JP2021178518A - Fiber reinforced molded article and housing for electronic device - Google Patents

Abstract

To provide a fiber reinforced molded article having a conductivity in a thickness direction without having any projection on a surface such as a bolt for ensuring conductivity.SOLUTION: A fiber reinforced molded article 10 comprises carbon fiber reinforced layers 21 and 21 which are integrally laminated on both sides of a resin layer 11 consisting of a foam body impregnated with a thermosetting resin and cured in a compressed state, in which a metal block 31 is embedded and penetrates through the resin layer 11 in the thickness direction, and the metal block 31 embedded in the resin layer 11 is in contact with the carbon fiber reinforced layers 21 and 21 on both sides of the resin layer 11, and a good conductivity between the carbon fiber reinforced layers 21 and 21 on both sides of the resin layer 11 is ensured by the metal block 31 embedded in the resin layer 11.SELECTED DRAWING: Figure 2

Description

The present invention relates to a fiber-reinforced molded body in which carbon fiber-reinforced layers are laminated and integrated on both sides of a resin layer, and a method for producing the same.

Conventionally, as a member that is required to be lightweight and highly rigid, there is a fiber-reinforced molded body in which carbon fiber-reinforced layers are laminated and integrated on both sides of a resin layer (Patent Document 1).
However, in the conventional fiber reinforced molded body, since the foam constituting the resin layer is insulating, the conductive carbon fiber reinforced layer is separated by the insulating foam, and is in the thickness direction. Conduction could not be ensured.
Therefore, the conventional fiber-reinforced molded product is not suitable for applications that require conductivity in the thickness direction.

As a method of ensuring conductivity in the thickness direction of the carbon fiber reinforced plastic structure, a metal bolt is penetrated in the thickness direction of the carbon fiber reinforced plastic structure, and both ends of the bolt are both sides of the carbon fiber reinforced plastic structure. (Patent Documents 2 and 3).

Japanese Unexamined Patent Publication No. 2011-93175 Japanese Unexamined Patent Publication No. 2012-166506 Japanese Unexamined Patent Publication No. 2016-154091

However, when a metal bolt is penetrated in the thickness direction of a carbon fiber reinforced plastic structure, the appearance is spoiled due to the presence of protrusions such as the head of the bolt on the surface, so the design surface and decorative surface are , There is a problem that it cannot be used.

The present invention has been made in view of the above points, has conductivity in the thickness direction, has no protrusion due to a bolt head or the like for ensuring conductivity on the surface, and has decorations on the design surface. An object of the present invention is to provide a fiber-reinforced molded body that can be imparted and a method for producing the same.

The first aspect of the invention is a fiber reinforced molded body in which carbon fiber reinforced layers are laminated and integrated on both sides of a resin layer, and a metal lump penetrates and is embedded in the resin layer in the thickness direction of the resin layer. The metal ingot is in contact with the carbon fiber reinforced layer on both sides of the resin layer.

A second aspect of the invention is characterized in that, in the first aspect of the invention, the metal ingot is an alloy containing tin and is provided at a plurality of positions in the resin layer.

A third aspect of the invention is characterized in that, in the first or second aspect of the invention, the resin layer is cured in a compressed state of a foam impregnated with a thermosetting resin.

In the fourth aspect of the present invention, carbon fiber prepregs are arranged on both sides of a foam impregnated with a thermosetting resin to be compressed and heated so that the foam impregnated with the thermosetting resin is compressed. In a method for producing a fiber-reinforced molded body in which a carbon fiber reinforced layer formed by curing a carbon fiber prepreg is laminated and integrated on both sides of a cured resin layer, both sides of a foam impregnated with the thermosetting resin are used. When the carbon fiber prepreg is arranged and compressed and heated, a metal block is arranged at at least one place between the foam impregnated with the thermosetting resin and the carbon fiber prepreg, and the compression and heating are performed. Thereby, the metal ingot is pushed into the foam impregnated with the thermosetting resin so that the metal ingot and the carbon fiber prepreg are in contact with each other on both sides of the foam impregnated with the thermosetting resin. It is characterized by curing a foam impregnated with a curable resin and the carbon fiber prepreg.

