can be joined with high joining strength, and the warp of the molded body 1 can be reduced.

The thermoplastic resin is preferably at least one thermoplastic resin selected from the above-mentioned polystyrene resin, polyamide resin, polycarbonate resin, polyester resin, polyethylene terephthalate resin, polyethylene resin and polypropylene resin, and the resin component is melted. The laminated body (A) 2 can be integrated and a strong bonding strength with the resin member (B) 3 can be obtained.

Further, the fiber weight content of the resin member (B) 3 is preferably 5 to 30% by weight. It is possible to increase the joint strength and reduce the warp of the molded body 1. If it is less than 5% by weight, it may be difficult to secure the strength of the molded body 1, and if it exceeds 30% by weight, the filling of the resin member (B) 3 may be partially insufficient in injection molding. is there. The fiber weight content is more preferably 8 to 28% by weight, still more preferably 12 to 25% by weight. Further, the weight average fiber length of the discontinuous carbon fiber or the glass fiber is preferably 0.3 to 3 mm.

Here, continuous fibers and discontinuous fibers are defined. The continuous fiber is a state in which the reinforcing fibers contained in the molded body 1 are substantially continuously arranged over the entire length or width of the molded body 1, and the reinforcing fibers are intermittently separated from the discontinuous fiber. It refers to the arranged mode. Generally, a unidirectional fiber reinforced resin obtained by impregnating a unidirectionally aligned reinforcing fiber with a resin corresponds to a continuous fiber, such as an SMC base material used for press molding and a pellet material containing the reinforcing fiber used for injection molding. Corresponds to discontinuous fibers.

Among the discontinuous fibers, the pellet material used for injection molding can be classified into two types, long fiber pellets and short fiber pellets. The long fibers treated in the present invention are composed of discontinuous fibers in the molded product 1. Those having a weight average fiber length of 0.3 mm or more remaining in the members are defined as short fibers, and those having a weight average fiber length of less than 0.3 mm are defined as short fibers.

Since the reinforcing fibers remaining in the resin member (B) 3 are long fibers, the effect of canceling the warp of the molded body 1 can be enhanced. In the case of short fibers having a weight average fiber length of less than 0.3 mm, the strength of the resin member (B) 3 may tend to decrease. If the weight average fiber length exceeds 3 mm, the resin viscosity becomes high, and it may be difficult to uniformly fill the resin member (B) 3 up to the corner portion of the molding die during injection molding. The weight average fiber length of the discontinuous carbon fiber or glass fiber is preferably 0.4 to 2.8 mm, more preferably 0.7 to 1.5 mm, and even more preferably 0.9 to 1.2 mm.

Further, in the present invention, it is preferable that the resin member (B) 3 has a standing wall-shaped portion 10 at least in a part thereof. The resin member (B) 3 arranged on the side surface portion of the molded body 1 shown in the cross-sectional view of FIG. 4 or 7 is provided with the vertical wall-shaped portion 10 extending below the resin member (B) 3 to form the molded body 1 in a box shape. It can be a shaped body.

Next, the method for producing the fiber-reinforced plastic molded product of the present invention will be described with reference to the drawings.
First, the method for manufacturing the fiber-reinforced plastic molded product 1 shown in FIG. 6 will be described with reference to FIGS. 10 to 12. As shown in FIG. 10, on the press-molded lower die 21, the woven fiber reinforced resin 4 prepared in advance, the unidirectional fiber reinforced resin 6 which is the skin layer 6, the core layer 7 and the unidirectional which is the skin layer 6 are unidirectional. The fiber-reinforced resin 6 is laminated and arranged in order to form a precursor of the laminated body (A) 2. The woven fiber reinforced resin 4 and the unidirectional fiber reinforced resin 6 are preferably in the form of a prepreg in which the reinforcing fibers are impregnated with a thermosetting resin, or in the form of a UD tape or a woven fabric containing a thermoplastic resin. The woven fiber reinforced resin 4 corresponds to the plate material (C) 4, and the sandwich structural member composed of the unidirectional fiber reinforced resin 6, the core layer 7, and the unidirectional fiber reinforced resin 6 corresponds to the plate material (D) 5. ..

