JP2021030616A - Fiber-reinforced resin composite molding and method for manufacturing the same - Google Patents
Fiber-reinforced resin composite molding and method for manufacturing the same Download PDFInfo
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- JP2021030616A JP2021030616A JP2019154490A JP2019154490A JP2021030616A JP 2021030616 A JP2021030616 A JP 2021030616A JP 2019154490 A JP2019154490 A JP 2019154490A JP 2019154490 A JP2019154490 A JP 2019154490A JP 2021030616 A JP2021030616 A JP 2021030616A
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- 239000000805 composite resin Substances 0.000 title claims abstract description 73
- 238000000465 moulding Methods 0.000 title claims abstract description 32
- 238000004519 manufacturing process Methods 0.000 title claims description 24
- 238000000034 method Methods 0.000 title description 2
- 229920005989 resin Polymers 0.000 claims abstract description 293
- 239000011347 resin Substances 0.000 claims abstract description 293
- 239000010410 layer Substances 0.000 claims abstract description 268
- 229920001187 thermosetting polymer Polymers 0.000 claims abstract description 161
- 239000000835 fiber Substances 0.000 claims abstract description 133
- 239000006260 foam Substances 0.000 claims abstract description 133
- 239000002344 surface layer Substances 0.000 claims abstract description 132
- 239000000463 material Substances 0.000 claims abstract description 124
- 150000001875 compounds Chemical class 0.000 claims abstract description 112
- 230000006835 compression Effects 0.000 claims abstract description 23
- 238000007906 compression Methods 0.000 claims abstract description 23
- 230000003014 reinforcing effect Effects 0.000 claims description 60
- 239000003677 Sheet moulding compound Substances 0.000 claims description 18
- 238000010438 heat treatment Methods 0.000 claims description 11
- 238000010030 laminating Methods 0.000 claims description 7
- 238000003475 lamination Methods 0.000 claims description 4
- 230000015572 biosynthetic process Effects 0.000 abstract 4
- 229920000049 Carbon (fiber) Polymers 0.000 description 12
- 239000004917 carbon fiber Substances 0.000 description 12
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- 239000011800 void material Substances 0.000 description 8
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- 230000000052 comparative effect Effects 0.000 description 6
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- 238000000748 compression moulding Methods 0.000 description 5
- 229920001567 vinyl ester resin Polymers 0.000 description 5
- 239000003822 epoxy resin Substances 0.000 description 4
- 239000003365 glass fiber Substances 0.000 description 4
- 230000005484 gravity Effects 0.000 description 4
- 229920000647 polyepoxide Polymers 0.000 description 4
- 230000000694 effects Effects 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 239000012783 reinforcing fiber Substances 0.000 description 3
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000004640 Melamine resin Substances 0.000 description 2
- 229920000877 Melamine resin Polymers 0.000 description 2
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- 230000035699 permeability Effects 0.000 description 2
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- JOYRKODLDBILNP-UHFFFAOYSA-N Ethyl urethane Chemical compound CCOC(N)=O JOYRKODLDBILNP-UHFFFAOYSA-N 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- 238000007605 air drying Methods 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
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Abstract
Description
本発明は、繊維強化樹脂複合成形体とその製造方法に関する。 The present invention relates to a fiber-reinforced resin composite molded product and a method for producing the same.
従来、繊維強化樹脂成形体は、高強度且つ高剛性であるという点から、スポーツ、レジャー、航空機などの幅広い産業分野で使用されている。
繊維強化樹脂成形体の製造方法として、補強繊維に熱硬化性樹脂を含浸したプリプレグや、シートモールディングコンパウンドなどを圧縮成形する方法が、多くの分野で採用されている。
Conventionally, a fiber reinforced resin molded product has been used in a wide range of industrial fields such as sports, leisure, and aircraft because of its high strength and high rigidity.
As a method for producing a fiber-reinforced resin molded product, a method of compression molding a prepreg in which reinforcing fibers are impregnated with a thermosetting resin, a sheet molding compound, or the like is adopted in many fields.
プリプレグは補強繊維として長繊維を用いるため、高強度・高剛性の成形体が得られる反面、複雑な形状に賦形し難い。それに対して、シートモールディングコンパウンドは、補強繊維として短い繊維を用いるため、成形品の強度は低くなるものの、成形時の流動性に優れ、リブやボスなどの複雑な形状にも賦形し易い。 Since the prepreg uses long fibers as reinforcing fibers, a molded product having high strength and high rigidity can be obtained, but it is difficult to shape the prepreg into a complicated shape. On the other hand, since the sheet molding compound uses short fibers as reinforcing fibers, the strength of the molded product is low, but the fluidity during molding is excellent, and it is easy to shape into complicated shapes such as ribs and bosses.
また、プリプレグとシートモールディングコンパウンドの双方の利点を取り入れるため、プリプレグとシートモールディングコンパウンドを積層して圧縮成形した成形品が提案されている（特許文献１）。 Further, in order to take advantage of both the prepreg and the sheet molding compound, a molded product obtained by laminating the prepreg and the sheet molding compound and compression molding has been proposed (Patent Document 1).
しかし、プリプレグとシートモールディングコンパウンドを積層して圧縮成形した成形品は、圧縮成形時のシートモールディングコンパウンドの流動によって、シートモールディングコンパウンドと接触しているプリプレグに繊維の乱れ（捩れ）が発生しやすく、外観上の問題となりやすい。 However, in a molded product obtained by laminating a prepreg and a sheet molding compound and compression molding, the prepreg in contact with the sheet molding compound is likely to be disturbed (twisted) due to the flow of the sheet molding compound during compression molding. It tends to be an appearance problem.
また、圧縮成形時にシートモールディングからの揮発物が、シートモールディングコンパウンドとプリプレグとの境界に溜まりやすく、ボイド等の原因となる場合がある。成形品は、ボイド等の存在によって、外観が損なわれることになる。 In addition, volatile matter from the sheet molding during compression molding tends to accumulate at the boundary between the sheet molding compound and the prepreg, which may cause voids and the like. The appearance of the molded product is impaired due to the presence of voids and the like.
本発明は、前記の点に鑑みなされたものであり、複雑な形状であっても繊維の乱れやボイド等の無い、良好な外観を有する繊維強化樹脂複合成形体とその製造方法の提供を目的とする。 The present invention has been made in view of the above points, and an object of the present invention is to provide a fiber-reinforced resin composite molded body having a good appearance without fiber disorder or voids even if it has a complicated shape, and a method for producing the same. And.
請求項１の発明は、表層部形成用繊維強化樹脂材から形成された表層部と、前記表層部形成用繊維強化樹脂材に含まれる繊維よりも短い繊維と熱硬化性樹脂とよりなる基層部形成用コンパウンドから形成された基層部と、前記表層部形成用繊維強化樹脂材と前記基層部形成用コンパウンド間に配置された連続気泡構造の熱硬化性樹脂発泡体シートから形成された中間層部とを有し、前記表層部形成用繊維強化樹脂材と前記連続気泡構造の熱硬化性樹脂発泡体シート及び前記基層部形成用コンパウンドが、加熱圧縮により硬化して積層一体化したものであることを特徴とする繊維強化樹脂複合成形体に係る。
The invention of
請求項２の発明は、請求項１において、前記中間層部と前記基層部との間に、補強層部形成用繊維強化樹脂材から形成された補強層部を有し、前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記基層部形成用コンパウンドが、加熱圧縮により硬化して積層一体化したものであることを特徴とする。
The invention of
請求項３の発明は、請求項２において、前記補強層部と前記基層部との間に、第２の連続気泡構造の熱硬化性樹脂発泡体シートから形成された第２の中間層部を有し、前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記第２の連続気泡構造の熱硬化性樹脂発泡体シートと、前記基層部形成用コンパウンドが、加熱圧縮により硬化して積層一体化したものであることを特徴とする。
According to the third aspect of the present invention, in
請求項４の発明は、請求項１から３の何れか一項において、前記繊維強化樹脂材はプリプレグであり、前記基層部形成用コンパウンドはシートモールディングコンパウンドであることを特徴とする。
The invention of claim 4 is characterized in that, in any one of
請求項５の発明は、表層部形成用繊維強化樹脂材から形成された表層部と、前記表層部形成用繊維強化樹脂材に含まれる繊維よりも短い繊維と熱硬化性樹脂とよりなる基層部形成用コンパウンドから形成された基層部と、前記表層部形成用繊維強化樹脂材と前記基層部形成用コンパウンド間に配置された連続気泡構造の熱硬化性樹脂発泡体シートから形成された中間層部とを有する繊維強化樹脂複合成形体の製造方法であって、前記表層部形成用繊維強化樹脂材と前記基層部形成用コンパウンドを、前記連続気泡構造の熱硬化性発泡体シートを挟んで積層して加熱圧縮し、前記圧縮状態で硬化させることにより、前記表層部と前記中間層部と前記基層部を積層一体化させることを特徴とする。
The invention of
請求項６の発明は、請求項５において、前記積層に際し、前記連続気泡構造の熱硬化性発泡体シートと前記基層部形成用コンパウンドの間に、補強層部形成用繊維強化樹脂材を配置し、前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記基層部形成用コンパウンドを、加熱圧縮により硬化させて積層一体化し、前記補強層部形成用繊維強化樹脂材から形成された補強層部を前記中間層部と前記基層部間に設けることを特徴とする。 In the fifth aspect of the present invention, in the fifth aspect, the fiber reinforced resin material for forming the reinforcing layer portion is arranged between the thermosetting foam sheet having the open cell structure and the compound for forming the base layer portion. The fiber-reinforced resin material for forming the surface layer portion, the thermosetting resin foam sheet having the open cell structure, the fiber-reinforced resin material for forming the reinforcing layer portion, and the compound for forming the base layer portion are cured by heating and compression. It is characterized in that the reinforcing layer portion formed from the fiber reinforced resin material for forming the reinforcing layer portion is provided between the intermediate layer portion and the base layer portion.