In the fifth aspect of the invention, the carbon fiber prepregs are arranged on both sides of the foam impregnated with the thermosetting resin and compressed and heated so that the foam impregnated with the thermosetting resin is compressed. In a method for producing a fiber-reinforced molded body in which a carbon fiber reinforced layer formed by curing a carbon fiber prepreg is laminated and integrated on both sides of a cured resin layer, both sides of a foam impregnated with the thermosetting resin are used. When the carbon fiber prepreg is arranged and compressed and heated, the thermosetting resin is formed by embedding a metal block in at least one place of the foam impregnated with the thermosetting resin and performing the compression and heating. It is characterized in that the foam impregnated with the thermosetting resin and the carbon fiber prepreg are cured by keeping the metal block and the carbon fiber prepreg in contact with each other on both sides of the foam impregnated with the thermosetting resin.

A sixth aspect of the invention is characterized in that, in the fifth aspect of the invention, a notch is provided in at least one position of the foam impregnated with the thermosetting resin, and the metal block is inserted into the notch and embedded. And.

A seventh aspect of the invention is characterized in that, in any one of the fourth to sixth aspects of the invention, the metal ingot is made of an alloy containing tin.

In the fiber-reinforced molded body of the present invention, the metal lumps embedded in the resin layer are in contact with the carbon fiber-reinforced layers on both sides of the resin layer, so that the conductivity between the carbon fiber-reinforced layers on both sides of the resin layer becomes the resin layer. It is suitable for applications where it can be secured by an embedded metal block, there are no protrusions on the surface, and conductivity in the thickness direction and aesthetic appearance of the surface are required.
Further, according to the manufacturing method of the present invention, it is possible to easily manufacture a fiber-reinforced molded product having conductivity in the thickness direction and having no protrusion on the surface.

It is a top view of one Embodiment of the fiber reinforced molded article in this invention. It is a cross-sectional view of 2-2 of FIG. It is a figure which shows the prepreg manufacturing process and the impregnation process to the foam in the production method of this invention. It is a figure which shows the stacking arrangement process and compression heating process in 1st Embodiment of the manufacturing method of this invention. It is a figure which shows the metal block embedding process, the laminated arrangement process, and the compression heating process in the 2nd Embodiment of the manufacturing method of this invention. It is a top view which shows the position of the cut in an Example. It is a top view which shows the measurement position of the conductivity in an Example. It is a table which shows the composition of Example and the comparative example, and the measurement result of the conductivity and the like.

Hereinafter, the fiber-reinforced molded product of the present invention and a method for producing the same will be described with reference to the drawings.
The fiber-reinforced molded body 10 according to the embodiment of the present invention shown in FIGS. 1 and 2 is a fiber-reinforced molded body in which carbon fiber-reinforced layers 21 and 21 are laminated and integrated on both sides of the resin layer 11, and is formed in the thickness direction. It has conductivity and has a good appearance that the protrusions due to the heads of bolts for ensuring conductivity do not exist on the surface, and is suitable for housings of portable devices such as tablets and notebook computers. .. The thickness of the fiber-reinforced molded product 10 is preferably 0.3 to 3.0 mm. The fiber-reinforced molded body 10 in the illustrated example has a rectangular plate shape, but is molded into a shape suitable for the intended use.

The resin layer 11 is preferably one obtained by curing the thermosetting resin in a compressed state of the foam impregnated with the thermosetting resin. The foam is not particularly limited, and for example, a foam having an open cell structure, specifically a melamine foam or a urethane foam is suitable. In particular, when the melamine foam is compressed, the melamine foam buckles due to the metal lump, and the metal lump is easily embedded in the resin layer, which is suitable. When the fiber-reinforced molded product 10 is required to have flame retardancy, the foam is preferably flame-retardant, and the melamine foam is suitable because the resin alone has good flame retardancy. .. Further, by curing the thermosetting resin in a compressed state of the foam, it is possible to reduce the thickness and improve the rigidity of the fiber-reinforced molded product 10.