Then, as shown in FIG. 11, the press-molding upper die 22 is lowered to a position where it comes into contact with the unidirectional fiber reinforced resin 6, and the precursor of the laminate (A) 2 is compression-molded by a constant press pressure. The laminated body (A) 2 is generated. At this time, it is also effective to interpose a release film (not shown) between the mold and the precursor of the laminate (A) 2 to assist the releasability.

After that, as shown in FIG. 12A, the laminate shown in FIG. 11 is formed between the injection molding lower mold 23 and the injection molding upper mold 24 having the space 26 for forming the resin member (B) 3. A) Place 2. Next, as shown in FIG. 12 (B), the resin member (B) 3 composed of the reinforcing fiber and the thermoplastic resin is injection-molded from the injection gate port 25. As a result, the resin member (B) 3 is joined and integrated with the outer peripheral side surface portion of the laminated body (A) 2 to form the fiber reinforced plastic molded body 1.

Next, a method for producing a fiber-reinforced plastic molded product in which the bonding layer (G) 8 shown in FIG. 7 is provided and the resin member (B) 9 is also bonded to the flat surface portion of the outer peripheral edge portion of the laminated body (A) 2. Will be described with reference to FIGS. 13 to 15. As shown in FIG. 13, the woven fiber reinforced resin 4 prepared in advance, the unidirectional fiber reinforced resin 6 which is the skin layer 6, the core layer 7, and the unidirectional which is the skin layer 6 are prepared on the press-molded lower die 21. The fiber reinforced resin 6 and the bonding layer (G) 8 are laminated and arranged in this order to form a precursor of the laminated body (A). The woven fiber reinforced resin 4 corresponds to the plate material (C) 4, and the sandwich structural member composed of the unidirectional fiber reinforced resin 6, the core layer 7, the unidirectional fiber reinforced resin 6 and the bonding layer (G) 8 is a plate material. (D) Corresponds to 5.

After that, as shown in FIG. 14, the press forming upper die 22 is lowered to a position where it comes into contact with the bonding layer (G) 8, and the precursor of the laminated body (A) 2 is compression molded by a constant press pressure to be laminated. Form body (A) 2.

Next, as shown in FIG. 15A, the laminate shown in FIG. 14 is formed between the injection molding lower mold 23 and the injection molding upper mold 24 having the space 26 for forming the resin member (B) 3. (A) Place 2.

Next, as shown in FIG. 15B, the resin member (B) 3 composed of the reinforcing fiber and the thermoplastic resin is injection-molded from the injection gate port 25. As a result, the resin member (B) 3 forms the fiber-reinforced plastic molded body 1 which is joined and integrated with the outer peripheral side surface portion and the outer peripheral edge portion of the laminated body (A) 2.

Hereinafter, the fiber-reinforced plastic molded product 1 of the present invention and the method for producing the same will be specifically described with reference to Examples, but the following Examples do not limit the present invention.

(1) Measurement of number average fiber length The number average fiber length Ln of the reinforcing fibers contained in the resin member (B) 3 or the core layer 7 is measured. A part of the resin member (B) 3 or the core layer 7 to be measured from the fiber reinforced plastic molded body 1 is cut out and heated in an electric furnace at 500 ° C. for 60 minutes to sufficiently incinerate and remove the resin to remove only the reinforcing fibers. Was separated. More than 400 fibers were randomly selected from the separated reinforcing fibers. The fiber lengths of these extracted reinforcing fibers were measured using an optical microscope, the lengths of 400 fibers were measured up to 1 μm, and the number average fiber length Ln was calculated using the following formula.
Number average fiber length Ln = (ΣLi) / 400
Li: Fiber length (mm)

(2) Measurement of Fiber Weight Content The fiber weight content of the unidirectional fiber reinforced resin, woven fiber reinforced resin, core layer or resin member (B) 3 constituting the laminate (A) 2 is determined by the following method. It was measured. Each of the above-mentioned members to be measured was cut out from the fiber-reinforced plastic molded body 1, and its weight w0 (g) was measured. Next, the cut-out sample was heated in air at 500 ° C. for 1 hour to sufficiently incinerate and remove the resin component, and the weight w1 (g) of the remaining reinforcing fiber was measured. The fiber weight content (wt%) was determined using the following formula. The measurement was performed at n = 3, and the average value was used.
Fiber weight content (wt%) = (weight of reinforcing fiber w1 / weight of cut-out sample w0) x 100

(3) Measurement of flexural rigidity and flexural modulus The flexural modulus of each member was measured based on JIS K 7171. The flexural rigidity of each member was calculated by multiplying the flexural modulus obtained from the measurement of the flexural modulus by the moment of inertia of area / plate width.