請求項７の発明は、請求項６において、前記積層に際し、前記補強層部形成用繊維強化樹脂材と前記基層部形成用コンパウンドの間に、第２の連続気泡構造の熱硬化性樹脂発泡体シートを配置し、前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記第２の連続気泡構造の熱硬化性樹脂発泡体シートと、前記基層部形成用コンパウンドを、加熱圧縮により硬化させて積層一体化し、前記第２の連続気泡構造の熱硬化性樹脂発泡体シートから形成された第２の中間層部を、前記補強層部と前記基層部間に設けることを特徴とする。
The invention of
請求項８の発明は、請求項５から７の何れか一項において、前記繊維強化樹脂材はプリプレグであり、前記基層部形成用コンパウンドはシートモールディングコンパウンドであることを特徴とする。
The invention of
本発明によれば、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドを、連続気泡構造の熱硬化性樹脂発泡体シートを挟んで積層して加熱圧縮し、基層部形成用コンパウンドを流動させて賦形する際に、基層部形成用コンパウンドの流動による表層部形成用繊維強化樹脂材に与える影響を、基層部形成用コンパウンドと表層部形成用繊維強化樹脂材との間に存在する連続気泡構造の熱硬化性樹脂発泡体シートによって緩和することができ、表層部形成用繊維強化樹脂材における繊維の乱れを防ぎ、繊維強化樹脂複合成形体の表層部の外観を良好なものにできる。 According to the present invention, a fiber-reinforced resin material for forming a surface layer portion and a compound for forming a base layer portion are laminated with a thermosetting resin foam sheet having an open cell structure sandwiched between them and heat-compressed to flow the compound for forming a base layer portion. The effect of the flow of the base layer forming compound on the surface layer forming fiber reinforced resin material during shaping is continuously present between the base layer forming compound and the surface layer forming fiber reinforced resin material. It can be relaxed by the thermosetting resin foam sheet having a bubble structure, the disorder of the fibers in the fiber reinforced resin material for forming the surface layer portion can be prevented, and the appearance of the surface layer portion of the fiber reinforced resin composite molded body can be improved.
また、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドを、連続気泡構造の熱硬化性樹脂発泡体シートを挟んで積層して加熱圧縮することにより、基層部形成用コンパウンドを流動させて賦形する際に、基層部形成用コンパウンドから生じる揮発物が、基層部形成用コンパウンドと表層部形成用繊維強化樹脂材との間に存在する連続気泡構造の熱硬化性樹脂発泡体シートに吸収されて分散し、あるいは連続気泡構造の熱硬化性樹脂発泡体シートを通って外部へ放出されるため、ボイド等の発生を防ぐことができ、繊維強化樹脂複合成形体の表層部の外観を良好なものにできる。 Further, the fiber-reinforced resin material for forming the surface layer portion and the compound for forming the base layer portion are laminated by sandwiching a thermosetting resin foam sheet having an open cell structure and heat-compressed to flow the compound for forming the base layer portion. At the time of shaping, the volatile substances generated from the base layer forming compound are absorbed by the thermosetting resin foam sheet having an open cell structure existing between the base layer forming compound and the surface layer forming fiber reinforced resin material. Since it is dispersed and released to the outside through a thermosetting resin foam sheet having an open cell structure, it is possible to prevent the generation of voids and the like, and the appearance of the surface layer portion of the fiber reinforced resin composite molded body is good. Can be made into something.
さらに、前記中間層部と前記基層部との間に補強層部形成用繊維強化樹脂材から形成された補強層部を設けることにより、表層部の外観が良好な繊維強化樹脂複合成形体の強度及び剛性を、さらに高くすることができる。 Further, by providing the reinforcing layer portion formed of the fiber reinforced resin material for forming the reinforcing layer portion between the intermediate layer portion and the base layer portion, the strength of the fiber reinforced resin composite molded body having a good appearance of the surface layer portion is provided. And the rigidity can be further increased.
さらに、前記補強層部と前記基層部との間に第２の連続気泡構造の熱硬化性樹脂発泡体シートから形成された第２の中間層部を設けることより、前記基層部形成用コンパウンドの流動及び揮発物による影響を、前記中間層部を形成する連続気泡構造の熱硬化性樹脂発泡体シートと、前記第２の中間層部を形成する第２の連続気泡構造の熱硬化性樹脂発泡体シートとの二つの連続気泡構造の熱硬化性樹脂発泡体シートによって緩和することができ、繊維強化樹脂複合成形体の表層部の外観をさらに良好なものにでき、かつ強度及び剛性を高いものにできる。 Further, by providing a second intermediate layer portion formed of a thermosetting resin foam sheet having a second open cell structure between the reinforcing layer portion and the base layer portion, the compound for forming the base layer portion can be provided. The influence of flow and volatile substances is affected by the thermosetting resin foam sheet having an open cell structure forming the intermediate layer portion and the thermosetting resin foam having a second open cell structure forming the second intermediate layer portion. It can be relaxed by the thermosetting resin foam sheet having two open cell structures with the body sheet, the appearance of the surface layer of the fiber reinforced resin composite molded body can be further improved, and the strength and rigidity are high. Can be done.
以下、本発明の繊維強化樹脂複合成形体及びその製造方法について説明する。
図１に示す第１実施形態の繊維強化樹脂複合成形体１０は、表層部形成用繊維強化樹脂材から形成された表層部１１と、基層部形成用コンパウンドから形成された基層部２１と、表層部１１と基層部２１との間に配置され、連続気泡構造の熱硬化性樹脂発泡体シートから形成された中間層部３１とよりなる。繊維強化樹脂複合成形体１０は、表層部１１における繊維の乱れや、基層部形成用コンパウンドからのボイドに起因する問題が無く、外観の良好なものである。なお、表層部１１と基層部２１の何れが、繊維強化樹脂複合成形体１０の表側の面あるいは裏側の面にされるかについては、繊維強化樹脂複合成形体１０の用途等に応じて決められる。
Hereinafter, the fiber-reinforced resin composite molded product of the present invention and a method for producing the same will be described.
The fiber-reinforced resin composite molded
表層部１１は、表層部形成用繊維強化樹脂材が加熱圧縮されて硬化したものからなる。
表層部形成用繊維強化樹脂材は、繊維シートに熱硬化性樹脂が含浸したものである。繊維シートとしては、炭素繊維、ガラス繊維、アラミド繊維等の繊維から構成されたものを挙げることができる。特に、軽量化と剛性向上の点から炭素繊維が好ましい。繊維シートは、織物、編み物、不織布等であってもよい。織物としては、平織、綾織、朱子織、三軸織等がある。また、繊維シートは、一方向あるいは複数方向に配向した繊維で構成されていてもよい。繊維シートは、剛性向上の点から、繊維織物が好ましい。
The surface layer portion 11 is made of a fiber-reinforced resin material for forming the surface layer portion, which is heat-compressed and cured.
The fiber-reinforced resin material for forming the surface layer portion is a fiber sheet impregnated with a thermosetting resin. Examples of the fiber sheet include those composed of fibers such as carbon fiber, glass fiber, and aramid fiber. In particular, carbon fiber is preferable from the viewpoint of weight reduction and rigidity improvement. The fiber sheet may be a woven fabric, a knitted fabric, a non-woven fabric, or the like. As the woven fabric, there are plain weave, twill weave, satin weave, triaxial weave and the like. Further, the fiber sheet may be composed of fibers oriented in one direction or a plurality of directions. As the fiber sheet, a fiber woven fabric is preferable from the viewpoint of improving rigidity.
繊維シートを構成する繊維は、後記の基層部形成用コンパウンドに含まれる繊維よりも繊維長が長いものが好ましく、例えば連続繊維あるいは不連続繊維からなるものが挙げられる。 The fibers constituting the fiber sheet preferably have a longer fiber length than the fibers contained in the base layer forming compound described later, and examples thereof include continuous fibers and discontinuous fibers.
繊維シートに含浸する熱硬化性樹脂としては、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、またはこれらの混合樹脂等が挙げられる。繊維シートに熱硬化性樹脂が含浸した表層部形成用繊維強化樹脂材としては、プリプレグが好ましい。 Examples of the thermosetting resin impregnated in the fiber sheet include an epoxy resin, a phenol resin, a vinyl ester resin, and a mixed resin thereof. A prepreg is preferable as the fiber-reinforced resin material for forming the surface layer portion in which the fiber sheet is impregnated with the thermosetting resin.
基層部２１は、表層部形成用繊維強化樹脂材に含まれる繊維よりも短い繊維と熱硬化性樹脂とよりなる基層部形成用コンパウンドが加熱圧縮されて硬化したものからなる。図示の基層部２１は、表面に凸部としての補強用リブ２３とボス２５が突出形成されている。なお、基層部２１の表面形状は、補強用リブ２３とボス２５とからなる凸部に限られず、繊維強化樹脂複合成形体１０の用途等に応じて適宜の凹形状、凸形状、凹凸形状、あるいは凹凸の無いものであってもよい。
The
基層部形成用コンパウンドに含まれる繊維の長さは、成形性の点から３０ｍｍ以下が好ましく、また、剛性向上の点からは５ｍｍ以上が好ましい。基層部形成用コンパウンドに含まれる繊維としては、炭素繊維、ガラス繊維等の短繊維が挙げられる。特に軽量化と剛性向上の点から炭素繊維が好ましい。 The length of the fiber contained in the base layer forming compound is preferably 30 mm or less from the viewpoint of moldability, and is preferably 5 mm or more from the viewpoint of improving rigidity. Examples of the fiber contained in the base layer forming compound include short fibers such as carbon fiber and glass fiber. In particular, carbon fiber is preferable from the viewpoint of weight reduction and rigidity improvement.
基層部形成用コンパウンドに含まれる熱硬化性樹脂としては、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、不飽和ポリエステル樹脂、またはこれらの混合樹脂等が挙げられる。
基層部形成用コンパウンドとしては、シートモールディングコンパウンド（以下ＳＭＣと記す）が好ましい。ＳＭＣは、熱硬化性樹脂に充填材や硬化剤などを含んだコンパウンドを、ガラス繊維や炭素繊維などの繊維材に含浸させたシート状の成形材料をいう。
Examples of the thermosetting resin contained in the base layer forming compound include epoxy resin, phenol resin, vinyl ester resin, unsaturated polyester resin, and a mixed resin thereof.
As the base layer forming compound, a sheet molding compound (hereinafter referred to as SMC) is preferable. SMC refers to a sheet-shaped molding material obtained by impregnating a fiber material such as glass fiber or carbon fiber with a compound containing a filler or a curing agent in a thermosetting resin.