The original thickness of the foam for the resin layer 11 before compression varies depending on the compressibility, but for example, when a fiber-reinforced molded product having a thickness of 3 mm or less is to be obtained, the original thickness is preferably 1 to 25 mm. If the original thickness is within this range, an appropriate amount of thermosetting resin can be impregnated, and the yield after heat compression is good. If the original thickness is thinner than 1 mm, the impregnated thermosetting resin cannot be retained in the foam, the impregnation ratio varies, and the quality becomes inconsistent. On the other hand, if the original thickness is thicker than 25 mm, when an attempt is made to obtain a fiber-reinforced molded product having a thickness of 3 mm or less, compression is difficult and a fiber-reinforced molded product having a uniform thickness cannot be obtained. Further, the foam for the resin layer 11 preferably ^{has a density of 5 to 80 kg / m 3} before compression from the viewpoint of ease of compression, impregnation property, light weight, and rigidity.

The thermosetting resin impregnated in the foam for the resin layer 11 is not particularly limited, but the thermosetting resin itself needs to have a certain degree of rigidity in order to increase the rigidity of the fiber-reinforced molded body 10. , Epoxy resin, phenol resin, and a mixture of epoxy resin and phenol resin can be selected from the group. Further, when the fiber reinforced molded product 10 is required to have flame retardancy, the thermosetting resin is preferably flame retardant. Since the phenol resin has good flame retardancy, it is suitable as a thermosetting resin to be impregnated in the foam.

Metal lumps 31 and 31 are embedded in a part of the resin layer 11 in the thickness direction of the resin layer 11. The metal lumps 31 and 31 are in contact with the inner surfaces of the carbon fiber reinforced layers 21 and 21 on both sides of the resin layer 11. That is, the metal lumps 31 and 31 are in contact with each other at the two interfaces of the resin layer 11 and the carbon fiber reinforced layer 21. The metal ingots 31 and 31 are preferably metals having a melting point that can be deformed by compression heating when the fiber-reinforced molded product 10 is manufactured, for example, a melting point of 130 to 270 ° C. Specifically, an alloy containing tin (Sn) is preferable. Alloys containing tin (Sn) include tin (Sn) and bismuth (Bi) alloys, tin (Sn) and lead (Pb) alloys, tin (Sn) and silver (Ag) and copper (Cu) alloys. And so on.

The size and shape of the metal ingots 31 and 31 before molding are not particularly limited, but the resin of the fiber reinforced molded body 10 is used to ensure contact between the carbon fiber reinforced layers 21 and 21 and the metal ingots 31 and 31. A linear or rod-shaped metal block having a diameter equal to or larger than the thickness of the layer 11 is preferable. The linear or rod-shaped metal block is embedded in the resin layer 11 in a state of being laid down (laid down) on the fiber-reinforced molded body 11. When a linear or rod-shaped metal block is laid down and buried, the diameter of the metal block is the thickness of the metal block (the same direction as the thickness direction of the fiber-reinforced molded body 10).

When a linear or rod-shaped metal block is used, the thickness (diameter) of the metal block before molding is preferably slightly larger or smaller than the total thickness of the fiber-reinforced molded body 10 after molding. Slightly larger than the total thickness of the fiber-reinforced molded body 10 after molding means that the metal ingot is softened and deformed by being compressed and heated during molding. That is, if the protrusions due to the presence of the metal lump do not appear on the design surface of the fiber-reinforced molded body 10 after molding and the protrusions cannot be visually determined by visual determination, the appearance is not poor. The allowable thickness of the metal ingot before molding is 120% or less with respect to the thickness of the fiber-reinforced molded body 10 after molding. Moreover, the thickness of the metal ingot before molding must be larger than the thickness of the resin layer after molding. The thickness (diameter) of the metal ingot before molding is smaller than the total thickness of the fiber-reinforced molded body 10 after molding. It means that the thickness (diameter) of the metal ingot before molding occupies the excluded thickness. The ratio (Φ1 / C1) of the thickness (Φ1) of the metal block before molding to the thickness (C1) of the resin layer is 1 to 28 times, more preferably 3 to 25 times.

The number and position of the metal ingots 31 and 31 to be buried are not particularly limited, but in order to obtain stable conductivity, the metal ingots are embedded in a plurality of horizontally separated places in the resin layer 11. Is preferable. In the illustrated example, one is embedded in each of the resin layers 11 at substantially the center position on the short side side, for a total of two.