(4) Measurement of Warpage FIG. 16 shows a method of measuring the warp state of the fiber reinforced plastic molded body 1. The warp of the molded body 1 was measured using a laser range finder manufactured by BOSCH. First, the molded body 1 is placed on a flat plate 30 that is kept horizontal. A reference surface 32 on which the laser range finder 31 can move is prepared above the molded body 1.

First, the distance between the reference surface 32 and both end portions 33 and 34 of the molded body 1 is measured by the laser range finder 31, and the line connecting the end portions 33 and 34 is set as the warped lower reference line 35. If the molded body 1 is, for example, a rectangle, measurement was performed on each of the four sides. The measurement location was performed by irradiating the vicinity of the outer peripheral ends of the four sides of the laminated body (A) 2 with a laser. This end portion is the end portion of the laminated body (A) 2, and does not include the resin member (B) 3.

Next, the laser 31 is moved between both end portions 33 and 34 at regular intervals, and the distance between the reference surface 32 and the molded body 1 at each location is measured. FIG. 16 illustrates seven odd-numbered points. At the place where the distance between the reference surface 32 and the molded body 1 is the shortest, the tangent line parallel to the lower warp reference line 35 is defined as the upper warp reference line 36. Let L (mm) be the distance between both ends 33 and 34, and A (mm) be the distance between the lower warp reference line 35 and the upper warp reference line 36.
Warp = (A / L) * 100 [%]
Specified in.

(Material Composition Example 1-1) Preparation of Unidirectional Fiber Reinforced Resin The following unidirectional fiber prepreg is used as a unidirectional fiber reinforced resin in which PAN-based carbon fiber bundles are arranged in a sheet shape in one direction and impregnated with an epoxy resin. Prepared.
One-way prepreg (1) (manufactured by Toray Industries, Inc., P3452S-15, carbon fiber weight content 67%, carbon fiber tensile modulus 235 GPa, thickness 0.15 mm)
One-way prepreg (2) (manufactured by Toray Industries, Inc., P3452S-10, carbon fiber weight content 67%, carbon fiber tensile modulus 235 GPa, thickness 0.10 mm)
One-way prepreg (3) (manufactured by Toray Industries, Inc., P12453F-16, carbon fiber weight content 67%, carbon fiber tensile modulus 550 GPa, thickness 0.15 mm)
One-way prepreg (4) (manufactured by Toray Industries, Inc., P12453F-11, carbon fiber weight content 67%, carbon fiber tensile modulus 550 GPa, thickness 0.10 mm)

(Material Composition Example 1-2) Preparation of Woven Fabric Reinforced Resin The following woven prepreg was prepared as the woven fiber reinforced resin.
A woven prepreg (1) having a texture of 198 g / m ² , a carbon fiber content of 56% by weight, and a thickness of 0.10 mm, which is composed of a woven carbon fiber having a tensile elastic modulus of 230 GPa and an epoxy resin having a glass transition temperature of 135 ° C.
A woven prepreg (2) having a grain size of 198 g / m ² , a carbon fiber content of 56% by weight, and a thickness of 0.10 mm, which is composed of a woven carbon fiber having a tensile elastic modulus of 550 GPa and an epoxy resin having a glass transition temperature of 135 ° C.
A woven prepreg (3) having a texture of 198 g / m ² , a carbon fiber content of 56% by weight, and a thickness of 0.05 mm, which is composed of a woven carbon fiber having a tensile elastic modulus of 230 GPa and an epoxy resin having a glass transition temperature of 135 ° C.