中間層部３１は、連続気泡構造の熱硬化性樹脂発泡体シートが、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドの間に配置されて、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドと共に加熱圧縮され、表層部形成用繊維強化樹脂材及び基層部形成用コンパウンドに含浸している熱硬化性樹脂と接触あるいは含浸して、該熱硬化性樹脂が硬化したものである。中間層部３１は、熱硬化性樹脂の硬化により、連続気泡構造の熱硬化性樹脂発泡体シートが圧縮された状態で形状固定されている。 In the intermediate layer portion 31, a thermosetting resin foam sheet having an open cell structure is arranged between the fiber reinforced resin material for forming the surface layer portion and the compound for forming the base layer portion, and the fiber reinforced resin material for forming the surface layer portion and the base layer are arranged. The thermosetting resin is cured by being heat-compressed together with the part-forming compound and contacting or impregnating with the thermosetting resin impregnated in the surface layer-forming fiber-reinforced resin material and the base layer-forming compound. .. The shape of the intermediate layer portion 31 is fixed in a compressed state of the thermosetting resin foam sheet having an open cell structure by curing the thermosetting resin.
連続気泡構造の熱硬化性樹脂発泡体シートとしては、ウレタン樹脂発泡体、メラミン樹脂発泡体等のシートが挙げられる。熱硬化性樹脂発泡体を連続気泡構造のものとすることにより、熱硬化性樹脂が熱硬化性樹脂発泡体シートに含浸可能になり、また熱硬化性樹脂発泡体シートの圧縮が容易になり、さらには繊維強化樹脂複合成形体１０の製造時にＳＭＣからの揮発物を逃がし、ボイドの発生を防止することができるようになる。連続気泡構造の熱硬化性樹脂発泡体シートがウレタン樹脂発泡体からなる場合、セル数（ＪＩＳ Ｋ ６４００−１）は５〜９０個／２５ｍｍが好ましい。セル数の値が小さ過ぎると、セルの径が大きくなって強度が低下するようになる。一方、セル数の値が大きすぎると、セルの径が小さくなって通気性が悪くなる。
Examples of the thermosetting resin foam sheet having an open cell structure include sheets such as urethane resin foam and melamine resin foam. By making the thermosetting resin foam a continuous cell structure, the thermosetting resin can be impregnated into the thermosetting resin foam sheet, and the thermosetting resin foam sheet can be easily compressed. Further, it becomes possible to release volatile substances from the SMC during the production of the fiber-reinforced resin composite molded
また、中間層部３１を、連続気泡構造の熱硬化性樹脂発泡体シートで構成することにより、繊維強化樹脂複合成形体１０を製造する際の加熱圧縮時に、連続気泡構造の熱硬化性樹脂発泡体シートが軟化したり融着したりせず、加熱圧縮時における基層部形成用コンパウンドの流動による表層部形成用繊維強化樹脂材への悪影響を、連続気泡構造の熱硬化性樹脂発泡体シートで防ぐことができる。
Further, by forming the intermediate layer portion 31 with a thermosetting resin foam sheet having an open cell structure, the thermosetting resin foam having an open cell structure is foamed during heat compression when the fiber-reinforced resin composite molded
表層部１１と基層部２１と中間層部３１は、繊維強化樹脂複合成形体１０の製造の際に、連続気泡構造の熱硬化性樹脂発泡体シートを挟んで表層部形成用繊維強化樹脂材と基層部形成用コンパウンドを積層して行われる加熱圧縮によって、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドの熱硬化性樹脂が硬化することにより一体化している。
The surface layer portion 11, the
繊維強化樹脂複合成形体１０の製造方法は、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドを、連続気泡構造の熱硬化性樹脂発泡体シートを挟んで積層して加熱圧縮し、表層部形成用繊維強化樹脂材と基層部形成用コンパウンドに含まれる熱硬化性樹脂を、前記圧縮状態で硬化させることにより行う。
In the method for producing the fiber-reinforced resin composite molded
加熱圧縮の一実施形態を、図２に示す成形金型５０を用いる場合について説明する。成形金型５０は、上型５１と下型５３とで構成される。本実施形態では、上型５１の型面は平坦となっている。下型５３の型面は、繊維強化樹脂複合成形体１０の基層部２１の表面に応じた形状からなり、本実施形態では繊維強化樹脂複合成形体１０の補強リブ２３とボス２５を形成するための成形用凹部５５、５７が設けられている。
An embodiment of heat compression will be described with respect to the case where the molding die 50 shown in FIG. 2 is used. The molding die 50 is composed of an upper die 51 and a lower die 53. In this embodiment, the mold surface of the upper mold 51 is flat. The mold surface of the lower mold 53 has a shape corresponding to the surface of the
成形金型５０は、予め加熱炉に入れることにより、あるいは成形金型５０に設けた加熱手段（例えば電熱ヒータ等）によって所定温度に加熱される。加熱温度は、表層部形成用繊維強化樹脂材及び基層部形成用コンパウンドに含まれる熱硬化性樹脂が硬化する温度に設定される。 The molding die 50 is heated to a predetermined temperature by putting it in a heating furnace in advance or by a heating means (for example, an electric heater or the like) provided in the molding die 50. The heating temperature is set to a temperature at which the thermosetting resin contained in the fiber-reinforced resin material for forming the surface layer portion and the compound for forming the base layer portion is cured.
成形金型５０を開いた状態にして、図３に示すように、下型５３の型面に基層部形成用コンパウンド２１Ａと、連続気泡構造の熱硬化性樹脂発泡体シート３１Ａと、表層部形成用繊維強化樹脂材１１Ａを、この順に重ねて配置し、積層する。上型５１及び下型５３の型面には、予め離型剤を塗布しておくのが好ましい。 With the molding die 50 open, as shown in FIG. 3, a compound 21A for forming a base layer portion, a thermosetting resin foam sheet 31A having an open cell structure, and a surface layer portion are formed on the mold surface of the lower mold 53. The fiber reinforced resin material 11A for use is arranged and laminated in this order. It is preferable to apply a mold release agent to the mold surfaces of the upper mold 51 and the lower mold 53 in advance.
基層部形成用コンパウンド２１Ａは、前記のように炭素繊維やガラス繊維などの短繊維に、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、不飽和ポリエステル樹脂、あるいはそれらの混合樹脂などの熱硬化性樹脂が含浸したものであり、ＳＭＣが好ましい。基層部形成用コンパウンド２１Ａに含まれる短繊維は、表層部形成用繊維強化樹脂材１１Ａに含まれる繊維よりも短い繊維からなり、成形性の点から３０ｍｍ以下が好ましく、また、剛性向上の点からは５ｍｍ以上が好ましい。 As described above, the base layer forming compound 21A contains short fibers such as carbon fibers and glass fibers, and a thermosetting resin such as an epoxy resin, a phenol resin, a vinyl ester resin, an unsaturated polyester resin, or a mixed resin thereof. It is impregnated, and SMC is preferable. The short fibers contained in the base layer forming compound 21A are shorter than the fibers contained in the surface layer forming fiber reinforced resin material 11A, and are preferably 30 mm or less from the viewpoint of moldability, and from the viewpoint of improving rigidity. Is preferably 5 mm or more.
基層部形成用コンパウンド２１Ａは、下型５３の型面に、成形用凹部５５、５７を覆うように載置される。基層部形成用コンパウンド２１Ａの大きさは、成形用凹部５５、５７を覆うことのできる大きさからなり、下型５３の型面の大きさと等しくてもよい。 The base layer portion forming compound 21A is placed on the mold surface of the lower mold 53 so as to cover the molding recesses 55 and 57. The size of the base layer portion forming compound 21A is such that it can cover the molding recesses 55 and 57, and may be equal to the size of the mold surface of the lower mold 53.
連続気泡構造の熱硬化性樹脂発泡体シート３１Ａは、前記のようにウレタン樹脂発泡体やメラミン樹脂発泡体等の連続気泡構造の熱硬化性樹脂発泡体からなり、予め、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、あるいはそれらの混合樹脂などからからなる熱硬化性樹脂を含浸させておいてもよい。連続気泡構造の熱硬化性樹脂発泡体シートがウレタン樹脂発泡体からなる場合、セル数（ＪＩＳ Ｋ ６４００−１は５〜９０個／２５ｍｍ、見かけ密度（ＪＩＳ Ｋ ７２２２）は２０〜１００ｋｇ／ｍ３が好ましく、より好ましくは３０〜７５ｋｇ／ｍ３である。さらに、通気性確保のため、公知のセル膜除去処理が行われたものが好ましい。また、連続気泡構造の熱硬化性樹脂発泡体シートの厚みは、薄過ぎると表層部１１における繊維の乱れやボイド等による外観の問題を生じるようになり、逆に厚過ぎると繊維強化樹脂複合成形体１０の強度が低下するようになるため、０．３〜３．０ｍｍの厚みが好ましい。
The thermosetting resin foam sheet 31A having an open cell structure is made of a thermosetting resin foam having an open cell structure such as a urethane resin foam or a melamine resin foam as described above. It may be impregnated with a thermosetting resin made of a vinyl ester resin or a mixed resin thereof. When the thermosetting resin foam sheet having an open cell structure is made of urethane resin foam, the number of cells (JIS K 640-1 is 5 to 90 cells / 25 mm, and the apparent density (JIS K 7222) is 20 to 100 kg / m 3). Is preferable, and more preferably 30 to 75 kg / m 3. Further, in order to ensure air permeability, a known cell film removing treatment is preferably performed. Further, a thermosetting resin foam sheet having an open cell structure is preferable. If the thickness is too thin, problems in appearance due to fiber disorder and voids in the surface layer portion 11 will occur, and conversely, if the thickness is too thick, the strength of the fiber-reinforced resin composite molded
なお、予め連続気泡構造の熱硬化性樹脂発泡体シートに熱硬化性樹脂を付着あるいは含浸させる場合、連続気泡構造の熱硬化性樹脂発泡体シートを熱硬化性樹脂に漬けるディッピングや塗布などに限られない。例えば、表層部形成用繊維強化樹脂材１１Ａや基層部形成用コンパウンド２１Ａに連続気泡構造の熱硬化性樹脂発泡体シートを貼り付ける（積層を含む）ことにより、表層部形成用繊維強化樹脂材１１Ａや基層部形成用コンパウンド２１Ａの表面に付着している熱硬化性樹脂を、連続気泡構造の熱硬化性樹脂発泡体シートに付着あるいは含浸させるようにしてもよい。 When the thermosetting resin is previously adhered or impregnated to the thermosetting resin foam sheet having an open cell structure, it is limited to dipping or coating in which the thermosetting resin foam sheet having an open cell structure is immersed in the thermosetting resin. I can't. For example, by attaching a thermosetting resin foam sheet having an open cell structure to the fiber-reinforced resin material 11A for forming the surface layer portion or the compound 21A for forming the base layer portion (including lamination), the fiber-reinforced resin material 11A for forming the surface layer portion is attached. The thermosetting resin adhering to the surface of the base layer portion forming compound 21A may be adhering to or impregnating the thermosetting resin foam sheet having an open cell structure.