The carbon fiber reinforcing layers 21 and 21 are made of carbon fibers impregnated with a thermosetting resin and cured, and have conductivity due to the carbon fibers. As the carbon fiber, a carbon fiber woven fabric is preferable because it is excellent in light weight and high rigidity. Further, the carbon fibers include those in which long fibers are arranged in parallel in the same direction, but so-called woven fabrics are preferable. A triaxial weave composed of the above is suitable for obtaining the strength of the molded body and the like. The carbon fiber woven fabric preferably has a fiber weight of 90 to 400 g / m ^{2 from the viewpoint of impregnation with a thermosetting resin and rigidity.}

The thermosetting resin impregnated in the carbon fibers is not particularly limited, but in order to increase the rigidity of the fiber-reinforced molded body 10, the thermosetting resin itself needs to have a certain degree of rigidity, and the epoxy resin and phenol It can be selected from the group consisting of a resin, a mixture of an epoxy resin and a phenol resin. When the fiber-reinforced molded product 10 is required to have flame-retardant properties, the thermosetting resin impregnated in the fiber woven fabric is preferably flame-retardant. Since the phenol resin has good flame retardancy, it is suitable as a thermosetting resin to be impregnated into the carbon fibers.

Further, the carbon fiber reinforced layers 21 and 21 are not limited to one layer on each side of the resin layer 11, and may be two or more layers on one side or both sides of the resin layer 11.

In the fiber reinforced molded body 10, the metal lumps 31 and 31 penetrating the resin layer 11 are in contact with the carbon fiber reinforced layers 21 and 21 on both sides of the resin layer 11, so that the resin layer 11 has. A conductive passage is formed between the carbon fiber reinforced layers 21 and 21 on both sides via the metal block 31, and the fiber reinforced molded body 10 has conductivity in the thickness direction. Further, in order to increase the conductivity in the thickness direction of the fiber-reinforced molded body 10, the design surface may be polished to remove the resin on the surface layer so that the carbon fibers appear on the design surface.

Next, the first embodiment of the method for producing a fiber-reinforced molded product of the present invention will be described by taking the production of the fiber-reinforced molded product 10 as an example. The method for producing the fiber-reinforced molded product 10 includes a prepreg manufacturing step, an impregnation step for the foam, a laminated arrangement step, and a compression heating step.

In the prepreg manufacturing step, as shown in (3-1) of FIG. 3, a carbon fiber prepreg (impregnated carbon fiber) 21C is required by impregnating a carbon fiber 21A made of a fiber fabric or the like with a thermosetting resin 21B and drying it. Form a number. The carbon fiber 21A and the thermosetting resin 21B are as described in the fiber reinforced molded product 10. The thermosetting resin 21B used for impregnation is an uncured liquid. Further, in order to facilitate impregnation, the thermosetting resin 21B is preferably dissolved in a solvent, and after impregnation, the carbon fiber prepreg 21C is dried at a temperature at which the curing reaction of the thermosetting resin does not occur. This removes the solvent. The impregnation means can be performed by an appropriate method such as a method of immersing the carbon fiber 21A in a tank containing a liquid thermosetting resin 21B, a method of applying by spraying, a method of applying by a roll coater, or the like.

In the step of impregnating the foam, as shown in (3-2) of FIG. 3, the foam 11A made of a melamine foam or the like is impregnated with the thermosetting resin 11B to obtain the impregnated foam 11C. The foam 11A and the thermosetting resin 11B are as described in the fiber reinforced molded product 10. The thermosetting resin 11B used for impregnation is made of an uncured liquid. Further, in order to facilitate impregnation, the thermosetting resin 11B is preferably dissolved in a solvent, and after impregnation, the impregnated foam 11C is dried at a temperature at which the curing reaction of the thermosetting resin does not occur. The solvent is removed from the impregnated foam 11C. The impregnation means can be performed by an appropriate method such as a method of immersing the foam in a tank containing a liquid thermosetting resin, a method of applying by spraying, a method of applying by a roll coater, or the like.
Either of the prepreg producing step and the impregnation step of the foam may be performed first.