(Material Composition Example 2) Preparation of Core Layer 7 The following core layer was prepared as the core layer.
-Core layer (1): Core layer (1) made of expanded polypropylene (manufactured by Toray Industries, Inc., RC2012W)
-Core layer (2): As a porous base material, discontinuous fiber (manufactured by Toray Industries, Inc., T700S, number average fiber length of carbon fiber 5 mm), thermoplastic resin (polypropylene), weight content of discontinuous fiber 30 weight Core layer consisting of% (2)

(Material Composition Example 3) Preparation of Resin Member (B) 3 Glass Fiber Pellet for Injection Molding (manufactured by Teijin Co., Ltd., GXV3540-UI, glass fiber, number average fiber length 0.2 mm, polycarbonate resin, fiber weight content 40 weight %) Was prepared and used as the resin member (B-1) 3.
Prepare glass fiber pellets for injection molding (manufactured by Toray Co., Ltd., A503-F1, glass fiber, number average fiber length 0.2 mm), PPS resin, fiber weight content 30% by weight), and resin member (B-2). It was set to 3.

(Material Composition Example 4) Preparation of Bonding Layer (G) 8 Polyester resin (“Hitrel” (registered trademark) 4057 manufactured by Toray DuPont Co., Ltd.) is charged from the hopper of a twin-screw extruder and melted by the extruder. After kneading, it was extruded from a T-shaped die. Then, it was cooled and solidified by taking it up with a chill roll at 60 ° C. to obtain a polyester resin film having a thickness of 0.05 mm. This was used as the thermoplastic joint layer (G) 8.

(Example 1)
In Example 1, the fiber-reinforced plastic molded body (1) 1 shown in FIG. 3 was prepared.
A 300 mm × 300 mm rectangular unidirectional prepreg (1) prepared in Material Composition Example 1-1 was prepared as the plate material (D) 5, and 300 mm × 300 mm × prepared in Material Composition Example 1-2 as the plate material (C) 4. A 0.1 mmt woven prepreg (1) 2 ply was prepared, and the plate material (D) 5 and the plate material (C) 4 were laminated to prepare a precursor of the laminated body (A-1) 2.

Next, using the molding die illustrated in FIG. 10, the precursor of the laminated body (A-1) 2 is sandwiched between mold release films (not shown) and placed on a rectangular press-molded lower die 21 of 300 mm × 300 mm. I put it.

Next, using the molding die illustrated in FIG. 11, the press molding upper die 22 was set, placed on a board surface having a board surface temperature of 150 ° C., the board surface was closed, and heat pressing was performed at 3 MPa. After 5 minutes had passed from the pressurization, the board surface was opened to obtain a laminated body (A-1) 2 which is a carbon fiber reinforced resin plate having a thickness of 0.5 mm and a rectangular flat plate shape of 300 mm × 300 mm.

Next, using the molding die illustrated in FIG. 12 (A), the laminate (A-1) 2 is arranged in the space formed by the injection molding lower mold 23 and the injection molding upper mold 24. , As shown in FIG. 12B, the resin member (B-1) 3 obtained in Material Composition Example 3 is injection-molded from the injection gate port 25 so that Am1 / Am2 becomes 20, and fiber-reinforced plastic molding is performed. Body (1) 1 was manufactured. When the amount of warpage of the obtained fiber-reinforced plastic molded body (1) 1 was measured, the warpage of all four sides of the rectangle was within 0.5% with respect to the length of the sides, which was a level that would not cause any problem in actual use. .. The material composition, physical properties, etc. of the fiber-reinforced plastic molded product are summarized in (Table 1). The amount of warpage shown in Table 1 represents the maximum value among the amounts of warpage on four sides. The same applies to the subsequent examples.

(Example 2)
In Example 2, the fiber-reinforced plastic molded body (2) 1 shown in FIG. 4 was prepared.
A laminate (A-) having the same formulation as that of Example 1 except that the bonding layer (G) 8 prepared in Material Composition Example 4 was laminated on the plate material (D) 5 and the plate material (C) 4 shown in Example 1. 2) The precursor of 2 was prepared.

Next, using the molding dies illustrated in FIGS. 13 and 14, a laminated body (A-2) 2 which is a carbon fiber reinforced resin plate was obtained under the same conditions as in Example 1.