また、表層部形成用繊維強化樹脂材１１Ａと連続気泡構造の熱硬化性樹脂発泡体シート３１Ａと基層部形成用コンパウンド２１Ａを加熱圧縮する際に、表層部形成用繊維強化樹脂材１１Ａ及び基層部形成用コンパウンド２１Ａから滲出した熱硬化性樹脂を、連続気泡構造の熱硬化性樹脂発泡体シート３１Ａに含浸させるようにしてもよい。 Further, when the surface layer forming fiber reinforced resin material 11A, the thermosetting resin foam sheet 31A having an open cell structure, and the base layer forming compound 21A are heated and compressed, the surface layer forming fiber reinforced resin material 11A and the base layer portion are formed. The thermosetting resin exuded from the forming compound 21A may be impregnated into the thermosetting resin foam sheet 31A having an open cell structure.
連続気泡構造の熱硬化性樹脂発泡体シート３１Ａは、基層部形成用コンパウンド２１Ａを覆うようにして下型５３内に配置される。連続気泡構造の熱硬化性樹脂発泡体シート３１Ａの大きさは、基層部形成用コンパウンド２１Ａの流動による影響が表層部形成用繊維強化樹脂材１１Ａに伝わらないようにするため、基層部形成用コンパウンド２１Ａの流動範囲と等しい、あるいはそれより広い範囲を覆う大きさにするのが好ましい。 The thermosetting resin foam sheet 31A having an open cell structure is arranged in the lower mold 53 so as to cover the base layer portion forming compound 21A. The size of the thermosetting resin foam sheet 31A having an open cell structure is such that the influence of the flow of the base layer forming compound 21A is not transmitted to the surface layer forming fiber reinforced resin material 11A. It is preferable that the size covers a range equal to or wider than the flow range of 21A.
表層部形成用繊維強化樹脂材１１Ａは、前記のように炭素繊維織物などの繊維シートに、エポキシ樹脂、フェノール樹脂、ビニルエステル樹脂、またはこれらの混合樹脂等からなる熱硬化性樹脂が含浸したものであり、プリプレグが好ましい。繊維シートの繊維は、基層部形成用コンパウンドに含まれる繊維よりも繊維長の長いものが好ましい。なお、表層部形成用繊維強化樹脂材１１Ａは、一枚のプリプレグで構成する場合に限られず、複数枚のプリプレグを積層したもので構成してもよい。 The fiber-reinforced resin material 11A for forming the surface layer is obtained by impregnating a fiber sheet such as a carbon fiber woven fabric with a thermosetting resin made of an epoxy resin, a phenol resin, a vinyl ester resin, or a mixed resin thereof as described above. Therefore, prepreg is preferable. The fibers of the fiber sheet are preferably those having a longer fiber length than the fibers contained in the base layer forming compound. The fiber-reinforced resin material 11A for forming the surface layer portion is not limited to the case where it is composed of one prepreg, and may be composed of a plurality of laminated prepregs.
下型５３の型面に、基層部形成用コンパウンド２１Ａと含浸発泡体シート３１Ａと表層部形成用繊維強化樹脂材１１Ａを、この順に積層した後、図４に示すように上型５１を下型５３に被せ、基層部形成用コンパウンド２１Ａと含浸発泡体シート３１Ａと表層部形成用繊維強化樹脂材１１Ａを積層状態で加熱圧縮する。 After laminating the base layer portion forming compound 21A, the impregnated foam sheet 31A, and the surface layer portion forming fiber reinforced resin material 11A on the mold surface of the lower mold 53 in this order, the upper mold 51 is mounted on the lower mold 51 as shown in FIG. It is put on 53, and the base layer portion forming compound 21A, the impregnated foam sheet 31A, and the surface layer portion forming fiber reinforced resin material 11A are heated and compressed in a laminated state.
なお、成形用凹部や凸部が下型の型面ではなく上型の型面に設けられている場合、下型の型面には、表層部形成用繊維強化樹脂材１１Ａと連続気泡構造の熱硬化性樹脂発泡体シート３１Ａと基層部形成用コンパウンド２１Ａを、この順に積層する。
また、成形用凹部や凸部が、下型の型面及び上型の型面の何れにも設けられていない場合、下型の型面に対する表層部形成用繊維強化樹脂材１１Ａと連続気泡構造の熱硬化性樹脂発泡体シート３１Ａと基層部形成用コンパウンド２１Ａの積層配置は、この順あるいは逆の何れであってもよい。
When the concave and convex portions for molding are provided not on the mold surface of the lower mold but on the mold surface of the upper mold, the lower mold surface has a fiber-reinforced resin material 11A for forming a surface layer portion and an open cell structure. The thermosetting resin foam sheet 31A and the base layer forming compound 21A are laminated in this order.
Further, when the molding recesses and protrusions are not provided on either the lower mold surface or the upper mold surface, the fiber reinforced resin material 11A for forming the surface layer portion and the open cell structure with respect to the lower mold surface are formed. The layered arrangement of the thermosetting resin foam sheet 31A and the base layer portion forming compound 21A may be in this order or in the reverse order.
加熱圧縮時における基層部形成用コンパウンド２１Ａ、連続気泡構造の熱硬化性樹脂発泡体シート３１Ａ、表層部形成用繊維強化樹脂材１１Ａの挙動を以下に説明する。
基層部形成用コンパウンド２１Ａは、加熱により流動性を生じ、下型５３の型面の成形用凹部５５、５７に入り込み、さらに下型５３の型面上に流延する。
The behaviors of the base layer portion forming compound 21A, the thermosetting resin foam sheet 31A having an open cell structure, and the surface layer portion forming fiber reinforced resin material 11A at the time of heat compression will be described below.
The base layer portion forming compound 21A generates fluidity by heating, enters the molding recesses 55 and 57 of the mold surface of the lower mold 53, and further flows onto the mold surface of the lower mold 53.
連続気泡構造の熱硬化性樹脂発泡体シート３１Ａは、基層部形成用コンパウンド２１Ａと表層部形成用繊維強化樹脂材１１Ａとの間で圧縮され、基層部形成用コンパウンド２１Ａ及び表層部形成用繊維強化樹脂材１１Ａの熱硬化性樹脂が接触し、あるいは含浸する。また、連続気泡構造の熱硬化性樹脂発泡体シート３１Ａは、基層部形成用コンパウンド２１Ａと表層部形成用繊維強化樹脂材１１Ａとの間にあって緩衝作用を発揮し、基層部形成用コンパウンド２１Ａの流動による影響が表層部形成用繊維強化樹脂材１１Ａに伝わるのを防ぐと共に、基層部形成用コンパウンド２１Ａからの揮発物を吸収し、ボイドの発生を防ぐ。 The thermosetting resin foam sheet 31A having an open cell structure is compressed between the base layer forming compound 21A and the surface layer forming fiber reinforced resin material 11A, and is compressed between the base layer forming compound 21A and the surface layer forming fiber reinforced. The thermosetting resin of the resin material 11A comes into contact with or is impregnated. Further, the thermosetting resin foam sheet 31A having an open cell structure is located between the base layer portion forming compound 21A and the surface layer portion forming fiber reinforced resin material 11A and exerts a buffering action, so that the base layer portion forming compound 21A flows. It prevents the influence of the above from being transmitted to the fiber reinforced resin material 11A for forming the surface layer portion, and absorbs the volatile matter from the compound 21A for forming the base layer portion to prevent the generation of voids.
表層部形成用繊維強化樹脂材１１Ａは、含浸されている熱硬化性樹脂が圧縮により滲出する。表層部形成用繊維強化樹脂材１１Ａから滲出した熱硬化性樹脂は、連続気泡構造の熱硬化性樹脂発泡体シート３１Ａに接触し、あるいは含浸する。 In the fiber-reinforced resin material 11A for forming the surface layer portion, the impregnated thermosetting resin exudes by compression. The thermosetting resin exuded from the fiber-reinforced resin material 11A for forming the surface layer portion comes into contact with or impregnates the thermosetting resin foam sheet 31A having an open cell structure.
そして、基層部形成用コンパウンド２１Ａ、連続気泡構造の熱硬化性樹脂発泡体シート３１Ａ及び表層部形成用繊維強化樹脂材１１Ａは、圧縮された状態でそれぞれの熱硬化性樹脂が硬化する。それによって、基層部形成用コンパウンド２１Ａから基層部２１が形成され、また連続気泡構造の熱硬化性樹脂発泡体シート３１Ａから中間層部３１が形成され、さらに表層部形成用繊維強化樹脂材１１Ａから表層部１１が形成される。それと共に、それぞれの熱硬化性樹脂が接触し、あるいは混ざり合って硬化することにより、基層部２１と中間層部３１及び表層部１１が接着一体化し、前記繊維強化樹脂複合成形体１０が形成される。繊維強化樹脂複合成形体１０は、基層部形成用コンパウンド２１Ａの流動による影響が連続気泡構造の熱硬化性樹脂発泡体シート３１Ａにより緩衝され、また基層部形成用コンパウンド２１Ａからの揮発物が連続気泡構造の熱硬化性樹脂発泡体シート３１Ａにより吸収されるため、複雑形状であっても繊維の乱れやボイド等の無い、良好な外観の表層部１１が得られる。
The thermosetting resin for forming the base layer portion 21A, the thermosetting resin foam sheet 31A having an open cell structure, and the fiber reinforced resin material 11A for forming the surface layer portion are each cured in a compressed state. As a result, the
図５に示す第２実施形態の繊維強化樹脂複合成形体１０１は、表層部１１１と、中間層部３１１と、補強層部１２１と、基層部２１１が積層一体化したものであり、補強層部１２１を中間層部３１１と基層部２１１間に有する点で第１実施形態の繊維強化樹脂複合成形体１０とは異なる。
In the fiber-reinforced resin composite molded body 101 of the second embodiment shown in FIG. 5, the surface layer portion 111, the intermediate layer portion 311 and the reinforcing layer portion 121 and the base layer portion 211 are laminated and integrated, and the reinforcing layer portion is integrated. It differs from the fiber-reinforced resin composite molded
表層部１１１は、表層部形成用繊維強化樹脂材から形成されたものであり、第１実施形態の表層部１１と同様の構成からなる。 The surface layer portion 111 is formed of a fiber-reinforced resin material for forming the surface layer portion, and has the same configuration as the surface layer portion 11 of the first embodiment.