In the laminating arrangement step, as shown in (4-1) of FIG. 4, the carbon fiber prepreg 21C, the impregnated foam 11C, the metal lumps 31, 31 and the above are formed on the mold surface of the lower mold 41 for press molding. The carbon fiber prepreg 21C is laminated in this order. In the illustrated example, the metal block 31 is arranged on the upper surface of the impregnated foam 11C, but may be arranged on the upper surface of the carbon fiber prepreg 21C on the lower surface side of the impregnated foam 11C. Further, the metal ingot 31 is arranged at one place on one side of the impregnated foam 11C, or at a plurality of places on one side or both sides. Further, the carbon fiber prepreg 21C may be laminated on one side or both sides of the impregnated foam 11C. Reference numeral 43 is an upper mold for press molding.

In the compression heating step, as shown in (4-2) of FIG. 4, the laminate composed of the carbon fiber prepreg 21C, the impregnated foam 11C, the metal block 31, and the carbon fiber prepreg 21C laminated in the lamination step. The body is compressed and heated by the press-molding lower die 41 and the press-molding upper die 43. The compression is preferably such that the thickness of the laminate is 0.3 to 3.0 mm. During the compression heating step, spacers are installed at appropriate positions between the lower die 41 for press molding and the upper die 43, and the space between the lower die 41 for press molding and the upper die 43 is set at a predetermined interval (compression of the laminate). Thickness). Further, the heating method is not particularly limited, but it is easy to provide a heating means such as a heater on the press molding lower mold 41 and the upper mold 43 and heat the press molding through the lower mold 41 and the upper mold 43. Is. The heating temperature is set to be equal to or higher than the curing reaction temperature of the impregnated thermosetting resin. Further, regarding the relationship between the heating temperature and the melting point of the metal ingot 31, it is preferable that the melting point of the metal ingot 31 is equal to or higher than the heating temperature of the lower mold 41 and the upper mold 43 for press molding. The heating temperature of the lower mold 41 and the upper mold 43 for press molding is the molding temperature of the thermosetting resin 11B, and the closer the molding temperature is to the melting point of the metal ingot 31, the more easily the metal ingot 31 is softened and deformed. An alloy having a low melting point is preferable as a metal ingot because it is easy to process.

During the compression heating step, the metal block 31 arranged on the surface of the impregnated foam 11C is pushed into the impregnated foam 11C and embedded, and the carbon is formed on both sides of the impregnated foam 11C. Contact with fiber prepregs 21C, 21C. Further, the metal block 31 is compressed together with the impregnated foam 11C and the carbon fiber prepregs 21C and 21C in a heated state, and is deformed to the compressed thickness of the impregnated foam 11C. Further, the thermosetting resin of the impregnated foam 11C and the thermosetting resins of the carbon fiber prepregs 21C and 21C start a curing reaction by heating, and the carbon fiber prepreg 21C and the metal block 31 are embedded. The impregnated foam 11C and the carbon fiber prepreg 21C are cured and integrated in a laminated and compressed state to form the fiber reinforced molded body 10. By the curing, the impregnated foam 11C becomes the solid resin layer 11 made of a thermosetting resin, and the carbon fiber prepregs 21C and 21C have the thermosetting resin as a matrix. The carbon fiber reinforced layers 21 and 21 are formed. After that, the lower die 41 for press molding and the upper die 43 for press molding are opened, and the fiber-reinforced molded body 10 is taken out.

A second embodiment of the method for manufacturing the fiber-reinforced molded product will be described. The second embodiment of the manufacturing method includes a prepreg manufacturing step, an impregnation step in a foam, a metal block burying step, a laminated placement step, and a compression heating step.

The prepreg producing step and the foam impregnation step in the second embodiment are the same as those in the first embodiment.
In the metal ingot burying step, as shown in FIG. 5 (5-1), the metal ingot 31 is embedded in a predetermined position of the impregnated foam 11C. A notch made of a slit or the like is formed on the surface of the impregnated foam 11C at the place where the metal ingot 31 is embedded in the impregnated foam 11C, and the metal ingot 31 is inserted into the notch and embedded. As a result, the metal block 31 can be easily embedded in the correct position. Further, the notch may be provided only on one side of the impregnated foam 11C, may be provided on both sides, or may be provided so as to penetrate between both sides. The notch may be formed on either the foam before the thermosetting resin impregnation or the impregnated foam.