Next, using the molding die illustrated in FIG. 15A, the laminated body (A-2) 2 is arranged in the space formed by the injection molding lower mold 23 and the injection molding upper mold 24. As shown in FIG. 15 (B), the resin member (B-1) 3 obtained in Material Composition Example 3 was injection-molded from the injection gate port 25 so that Am1 / Am2 had the values shown in Table 1. A fiber-reinforced plastic molded product (2) 1 was manufactured. The amount of warpage of the obtained fiber-reinforced plastic molded product (2) 1 was small, and there was no problem in actual use. The material composition, physical properties, etc. of the fiber-reinforced plastic molded product are summarized in (Table 1).

(Example 3)
In Example 3, the fiber-reinforced plastic molded body (3) 1 shown in FIG. 6 was prepared.
As the plate material (D) 5, the unidirectional prepreg prepared in the material composition example 1-1 and the core layer (1) prepared in the material composition example 2-1 were used, and the "unidirectional prepreg (1) 0 ° / unidirectional" was used. Prepreg of 300 mm × 300 mm rectangular plate (D) 5 laminated in the order of prepreg (2) 90 ° / core layer (1) / unidirectional prepreg (2) 90 ° / unidirectional prepreg (1) 0 ° ” Prepared. Next, 2 plies of the 300 mm × 300 mm × 0.1 mmt woven prepreg (1) prepared in Material Composition Example 1-2 as the plate material (C) 4 are laminated on one side of the precursor of the plate material (D) 5. The precursor of (A-2) 2 was prepared. The flexural modulus Md of the plate material (D) 5 is "unidirectional prepreg (1) 0 ° / unidirectional prepreg (2) 90 ° / core layer (1) unidirectional prepreg (1) 0 ° / unidirectional prepreg (2) 90 ° / core layer (1) The elastic modulus of the cured product of the prepreg structure of "1) / unidirectional prepreg (2) 90 ° / unidirectional prepreg (1) 0 °" was measured.

Next, using the molds illustrated in FIGS. 10 and 11, a laminated body (A-3) 2 which is a carbon fiber reinforced resin plate was obtained under the same conditions as in Example 1.

Next, using the mold illustrated in FIG. 12 (A), the laminated body (A-3) 2 is arranged in the space formed by the injection molding lower mold 23 and the injection molding upper mold 24. As shown in FIG. 12B, the resin member (B-1) 3 obtained in Material Composition Example 3 is injection-molded from the injection gate port 25 so that Am1 / Am2 have the values shown in Table 1. The fiber-reinforced plastic molded product (3) 1 was manufactured. The amount of warpage of the obtained fiber-reinforced plastic molded product (3) 1 was small, and there was no problem in actual use. The material composition, physical properties, etc. of the fiber-reinforced plastic molded product are summarized in Table 1.

(Example 4)
In Example 4, the fiber-reinforced plastic molded body (4) 1 shown in FIG. 7 was prepared.
A laminated body (A-) having the same formulation as in Example 3 except that the bonding layer (G) 8 prepared in Material Composition Example 4 was laminated on the plate material (D) 5 and the plate material (C) 4 shown in Example 3. 4) The precursor of 2 was prepared.

Next, using the molding dies illustrated in FIGS. 13 and 14, a laminated body (A-4) 2 which is a carbon fiber reinforced resin plate was obtained under the same conditions as in Example 1.

Next, using the molding die illustrated in FIG. 15A, the laminated body (A-4) 2 is arranged in the space formed by the injection molding lower mold 23 and the injection molding upper mold 24. , As shown in FIG. 15 (B), the resin member (B-1) 3 prepared in Material Composition Example 3 was injection-molded from the injection gate port 25 so that Am1 / Am2 had the values shown in Table 1, and the fibers were formed. A reinforced plastic molded product (4) 1 was manufactured. The amount of warpage of the obtained fiber-reinforced plastic molded product (4) 1 was small, and there was no problem in actual use. The material composition, physical properties, etc. of the fiber-reinforced plastic molded product are summarized in (Table 1).