中間層部３１１は、連続気泡構造の熱硬化性樹脂発泡体シートから形成されたものであり、第１実施形態の中間層部３１と同様の構成からなる。 The intermediate layer portion 311 is formed of a thermosetting resin foam sheet having an open cell structure, and has the same structure as the intermediate layer portion 31 of the first embodiment.
補強層部１２１は、補強層部形成用繊維強化樹脂材から形成されたものである。補強層形成用繊維強化樹脂材は、表層部形成用繊維強化樹脂材と同様に繊維シートに熱硬化性樹脂が含浸したものからなり、プリプレグが好ましい。 The reinforcing layer portion 121 is formed of a fiber-reinforced resin material for forming the reinforcing layer portion. The fiber-reinforced resin material for forming a reinforcing layer is made of a fiber sheet impregnated with a thermosetting resin in the same manner as the fiber-reinforced resin material for forming a surface layer portion, and a prepreg is preferable.
基層部２１１は、基層部形成用コンパウンドから形成されたものであり、第１実施形態の基層部２１と同様の構成からなる。基層部形成用コンパウンドに含まれる繊維は、表層部形成用繊維強化樹脂材及び補強層部形成用繊維強化樹脂材に含まれる繊維よりも短い繊維からなる。基層部２１１の表面には、凸部としての補強用リブ２３１とボス２５１が突出形成されている。
The base layer portion 211 is formed from a compound for forming a base layer portion, and has the same configuration as the
表層部１１１、中間層部３１１、補強層部１２１、基層部２１１は、繊維強化樹脂複合成形体１０１の製造の際に、表層部形成用繊維強化樹脂材、連続気泡構造の熱硬化性樹脂発泡体シート、補強層部形成用繊維強化樹脂材、基層部形成用コンパウウンドを積層して行われる加熱圧縮によって、表層部形成用繊維強化樹脂材と補強層部形成用繊維強化樹脂材及び基層部形成用コンパウンドの熱硬化性樹脂が滲出して連続気泡構造の熱硬化性樹脂発泡体シートに付着、含浸し、また滲出した熱硬化性樹脂同士が接触あるいは混ざり合って硬化することにより一体化している。 The surface layer portion 111, the intermediate layer portion 311 and the reinforcing layer portion 121 and the base layer portion 211 are formed of a fiber-reinforced resin material for forming the surface layer portion and a thermosetting resin foam having an open cell structure during the production of the fiber-reinforced resin composite molded body 101. A fiber-reinforced resin material for forming a surface layer, a fiber-reinforced resin material for forming a reinforcing layer, and a base layer are formed by heating and compressing a body sheet, a fiber-reinforced resin material for forming a reinforcing layer, and a compound for forming a base layer. The thermosetting resin of the compound for use exudes and adheres to and impregnates the thermosetting resin foam sheet having an open cell structure, and the exuded thermosetting resins are integrated by contacting or mixing with each other and curing. ..
第２実施形態の繊維強化樹脂複合成形体１０１の製造方法について、次に示す。
図６に示すように、成形金型５０の下型５３の型面に、基層部形成用コンパウンド２１１Ａ、補強層部形成用繊維強化樹脂材１２１Ａ、連続気泡構造の熱硬化性樹脂発泡体シート３１１Ａ、表層部形成用繊維強化樹脂材１１１Ａを、この順に配置し、積層する。なお、成形金型５０は、第１実施形態の製造方法で説明したとおりである。
The method for producing the fiber-reinforced resin composite molded body 101 of the second embodiment is shown below.
As shown in FIG. 6, a compound 211A for forming a base layer portion, a fiber reinforced resin material 121A for forming a reinforcing layer portion, and a thermosetting resin foam sheet 311A having an open cell structure are formed on the mold surface of the lower mold 53 of the molding die 50. , The fiber reinforced resin material 111A for forming the surface layer portion is arranged in this order and laminated. The molding die 50 is as described in the manufacturing method of the first embodiment.
次に、上型５１を下型５３に被せ、基層部形成用コンパウンド２１１Ａ、補強層部形成用繊維強化樹脂材１２１Ａ、連続気泡構造の熱硬化性樹脂発泡体シート３１１Ａ、表層部形成用繊維強化樹脂材１１１Ａを積層状態で加熱圧縮する。その加熱圧縮により、基層部形成用コンパウンド２１１Ａが流動して下型５３の型面形状になるとともに、基層部形成用コンパウンド２１１Ａと補強層部形成用繊維強化樹脂材１２１Ａ及び表層部形成用繊維強化樹脂材１１１Ａから熱硬化性樹脂が滲出して連続気泡構造の熱硬化性樹脂発泡体シート３１１Ａに付着、含浸し、また滲出した熱硬化性樹脂同士が混ざり合って硬化する。それにより、図５に示した、表層部１１１と中間層部３１１と補強層部１２１と基層部２１１が積層一体化した繊維強化樹脂複合成形体１０１が得られる。 Next, the upper mold 51 is put on the lower mold 53, the base layer portion forming compound 211A, the reinforcing layer portion forming fiber reinforced resin material 121A, the thermosetting resin foam sheet 311A having an open cell structure, and the surface layer portion forming fiber reinforcement. The resin material 111A is heated and compressed in a laminated state. Due to the heat compression, the base layer portion forming compound 211A flows to form the mold surface shape of the lower mold 53, and the base layer portion forming compound 211A, the reinforcing layer portion forming fiber reinforced resin material 121A, and the surface layer portion forming fiber reinforcing material are reinforced. The thermosetting resin exudes from the resin material 111A and adheres to and impregnates the thermosetting resin foam sheet 311A having an open cell structure, and the exuded thermosetting resins are mixed and cured. As a result, the fiber-reinforced resin composite molded body 101 in which the surface layer portion 111, the intermediate layer portion 311 and the reinforcing layer portion 121 and the base layer portion 211 are laminated and integrated as shown in FIG. 5 is obtained.
第２実施形態の繊維強化樹脂複合成形体１０１は、加熱圧縮によって基層部形成用コンパウンドを流動させて賦形する際に、基層部形成用コンパウンドの流動による影響や、基層部形成用コンパウンドからの揮発物による影響を、連続気泡構造の熱硬化性樹脂発泡体シートによって緩和することができ、表層部１１１の外観が良好なものになる。さらに、補強層部１２１の存在によって、繊維強化樹脂複合成形体１０１の強度及び剛性がより高いものになる。 In the fiber-reinforced resin composite molded body 101 of the second embodiment, when the compound for forming the base layer portion is flowed and shaped by heat compression, the influence of the flow of the compound for forming the base layer portion and the influence of the flow of the compound for forming the base layer portion and the compound for forming the base layer portion The influence of volatile substances can be mitigated by the thermosetting resin foam sheet having an open cell structure, and the appearance of the surface layer portion 111 is improved. Further, the presence of the reinforcing layer portion 121 makes the fiber reinforced resin composite molded body 101 stronger and more rigid.
図７に示す第３実施形態の繊維強化樹脂複合成形体１０２は、表層部１１２と、中間層部３１２と、補強層部１２２と、第２の中間層部３２２と、基層部２１２とが積層一体化したものである。中間層部３１２と基層部２１２の間に補強層部１２２と第２の中間層部３２２を有する点で、第１の実施形態の繊維強化樹脂複合成形体１０と異なる。また、補強層部１２２と基層部２１２間に第２の中間層部３２２を有する点で、第２の実施形態の繊維強化樹脂複合成形体１０１と異なる。
In the fiber-reinforced resin composite molded body 102 of the third embodiment shown in FIG. 7, the surface layer portion 112, the intermediate layer portion 312, the reinforcing layer portion 122, the second intermediate layer portion 322, and the base layer portion 212 are laminated. It is an integrated product. It differs from the fiber-reinforced resin composite molded
表層部１１２は、表層部形成用繊維強化樹脂材から形成されたものであり、第１実施形態の表層部１１及び第２実施形態の表層部１１１と同様の構成からなる。 The surface layer portion 112 is formed of a fiber-reinforced resin material for forming the surface layer portion, and has the same configuration as the surface layer portion 11 of the first embodiment and the surface layer portion 111 of the second embodiment.
中間層部３１２は、連続気泡構造の熱硬化性樹脂発泡体シートから形成されたものであり、第１実施形態の中間層部３１及び第２実施形態の中間層部３１１と同様の構成からなる。 The intermediate layer portion 312 is formed of a thermosetting resin foam sheet having an open cell structure, and has the same configuration as the intermediate layer portion 31 of the first embodiment and the intermediate layer portion 311 of the second embodiment. ..
補強層部１２２は、補強層部形成用繊維強化樹脂材から形成されたものであり、第１実施形態の補強層部１２１と同様の構成からなる。 The reinforcing layer portion 122 is formed of a fiber-reinforced resin material for forming the reinforcing layer portion, and has the same configuration as the reinforcing layer portion 121 of the first embodiment.
第２の中間層部３２２は、第２の連続気泡構造の熱硬化性樹脂発泡体シートから形成されたものである。第２の連続気泡構造の熱硬化性樹脂発泡体シートは、中間層部３１２を構成する連続気泡構造の熱硬化性樹脂発泡体シートと同様の材質からなる。 The second intermediate layer portion 322 is formed of a thermosetting resin foam sheet having a second open cell structure. The second open-cell structure thermosetting resin foam sheet is made of the same material as the open-cell structure thermosetting resin foam sheet constituting the intermediate layer portion 312.