In the laminating arrangement step, as shown in FIG. 5 (5-2), the carbon fiber prepreg 21C, the impregnated foam 11C in which the metal ingot 31 is embedded, and the above By laminating the carbon fiber prepregs 21C in this order, a laminated body in which the carbon fiber prepregs 21C and 21C are arranged on both sides of the foam 11C in which the thermosetting resin is impregnated and the metal lump 31 is embedded is formed. In addition, the carbon fiber prepreg 21C may be laminated in a plurality of layers on one side or both sides of the impregnated foam 11C in which the metal block 31 is embedded. Reference numeral 43 is an upper mold for press molding.

In the compression heating step, as shown in FIG. 5 (5-3), the carbon fiber prepreg 21C laminated in the laminating step, the impregnated foam 11C in which the metal block 31 is embedded, and the carbon fiber prepreg 21C are used. The laminate is compressed and heated by the press forming lower die 41 and the press forming upper die 43. The compression is preferably such that the thickness of the laminate is 0.3 to 3.0 mm. During the compression heating step, spacers are installed at appropriate positions between the lower die 41 for press molding and the upper die 43, and the space between the lower die 41 for press molding and the upper die 43 is set at a predetermined interval (compression of the laminate). Thickness). The heating method, the relationship between the heating temperature and the melting point of the metal block 31, and the like are the same as in the first embodiment.

During the compression heating step, the metal block 31 embedded in the impregnated foam 11C is compressed together with the impregnated foam 11C in a state of being softened by heating, and is deformed to the compressed thickness of the impregnated foam 11C. Then, both sides of the impregnated foam 11C come into contact with the carbon fiber prepregs 21C and 21C. Further, the thermosetting resin of the impregnated foam 11C and the thermosetting resins of the carbon fiber prepregs 21C and 21C start a curing reaction by heating, and the carbon fiber prepreg 21C and the metal block 31 are embedded. The impregnated foam 11C and the carbon fiber prepreg 21C are cured and integrated in a laminated and compressed state to form the fiber reinforced molded body 10. After that, the lower die 41 for press molding and the upper die 43 for press molding are opened, and the fiber-reinforced molded body 10 is taken out.

Ayaori carbon fiber woven fabric (manufactured by Toho Tenax Co., Ltd., product name: W-3161) in a phenol resin (manufactured by Sumitomo Bakelite Co., Ltd., product name: PR-55791B, resin concentration 60 wt% ethanol solution) as a thermosetting resin. , Fiber weight 200 g / m ² ) is soaked, taken out, naturally dried at room temperature of 25 ° C. for 2 hours, and further dried in an atmosphere of 60 ° C. for 1 hour to obtain carbon fiber prepreg (impregnated carbon fiber). The required number was formed. As the carbon fiber woven fabric, one cut into a flat size of 200 × 300 mm (weight 12 g / sheet) was used. The amount of carbon fiber prepreg (impregnated fiber) after drying was 28 g per sheet.

Further, as the foam, a melamine foam (manufactured by BASF, product name: Basotect V3012, density 9 kg / m ³ ) cut into a thickness of 5 mm and a plane size of 200 × 300 mm (weight 2.7 g) was used in the same manner as the carbon fiber woven fabric. After being immersed in a phenol resin and taken out, it was naturally dried at room temperature of 25 ° C. for 2 hours, and further dried in an atmosphere of 60 ° C. for 1 hour to form an impregnated foam. The weight of the impregnated foam after drying was 27 g.

Next, except for Example 6 and Comparative Example 1, as shown in FIG. 6, a notch is made in the surface of a set of opposite corners in the impregnated foam, and a metal block is inserted into the notch and impregnated. It was buried in a foam. The metal ingot used was linear and was inserted in a state of lying down on the impregnated foam (a state substantially parallel to the surface of the impregnated foam). The material, diameter and length of the metal block are as shown in the table of FIG.