(Example 5)
In Example 5, the fiber-reinforced plastic molded body (5) 1 shown in FIG. 8 was prepared.
As the plate material (D) 5, the woven prepreg prepared in Material Composition Example 1-2 and the core layer (2) prepared in Material Composition Example 2-1 were used, and "Twill prepreg (3) 0 ° / Twill prepreg (2). ) 90 ° / foamed polypropylene / twill prepreg (2) 90 ° / twill prepreg (3) 0 ° ”, a precursor of a 300 mm × 300 mm rectangular plate (D) 5 was prepared. Next, 2 plies of the 300 mm × 300 mm × 0.1 mmt woven fabric prepreg (1) prepared in Material Composition Example 1-2 as the plate material (C) 4 are laminated on one side of the precursor of the plate material (D) 5. The precursor of (A-5) 2 was prepared. The flexural modulus Md of the plate material (D) 5 is "twill prepreg (3) 0 ° / twill prepreg (2) 90 ° / foamed polypropylene / twill prepreg (twill prepreg) in which woven prepregs are sandwiched and laminated on both sides of the core layer (1) 7. The elastic modulus of the cured prepreg having a structure of "2) 90 ° / twill prepreg (3) 0 °" was measured.

Next, using the molds illustrated in FIGS. 10 and 11, a laminated body (A-5) 2 which is a carbon fiber reinforced resin plate was obtained under the same conditions as in Example 1.

Next, using the mold illustrated in FIG. 12 (A), the laminated body (A-5) 2 is arranged in the space formed by the injection molding lower mold 23 and the injection molding upper mold 24. As shown in FIG. 12B, the resin member (B-2) 3 prepared in Material Composition Example 3 is injection-molded from the injection gate port 25 so that Am1 / Am2 have the values shown in Table 1. , Fiber-reinforced plastic molded product (5) 1 was manufactured. The amount of warpage of the obtained fiber-reinforced plastic molded product (5) 1 was small, and there was no problem in actual use. The material composition, physical properties, etc. of the fiber-reinforced plastic molded product are summarized in (Table 1).

(Example 6)
In Example 6, the fiber-reinforced plastic molded body (6) 1 shown in FIG. 9 was prepared.
A laminate (A-) having the same formulation as that of Example 5 except that the bonding layer (G) 8 prepared in Material Composition Example 4 was laminated on the plate material (D) 5 and the plate material (C) 4 shown in Example 5. 4) The precursor of 2 was prepared.

Next, using the molding dies illustrated in FIGS. 13 and 14, a laminated body (A-6) 2 which is a carbon fiber reinforced resin plate was obtained under the same conditions as in Example 1.

Next, using the molding die illustrated in FIG. 15A, the laminate (A-6) 2 is arranged in the space formed by the injection molding lower mold 23 and the injection molding upper mold 24. As shown in FIG. 15B, the resin member (B-2) 3 obtained in Material Composition Example 3 was injection-molded from the injection gate port 25 so that Am1 / Am2 had the values shown in Table 1. A fiber-reinforced plastic molded product (6) 1 was manufactured. The amount of warpage of the obtained fiber-reinforced plastic molded product (6) 1 was small, and there was no problem in actual use. The material composition, physical properties, etc. of the fiber-reinforced plastic molded product are summarized in (Table 1).

(Comparative Example 1)
Comparative Example 1 was carried out using the material formulations and dimensions shown in (Table 1). It is a molded product having a low Am2 / Am1 and the obtained fiber-reinforced plastic molded product 1 has a large warp, which causes a problem in actual use.

(Comparative Example 2)
Comparative Example 2 was performed using the material formulations and dimensions shown in (Table 1). Since the molded product has a high Am2 / Am1, the thickness of the obtained fiber-reinforced plastic molded product 1 is large, and the warpage of the molded product 1 is large, which causes a problem in actual use.

The fiber-reinforced plastic molded product of the present invention can be effectively used for automobile interior / exterior, electrical / electronic equipment housings, bicycles, structural materials for sports equipment, aircraft interior materials, transportation boxes, and the like.