基層部２１２は、基層部形成用コンパウンドから形成されたものであり、第１実施形態の基層部２１及び第２実施形態の基層部２１１と同様の構成からなる。基層部２１２の表面には、凸部としての補強用リブ２３２とボス２５２が突出形成されている。
The base layer portion 212 is formed from a compound for forming a base layer portion, and has the same configuration as the
表層部１１２、中間層部３１２、補強層部１２２、第２の中間層部３２２、基層部２１２は、繊維強化樹脂複合成形体１０２の製造の際に、表層部形成用繊維強化樹脂材、連続気泡構造の熱硬化性樹脂発泡体シート、補強層部形成用繊維強化樹脂材、第２の連続気泡構造の熱硬化性樹脂発泡体シート、基層部形成用コンパウウンドを積層して行われる加熱圧縮によって、表層部形成用繊維強化樹脂材と補強層部形成用繊維強化樹脂材及び基層部形成用コンパウンドの熱硬化性樹脂が滲出して、連続気泡構造の熱硬化性樹脂発泡体シート及び第２の連続気泡構造の熱硬化性樹脂発泡体シートに付着、含浸し、また滲出した熱硬化性樹脂同士が接触あるいは混ざり合って硬化することにより一体化している。 The surface layer portion 112, the intermediate layer portion 312, the reinforcing layer portion 122, the second intermediate layer portion 322, and the base layer portion 212 are continuous with the fiber reinforced resin material for forming the surface layer portion during the production of the fiber reinforced resin composite molded body 102. By heat compression performed by laminating a thermosetting resin foam sheet having a bubble structure, a fiber-reinforced resin material for forming a reinforcing layer portion, a thermosetting resin foam sheet having a second open cell structure, and a compound for forming a base layer portion. , The thermosetting resin material for forming the surface layer portion, the thermosetting resin material for forming the reinforcing layer portion, and the thermosetting resin of the compound for forming the base layer portion are exuded, and the thermosetting resin foam sheet having an open cell structure and the second It adheres to and impregnates the thermosetting resin foam sheet having an open cell structure, and the exuded thermosetting resins are integrated by contacting or mixing with each other and curing.
第３実施形態の繊維強化樹脂複合成形体１０２の製造方法について、次に示す。
図８に示すように、成形金型５０の下型５３の型面に、基層部形成用コンパウンド２１２Ａ、第２の連続気泡構造の熱硬化性樹脂発泡体シート３２２Ａ、補強層部形成用繊維強化樹脂材１２２Ａ、連続気泡構造の熱硬化性樹脂発泡体シート３１２Ａ、表層部形成用繊維強化樹脂材１１２Ａを、この順に配置し、積層する。なお、成形金型５０は、第１実施形態の製造方法で説明したとおりである。
The method for producing the fiber-reinforced resin composite molded body 102 of the third embodiment is shown below.
As shown in FIG. 8, a compound 212A for forming a base layer portion, a thermosetting resin foam sheet 322A having a second open cell structure, and fiber reinforcement for forming a reinforcing layer portion are formed on the mold surface of the lower mold 53 of the molding die 50. The resin material 122A, the thermosetting resin foam sheet 312A having an open cell structure, and the fiber reinforced resin material 112A for forming the surface layer portion are arranged and laminated in this order. The molding die 50 is as described in the manufacturing method of the first embodiment.
次に、上型５１を下型５３に被せ、基層部形成用コンパウンド２１２Ａ、第２の連続気泡構造の熱硬化性樹脂発泡体シート３２２Ａ、補強層部形成用繊維強化樹脂材１２２Ａ、連続気泡構造の熱硬化性樹脂発泡体シート３１２Ａ、表層部形成用繊維強化樹脂材１１２Ａを積層状態で加熱圧縮する。その加熱圧縮により、基層部形成用コンパウンド２１２Ａが流動して下型５３の型面形状になるとともに、基層部形成用コンパウンド２１２Ａと補強層部形成用繊維強化樹脂材１２２Ａ及び表層部形成用繊維強化樹脂材１１２Ａから熱硬化性樹脂が滲出して連続気泡構造の熱硬化性樹脂発泡体シート３１２Ａ及び第２の連続気泡構造の発泡体シート３２２Ａに付着、含浸し、また滲出した熱硬化性樹脂同士が混ざり合って硬化する。それにより、図７に示した、表層部１１２と中間層部３１２と補強層部１２２と第２の中間層部３２２と基層部２１２が積層一体化した繊維強化樹脂複合成形体１０２が得られる。 Next, the upper mold 51 is put on the lower mold 53, the base layer portion forming compound 212A, the second open cell structure thermosetting resin foam sheet 322A, the reinforcing layer portion forming fiber reinforced resin material 122A, and the open cell structure. The thermosetting resin foam sheet 312A and the fiber reinforced resin material 112A for forming the surface layer portion are heat-compressed in a laminated state. Due to the heating and compression, the base layer portion forming compound 212A flows to form the mold surface shape of the lower mold 53, and the base layer portion forming compound 212A, the reinforcing layer portion forming fiber reinforced resin material 122A, and the surface layer portion forming fiber reinforcement are formed. The thermosetting resin exudes from the resin material 112A and adheres to and impregnates the thermosetting resin foam sheet 312A having an open cell structure and the foam sheet 322A having a second open cell structure, and the exuded thermosetting resins to each other. Are mixed and hardened. As a result, the fiber-reinforced resin composite molded body 102 in which the surface layer portion 112, the intermediate layer portion 312, the reinforcing layer portion 122, the second intermediate layer portion 322, and the base layer portion 212 are laminated and integrated as shown in FIG. 7 is obtained.
第３実施形態の繊維強化樹脂複合成形体１０２は、加熱圧縮によって基層部形成用コンパウンドを流動させて賦形する際に、基層部形成用コンパウンドの流動による影響や、基層部形成用コンパウンドからの揮発物による影響を、連続気泡構造の熱硬化性樹脂発泡体シート及び第２の連続気泡構造の熱硬化性樹脂発泡体シートによって緩和することができ、表層部１１２の外観が良好なものになる。さらに、補強層部１２２の存在によって、繊維強化樹脂複合成形体１０２の強度及び剛性がより高いものになる。 In the fiber-reinforced resin composite molded body 102 of the third embodiment, when the compound for forming the base layer portion is flowed and shaped by heat compression, the influence of the flow of the compound for forming the base layer portion and the influence of the flow of the compound for forming the base layer portion and the compound for forming the base layer portion The influence of volatile substances can be mitigated by the thermosetting resin foam sheet having an open cell structure and the thermosetting resin foam sheet having a second open cell structure, and the appearance of the surface layer portion 112 is improved. .. Further, the presence of the reinforcing layer portion 122 increases the strength and rigidity of the fiber reinforced resin composite molded body 102.
本発明による効果を確認するため、図９に示す成形金型６０を用いて以下に示す各実施例及び比較例の繊維強化樹脂複合成形体を作製した。
成形金型６０は、上型６１及び下型６３の何れも型面が平坦となっている。型面の平面サイズは２００×３００ｍｍであり、閉型時の上型６１の型面と下型６３の型面間の寸法（成形品の厚みに相当）が、１．５ｍｍに設定されている。
In order to confirm the effect of the present invention, the fiber-reinforced resin composite molded bodies of the following Examples and Comparative Examples were produced using the molding die 60 shown in FIG.
The molding die 60 has a flat mold surface in both the upper mold 61 and the lower mold 63. The plane size of the mold surface is 200 x 300 mm, and the dimension between the mold surface of the upper mold 61 and the mold surface of the lower mold 63 (corresponding to the thickness of the molded product) when the mold is closed is set to 1.5 mm. ..
・実施例１
まず、フェノール樹脂溶液（住友ベークライト株式会社製、品名：ＰＲ−５５７９１Ｂ、樹脂濃度６０ｗｔ％エタノール溶液）中に、綾織の炭素繊維織物（帝人株式会社製、品名：Ｗ−３１０１、繊維重量２００ｇ／ｍ２）を２００×３００ｍｍに裁断したものを漬け、取り出した後に、２５℃の室温で２時間自然乾燥することにより、フェノール樹脂含浸済み炭素繊維織物を作製した。
・ Example 1
First, in a phenol resin solution (manufactured by Sumitomo Bakelite Co., Ltd., product name: PR-55791B,
フェノール樹脂含浸済み炭素繊維織物の表面に、連続気泡構造の熱硬化性樹脂発泡体シート（セル膜除去処理済みのウレタン樹脂発泡体、株式会社イノアックコーポレーション製、品名：ＭＦ−５０、見かけ密度（ＪＩＳ Ｋ ７２２２）３０ｋｇ／ｍ３、セル数（ＪＩＳ Ｋ ６４００−１）５０個／２５ｍｍ、空隙率９７．１％、厚み０．４ｍｍ）を２００×３００ｍｍに裁断したものを貼り合わせた。空隙率の計算式は次の通りである。空隙率＝（ウレタン樹脂の真比重−嵩比重（≒ウレタン樹脂発泡体見かけ密度））／ウレタン樹脂の真比重×１００
なお、ウレタン樹脂の真比重とは、１．０５である。
Thermosetting resin foam sheet with open cell structure on the surface of carbon fiber woven fabric impregnated with phenol resin (urethane resin foam with cell film removal treatment, manufactured by Inoac Corporation, product name: MF-50, apparent density (JIS) K 7222) 30 kg / m 3 , the number of cells (JIS K 640-1) 50 cells / 25 mm, void ratio 97.1%, thickness 0.4 mm) were cut into 200 × 300 mm and bonded. The formula for calculating the porosity is as follows. Porosity = (true specific gravity of urethane resin-bulk specific gravity (≈ apparent density of urethane resin foam)) / true specific gravity of urethane resin x 100
The true specific gravity of the urethane resin is 1.05.
その後、フェノール樹脂含浸済み炭素繊維織物とその表面の連続気泡構造の熱硬化性樹脂発泡体シートを、６０℃の雰囲気下で１時間乾燥させて、フェノール樹脂含浸済み炭素繊維織物から表層部形成用繊維強化樹脂材（プリプレグ）を形成し、その表面に連続気泡構造の熱硬化性樹脂発泡体シートを貼り付けた状態とした。 Then, the phenol resin impregnated carbon fiber woven fabric and the thermosetting resin foam sheet having an open cell structure on the surface thereof are dried in an atmosphere of 60 ° C. for 1 hour to form a surface layer portion from the phenol resin impregnated carbon fiber woven fabric. A fiber-reinforced resin material (prepreg) was formed, and a thermosetting resin foam sheet having an open cell structure was attached to the surface thereof.