1 Fiber reinforced plastic molded body 2 Laminated body (A)
3 Resin member (B)
4 Plate material (C)
5 Plate material (D)
6 Epidermis layer 7 Core layer 8 Joint layer (G)
9 Resin member (B) joined to the flat surface of the outer peripheral edge of the laminated body (A)
10 Standing wall shape portion 11 Wall thickness of laminated body (A) 2 12 Divided center line 13 Region (R1) on which the plate material (C) is laminated
14 Region (R2) on which the plate material (C) is not laminated
21 Press-molded lower die 22 Press-molded upper die 23 Injection-molded lower die 24 Injection-molded upper die 25 Injection gate port 26 Space for forming resin member (B) 30 Flat plate 31 Laser distance meter 32 Reference surfaces 33, 34 Both ends of the molded product 35 Warp lower reference line 36 Warp upper reference line

Claims (11)

A resin member (B) bonded to a laminated body (A) which is a planar structure made of at least a fiber reinforced resin and a part or all of an outer peripheral side surface portion and / or an outer peripheral peripheral portion of the laminated body (A). ), Which is a fiber reinforced plastic molded body.
The laminated body (A) has a structure in which a plate material (C) and a plate material (D) having at least different bending rigidity are laminated, and the bending rigidity of the plate material (D) is larger than the bending rigidity of the plate material (C). , The laminated body (A) is divided into halves in the wall thickness direction, and the resin member (B) existing in the region (R1) on which the plate material (C) is laminated rather than the divided center line. Assuming that the amount of the resin member (B) existing in the region (R2) on which the plate material (C) is not laminated is Am2, Am2 / Am1 is in the range of 2 to 25. Characterized fiber reinforced plastic molded body. According to claim 1, where the flexural modulus of the plate material (D) is Md (GPa) and the flexural modulus of the plate material (C) is Mc (GPa), Md / Mc is in the range of 1.2 to 17. The fiber reinforced plastic molded article described. The fiber-reinforced plastic molded product according to claim 1 or 2, wherein the flexural modulus Md of the plate material (D) is in the range of 100 to 500 GPa, and the flexural modulus Mc of the plate material (C) is in the range of 30 to 80 GPa. According to claims 1 to 3, where the wall thickness of the plate material (D) is Td (mm) and the wall thickness of the plate material (C) is Tc (mm), Td / Tc is in the range of 1.2 to 40. The fiber reinforced plastic molded body according to any one. The fiber according to any one of claims 1 to 4, wherein the wall thickness Td of the plate material (D) is in the range of 0.6 to 2 mm, and the wall thickness Tc of the plate material (C) is in the range of 0.05 to 0.5 mm. Reinforced plastic molded body. The plate material (C) is one layer or two or more layers of woven fiber reinforced resin composed of a woven fiber and a matrix resin, and the plate material (D) is composed of a unidirectional continuous fiber and a matrix resin. The fiber-reinforced plastic molded body according to any one of claims 1 to 5, which is a unidirectional fiber-reinforced resin having one layer or two or more layers. The plate material (C) is one layer or two or more layers of woven fiber reinforced resin composed of a woven fiber and a matrix resin, and the plate material (D) is a unidirectional continuous fiber on both surfaces of the core layer. It is a sandwich structural member sandwiched between one layer or two or more unidirectional fiber reinforced plastics composed of the matrix resin and one layer or two or more layers of the woven fiber reinforced resin composed of the woven fibers and the matrix resin. The fiber-reinforced plastic molded body according to any one of claims 1 to 5. The fiber-reinforced plastic molded product according to any one of claims 1 to 7, wherein the plate material (C) is arranged on the outermost layer on the design surface side of the fiber-reinforced plastic molded product. The fiber-reinforced plastic molded product according to any one of claims 1 to 8, wherein the resin member (B) is joined and formed over the entire circumference of the outer peripheral side surface portion and / or the outer peripheral edge portion of the laminated body (A). .. The laminated body (A) has a configuration in which the bonding layer (G) is arranged in a part or all of the flat surface portion of the outer peripheral edge portion of the plate material (D) on the side where the plate material (C) is not laminated. The fiber-reinforced plastic molded product according to any one of claims 1 to 9, wherein the resin member (B) is bonded to the laminated body (A) via a bonding layer (G). The fiber-reinforced plastic molded product according to any one of claims 1 to 10, wherein the warpage of the fiber-reinforced plastic molded product is 2% or less.

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