成形金型６０を１４０℃に加熱し、その成形金型６０を開いて型面に離型剤を塗布した後、下型６３の型面に、１６０×２４０ｍｍのサイズに切り出した基層部形成用コンパウンド（ＳＭＣ、三菱ケミカル株式会社製、品名：ＳＴＲ１２０Ｎ１３１、厚み２ｍｍ、繊維含有率５３％）と、連続気泡構造の熱硬化性樹脂発泡体シートと、表層部形成用繊維強化樹脂材（プリプレグ）を、その順に配置した。そして、上型６１を重ねて成形金型６０を閉じ、１４０℃で１５分間、５ＭＰａの圧力を加え、基層部形成用コンパウンド、連続気泡構造の熱硬化性樹脂発泡体シート及び表層部形成用繊維強化樹脂材を加熱圧縮し、基層部形成用コンパウンド、連続気泡構造の熱硬化性樹脂発泡体シート及び表層部形成用繊維強化樹脂材の熱硬化性樹脂を硬化させた。
The molding die 60 is heated to 140 ° C., the molding die 60 is opened, a mold release agent is applied to the mold surface, and then the mold surface of the lower mold 63 is cut out to form a base layer portion having a size of 160 × 240 mm. Compound (SMC, manufactured by Mitsubishi Chemical Co., Ltd., product name: STR120N131,
その後、成形金型６０を室温で冷却した後、上型６１と下型６３を開き、表層部形成用繊維強化樹脂材から形成された表層部と、連続気泡構造の熱硬化性樹脂発泡体シートから形成された中間層部と、基層部形成用コンパウンドから形成された基層部との一体品からなる実施例１の繊維強化樹脂複合成形体を得た。 Then, after cooling the molding die 60 at room temperature, the upper die 61 and the lower die 63 are opened, and the surface layer portion formed of the fiber reinforced resin material for forming the surface layer portion and the thermosetting resin foam sheet having an open cell structure are formed. A fiber-reinforced resin composite molded product of Example 1 was obtained, which consisted of an integral product of an intermediate layer portion formed from and a base layer portion formed from a compound for forming a base layer portion.
・実施例２
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートの厚みを０．６ｍｍに変更した以外、実施例１と同様にして実施例２の繊維強化樹脂複合成形体を作製した。
-Example 2
A fiber-reinforced resin composite molded product of Example 2 was produced in the same manner as in Example 1 except that the thickness of the thermosetting resin foam sheet having an open cell structure in Example 1 was changed to 0.6 mm.
・実施例３
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートの厚みを１．０ｍｍに変更した以外、実施例１と同様にして実施例３の繊維強化樹脂複合成形体を作製した。
・ Example 3
A fiber-reinforced resin composite molded product of Example 3 was produced in the same manner as in Example 1 except that the thickness of the thermosetting resin foam sheet having an open cell structure in Example 1 was changed to 1.0 mm.
・実施例４
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートの厚みを２．０ｍｍに変更した以外、実施例１と同様にして実施例４の繊維強化樹脂複合成形体を作製した。
・ Example 4
A fiber-reinforced resin composite molded product of Example 4 was produced in the same manner as in Example 1 except that the thickness of the thermosetting resin foam sheet having an open cell structure in Example 1 was changed to 2.0 mm.
・実施例５
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートの厚みを３．０ｍｍに変更した以外、実施例１と同様にして実施例５の繊維強化樹脂複合成形体を作製した。
・ Example 5
A fiber-reinforced resin composite molded product of Example 5 was produced in the same manner as in Example 1 except that the thickness of the thermosetting resin foam sheet having an open cell structure in Example 1 was changed to 3.0 mm.
・実施例６
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートを、セル数（ＪＩＳ Ｋ ６４００−１）８０個／２５ｍｍ、空隙率９５．２％、見かけ密度（ＪＩＳ Ｋ ７２２２）７５ｋｇ／ｍ３、厚み１．０ｍｍのセル膜除去処理済みウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名：ＭＦ−８０Ａ）に変更した以外、実施例１と同様にして実施例６の繊維強化樹脂複合成形体を作製した。
-Example 6
The thermosetting resin foam sheet having an open cell structure in Example 1 had 80 cells (JIS K 640-1) / 25 mm, a void ratio of 95.2%, and an apparent density (JIS K 7222) of 75 kg / m 3 . The fiber-reinforced resin composite molded product of Example 6 was prepared in the same manner as in Example 1 except that it was changed to a urethane resin foam having a thickness of 1.0 mm and having been treated to remove the cell film (manufactured by Inoac Corporation, product name: MF-80A). Made.
・実施例７
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートを、セル数（ＪＩＳ Ｋ ６４００−１）１０個／２５ｍｍ、空隙率９７．３％、見かけ密度（ＪＩＳ Ｋ ７２２２）３０ｋｇ／ｍ３、厚み１．０ｍｍのセル膜除去処理済みウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名：ＭＦ−１０）に変更した以外、実施例１と同様にして実施例７の繊維強化樹脂複合成形体を作製した。
-Example 7
The thermosetting resin foam sheet having an open cell structure in Example 1 had 10 cells (JIS K 640-1) / 25 mm, a void ratio of 97.3%, and an apparent density (JIS K 7222) of 30 kg / m 3 . The fiber-reinforced resin composite molded product of Example 7 was prepared in the same manner as in Example 1 except that it was changed to a urethane resin foam having a thickness of 1.0 mm and which had been treated to remove the cell film (manufactured by Inoac Corporation, product name: MF-10). Made.
・実施例８
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートを、セル数（ＪＩＳ Ｋ ６４００−１）８個／２５ｍｍ、空隙率９７．４％、見かけ密度（ＪＩＳ Ｋ ７２２２）３０ｋｇ／ｍ３、厚み１．０ｍｍのセル膜除去処理済みウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名：ＭＦ−８）に変更した以外、実施例１と同様にして実施例８の繊維強化樹脂複合成形体を作製した。
-Example 8
The thermosetting resin foam sheet having an open cell structure in Example 1 had 8 cells (JIS K 640-1) / 25 mm, a void ratio of 97.4%, and an apparent density (JIS K 7222) of 30 kg / m 3 . The fiber-reinforced resin composite molded product of Example 8 was prepared in the same manner as in Example 1 except that it was changed to a urethane resin foam having a thickness of 1.0 mm and which had been treated to remove the cell film (manufactured by Inoac Corporation, product name: MF-8). Made.
・実施例９
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートを、セル数（ＪＩＳ Ｋ ６４００−１）５０個／２５ｍｍ、空隙率９７．０％、見かけ密度（ＪＩＳ Ｋ ７２２２）３０ｋｇ／ｍ３、厚み１．０ｍｍ、セル膜除去処理無しのウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名：ＭＦ−５０）に変更した以外、実施例１と同様にして実施例９の繊維強化樹脂複合成形体を作製した。
-Example 9
The thermosetting resin foam sheet having an open cell structure in Example 1 had 50 cells (JIS K 640-1) / 25 mm, a void ratio of 97.0%, and an apparent density (JIS K 7222) of 30 kg / m 3 . Fiber reinforced resin composite molded product of Example 9 in the same manner as in Example 1 except that it was changed to a urethane resin foam having a thickness of 1.0 mm and no cell film removal treatment (manufactured by Inoac Corporation, product name: MF-50). Was produced.
・比較例
実施例１における連続気泡構造の熱硬化性樹脂発泡体シートを無しとし、他は実施例１と同様にして比較例の繊維強化樹脂複合成形体（中間層部無し）を作製した。
-Comparative Example A thermosetting resin foam sheet having an open cell structure in Example 1 was eliminated, and a fiber-reinforced resin composite molded body (without an intermediate layer portion) of Comparative Example was produced in the same manner as in Example 1 except for the thermosetting resin foam sheet.
各実施例及び比較例の繊維強化樹脂複合成形体に対し、全体厚み（ｍｍ）及び曲げ弾性率（ＧＰａ）を測定し、また外観を判断した。
曲げ弾性率（ＧＰａ）はＪＩＳ Ｋ ７０７４に基づいて測定した。
外観は、繊維強化樹脂複合成形体における表層部の表面を目視によって観察し、ボイドについて判断した。繊維ヨレ（撚れ）に関しては、物差しを用いて次のように測定、判断した。
繊維ヨレは、表層部の表面における２ｍｍ以上の範囲に渡って繊維の配列が乱れている場合に、２ｍｍ以上のヨレがあるとして「×」とし、ヨレが２ｍｍ未満の場合に「〇」とした。
ボイドは、表層部の表面の熱硬化性樹脂に孔（ピンホール）が見られる場合にボイド「有」とし、孔が見られない場合にボイド「無」とした。
The total thickness (mm) and flexural modulus (GPa) of the fiber-reinforced resin composite molded bodies of each Example and Comparative Example were measured, and the appearance was judged.
The flexural modulus (GPa) was measured based on JIS K 7074.
As for the appearance, the surface of the surface layer portion of the fiber-reinforced resin composite molded product was visually observed to determine the void. The fiber twist was measured and judged as follows using a measuring rod.
The fiber twist is marked with "x" when the fiber arrangement is disturbed over a range of 2 mm or more on the surface of the surface layer, assuming that there is a twist of 2 mm or more, and "○" when the twist is less than 2 mm. ..
The void was defined as "yes" when holes (pinholes) were found in the thermosetting resin on the surface of the surface layer, and "absent" when no holes were found.
図１０に、各実施例及び比較例における熱硬化性樹脂発泡体シートの構成と、繊維強化樹脂複合成形体の測定結果及び外観判断の結果を示す。
実施例１〜９の繊維強化樹脂複合成形体は、全体厚みが１．４〜１．７ｍｍ、曲げ弾性率が３２〜３８ＧＰａ、外観判断が繊維ヨレ「〇」、ボイド「無」であり、強度が十分でかつ表層部の外観が良好なものであった。
一方、中間層部が無く、表層部と基層部が接している比較例は、全体厚みが１．４ｍｍ、曲げ弾性率が３８ＧＰａ、外観判断が繊維ヨレ「×」、ボイド有であり、強度は十分であったが、表層部の外観が劣っていた。
FIG. 10 shows the constitution of the thermosetting resin foam sheet in each Example and Comparative Example, the measurement result of the fiber reinforced resin composite molded body, and the result of appearance judgment.
The fiber-reinforced resin composite molded bodies of Examples 1 to 9 have an overall thickness of 1.4 to 1.7 mm, a flexural modulus of 32 to 38 GPa, an appearance judgment of fiber twist "○" and void "none", and strength. Was sufficient and the appearance of the surface layer was good.
On the other hand, in the comparative example in which the surface layer portion and the base layer portion are in contact with each other without the intermediate layer portion, the overall thickness is 1.4 mm, the flexural modulus is 38 GPa, the appearance judgment is fiber twist "x", and the strength is high. It was sufficient, but the appearance of the surface layer was inferior.
このように、本発明によれば、流動性のよい基層部形成用コンパウンドから形成された基層部を有する繊維強化樹脂複合成形体を、繊維の乱れやボイド等の無い、良好な外観の表層部を有するものにできる。そのため、本発明は、複雑な表面形状が求められる繊維強化樹脂複合成形体に好適である。 As described above, according to the present invention, a fiber-reinforced resin composite molded product having a base layer portion formed from a compound for forming a base layer portion having good fluidity is provided with a surface layer portion having a good appearance without fiber disorder or voids. Can have. Therefore, the present invention is suitable for a fiber-reinforced resin composite molded product that requires a complicated surface shape.
１０、１０１、１０２ 繊維強化樹脂複合成形体
１１、１１１、１１２ 表層部
１１Ａ、１１１Ａ、１１２Ａ 表層部形成用繊維強化樹脂材
２１、２１１、２１２ 基層部
２１Ａ、２１１Ａ、２１２Ａ 基層部形成用コンパウンド
３１、３１１、３１２ 中間層部
３１Ａ、３１１Ａ、３１２Ａ 連続気泡構造の熱硬化性樹脂発泡体シート
３２２ 第２の中間層部
３２２Ａ 第２の連続気泡構造の熱硬化性樹脂発泡体シート
５０ 成形金型
５１ 上型
５３ 下型
５５、５７ 成形用凹部
６０ 実施例用成形金型
６１ 実施例用上型
６３ 実施例用下型
10, 101, 102 Fiber-reinforced resin composite molded body 11, 111, 112 Surface layer 11A, 111A, 112A Fiber-reinforced resin material for forming
Claims (8)
前記表層部形成用繊維強化樹脂材に含まれる繊維よりも短い繊維と熱硬化性樹脂とよりなる基層部形成用コンパウンドから形成された基層部と、
前記表層部形成用繊維強化樹脂材と前記基層部形成用コンパウンド間に配置された連続気泡構造の熱硬化性樹脂発泡体シートから形成された中間層部とを有し、
前記表層部形成用繊維強化樹脂材と前記連続気泡構造の熱硬化性樹脂発泡体シート及び前記基層部形成用コンパウンドが、加熱圧縮により硬化して積層一体化したものであることを特徴とする繊維強化樹脂複合成形体。 The surface layer part formed from the fiber reinforced resin material for forming the surface layer part, and
A base layer portion formed from a base layer portion forming compound composed of fibers shorter than the fibers contained in the fiber-reinforced resin material for forming the surface layer portion and a thermosetting resin, and
It has a fiber-reinforced resin material for forming a surface layer portion and an intermediate layer portion formed from a thermosetting resin foam sheet having an open cell structure arranged between the compound for forming a base layer portion.
A fiber characterized in that the fiber-reinforced resin material for forming a surface layer portion, the thermosetting resin foam sheet having an open cell structure, and the compound for forming a base layer portion are cured by heat compression and laminated and integrated. Reinforced resin composite molded body.
前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記基層部形成用コンパウンドが、加熱圧縮により硬化して積層一体化したものであることを特徴とする請求項１に記載の繊維強化樹脂複合成形体。 A reinforcing layer portion formed of a fiber-reinforced resin material for forming a reinforcing layer portion is provided between the base layer portion and the intermediate layer portion.
The fiber-reinforced resin material for forming the surface layer portion, the thermosetting resin foam sheet having the open cell structure, the fiber-reinforced resin material for forming the reinforcing layer portion, and the compound for forming the base layer portion are cured by heat compression. The fiber-reinforced resin composite molded product according to claim 1, wherein the product is laminated and integrated.
前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記第２の連続気泡構造の熱硬化性樹脂発泡体シートと、前記基層部形成用コンパウンドが、加熱圧縮により硬化して積層一体化したものであることを特徴とする請求項２に記載の繊維強化樹脂複合成形体。 A second intermediate layer portion formed from a thermosetting resin foam sheet having a second open cell structure is provided between the reinforcing layer portion and the base layer portion.
The fiber-reinforced resin material for forming the surface layer portion, the thermosetting resin foam sheet having the open cell structure, the fiber reinforced resin material for forming the reinforcing layer portion, and the thermosetting resin foam having the second open cell structure. The fiber-reinforced resin composite molded body according to claim 2, wherein the body sheet and the compound for forming the base layer portion are cured by heat compression and laminated and integrated.
前記基層部形成用コンパウンドはシートモールディングコンパウンドであることを特徴とする請求項１から３の何れか一項に記載の繊維強化樹脂複合成形体。 The fiber reinforced resin material is a prepreg and
The fiber-reinforced resin composite molded body according to any one of claims 1 to 3, wherein the base layer portion forming compound is a sheet molding compound.
前記表層部形成用繊維強化樹脂材と前記基層部形成用コンパウンドを、前記連続気泡構造の熱硬化性発泡体シートを挟んで積層して加熱圧縮し、前記圧縮状態で硬化させることにより、前記表層部と前記中間層部と前記基層部を積層一体化させることを特徴とする繊維強化樹脂複合成形体の製造方法。 It was formed from a surface layer portion formed of a fiber reinforced resin material for forming a surface layer portion, a base layer portion forming compound composed of fibers shorter than the fibers contained in the fiber reinforced resin material for forming a surface layer portion, and a thermosetting resin. A fiber-reinforced resin composite having a base layer portion, a fiber-reinforced resin material for forming the surface layer portion, and an intermediate layer portion formed from a thermosetting resin foam sheet having an open cell structure arranged between the compound for forming the base layer portion. It is a method of manufacturing a molded body.
The surface layer is formed by laminating the fiber-reinforced resin material for forming the surface layer portion and the compound for forming the base layer portion with the thermosetting foam sheet having the open cell structure sandwiched between them, heat-compressing them, and curing them in the compressed state. A method for producing a fiber-reinforced resin composite molded product, which comprises laminating and integrating a portion, the intermediate layer portion, and the base layer portion.
前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記基層部形成用コンパウンドを、加熱圧縮により硬化させて積層一体化し、前記補強層部形成用繊維強化樹脂材から形成された補強層部を前記中間層部と前記基層部間に設けることを特徴とする請求項５に記載の繊維強化樹脂複合成形体の製造方法。 At the time of the lamination, a fiber reinforced resin material for forming a reinforcing layer portion is arranged between the thermosetting foam sheet having the open cell structure and the compound for forming the base layer portion.
The fiber-reinforced resin material for forming the surface layer portion, the thermosetting resin foam sheet having the open cell structure, the fiber-reinforced resin material for forming the reinforcing layer portion, and the compound for forming the base layer portion are cured by heat compression. The fiber-reinforced resin composite molding according to claim 5, wherein the reinforcing layer portion formed from the fiber-reinforced resin material for forming the reinforcing layer portion is provided between the intermediate layer portion and the base layer portion. How to make a body.
前記表層部形成用繊維強化樹脂材と、前記連続気泡構造の熱硬化性樹脂発泡体シートと、前記補強層部形成用繊維強化樹脂材と、前記第２の連続気泡構造の熱硬化性樹脂発泡体シートと、前記基層部形成用コンパウンドを、加熱圧縮により硬化させて積層一体化し、前記第２の連続気泡構造の熱硬化性樹脂発泡体シートから形成された第２の中間層部を、前記補強層部と前記基層部間に設けることを特徴とする請求項６に記載の繊維強化樹脂複合成形体の製造方法。 At the time of the lamination, a thermosetting resin foam sheet having a second open cell structure was arranged between the fiber-reinforced resin material for forming the reinforcing layer portion and the compound for forming the base layer portion.
The fiber-reinforced resin material for forming the surface layer portion, the thermosetting resin foam sheet having the open cell structure, the fiber reinforced resin material for forming the reinforcing layer portion, and the thermosetting resin foam having the second open cell structure. The body sheet and the compound for forming the base layer portion are cured by heating and compression to be laminated and integrated, and the second intermediate layer portion formed from the thermosetting resin foam sheet having the second open cell structure is obtained. The method for producing a fiber-reinforced resin composite molded body according to claim 6, wherein the fiber-reinforced resin composite molded body is provided between the reinforcing layer portion and the base layer portion.
前記基層部形成用コンパウンドはシートモールディングコンパウンドであることを特徴とする請求項５から７の何れか一項に記載の繊維強化樹脂複合成形体の製造方法。 The fiber reinforced resin material is a prepreg and
The method for producing a fiber-reinforced resin composite molded body according to any one of claims 5 to 7, wherein the compound for forming a base layer portion is a sheet molding compound.
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| JP2019154490A JP7220004B2 (en) | 2019-08-27 | 2019-08-27 | Fiber-reinforced resin composite molding and method for producing the same |
| PCT/JP2020/031851 WO2021039722A1 (en) | 2019-08-27 | 2020-08-24 | Fiber-reinforced-resin composite molded article and method for producing same, antibacterial composite molded article and method for producing same, antibacterial fiber-reinforced-resin composite molded article and method for producing same, and fiber-reinforced-resin laminated molded article and method for producing same |
| US17/638,199 US20220402238A1 (en) | 2019-08-27 | 2020-08-24 | Fiber-reinforced-resin composite molded article and method for producing same, antibacterial composite molded article and method for producing same, antibacterial fiber-reinforced resin composite molded article and method for producing same, and fiber-reinforced-resin laminated molded article and method for producing same |
| CN202080061111.7A CN114375252A (en) | 2019-08-27 | 2020-08-24 | Fiber-reinforced resin composite molded article and method for producing same, antibacterial fiber-reinforced resin composite molded article and method for producing same, and fiber-reinforced resin laminate molded article and method for producing same |
| EP20858902.8A EP4023427A4 (en) | 2019-08-27 | 2020-08-24 | Fiber-reinforced-resin composite molded article and method for producing same, antibacterial composite molded article and method for producing same, antibacterial fiber-reinforced-resin composite molded article and method for producing same, and fiber-reinforced-resin laminated molded article and method for producing same |
| TW109129237A TW202116557A (en) | 2019-08-27 | 2020-08-27 | Fiber-reinforced-resin composite molded article and method for producing same, antibacterial composite molded article and method for producing same, antibacterial fiber-reinforced-resin composite molded article and method for producing same, and fiber-reinforced-resin laminated molded article and method for producing same |
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