Next, the required number of carbon fiber prepregs, the impregnated foam in which the metal lumps are inserted, and the carbon fiber prepregs are placed on a SUS press-molding lower mold (flat plate) to which a mold release agent is previously applied to the surface. The layers were arranged in the order of the required number to form a laminated body. The total number of the carbon fiber prepregs is as shown in the column of "ply number" in the table of FIG. 7.
In Example 6, a required number of carbon fiber prepregs, an impregnated foam, a metal block, and carbon were placed on a SUS press-molding lower mold (flat plate) to which a mold release agent was previously applied to the surface. The fiber prepregs were arranged in the required number in order to form a laminated body.

The laminate on the lower die for press molding is compressed and heated by applying a surface pressure of 10 MPa at 150 ° C. for 10 minutes with the upper die for press molding (flat plate), and in the compressed state. The phenolic resin was reaction-cured. At that time, the laminated body was heated by the cast heaters attached to the upper and lower press molds. Further, a SUS spacer set to the product plate thickness was interposed between the lower mold for press molding and the upper mold for press molding to adjust the distance between the lower mold and the upper mold, that is, the compression thickness of the laminate. Then, after cooling the lower mold for press molding and the upper mold for press molding at room temperature, the lower mold for press molding and the upper mold for press molding were opened to obtain fiber-reinforced molded products of each Example and each comparative example.

For the fiber-reinforced molded bodies of each Example and each Comparative Example, the appearance was judged and the resistance value and the flexural modulus in the thickness direction were measured.
In the appearance judgment, the presence of the protrusion was judged by visual inspection and tactile sensation. "◎" when no protrusions can be seen by palpation or visual inspection in the buried part of the metal block, "○" when a slight protrusion is felt by palpation, although it is not visible by palpation. When it feels, it is marked as "x".
For the resistance value in the thickness direction, a digital multimeter (manufactured by Hioki Electric Co., Ltd .: DT4281) was used, and as shown in FIG. 7, the position of "* 1" on one surface of the fiber reinforced molded body and the "* 1" position on the opposite surface. The resistance value between the positions of "* 2" was measured.
The flexural modulus was determined according to the JIS K7074-1988A method.
The appearance judgment result and the measurement result of the resistance value and the bending elastic modulus are shown in the table of FIG.
The "hardness (Hv) of the metal block" in the table of FIG. 8 is a value measured according to the JIS Z 2244-Vickers hardness test.
Further, in the table of FIG. 8, the “ply number” is the total number of laminated carbon fiber reinforced layers (carbon fiber prepregs), and the “overall thickness” is the thickness of the fiber reinforced molded body (same as the thickness of the spacer). The "resin layer thickness (mm) C1" was substituted by a value obtained by subtracting the total thickness (total thickness) of the carbon fiber woven fabric used from the "total thickness".

In Example 1, an alloy of tin and bismuth (metal ratio 42/58), a diameter (Φ1) of 0.6 mm, and a length of 10 mm are used as the metal ingots, and the carbon fiber reinforced layer (carbon fiber prepreg) is fully laminated (the carbon fiber prepreg). This is an example in which the number of ply) is 2, the total thickness is 0.6 mm, and the resin layer thickness (C1) is 0.12 mm. In Example 1, the value of Φ1 / C1 is 5.00, the appearance is "◎", the resistance value in the thickness direction is 53Ω, the flexural modulus in the bending direction is 31 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. Has conductivity.

In Example 2, a tin-lead alloy (metal ratio 60/40), a diameter (Φ1) of 1.0 mm, and a length of 10 mm are used as the metal ingots, and the carbon fiber reinforced layer (carbon fiber prepreg) is fully laminated (the carbon fiber prepreg). This is an example in which the number of ply) is 2, the total thickness is 1.0 mm, and the resin layer thickness (C1) is 0.52 mm. In Example 2, the value of Φ1 / C1 is 1.92, the appearance is “◎”, the resistance value in the thickness direction is 12 MΩ, the flexural modulus in the bending elasticity is 45 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

In Example 3, the diameter of the metal block in Example 2 is 0.6 mm, the total number of laminated carbon fiber reinforced layers (carbon fiber prepregs) is 4, the total thickness is 1.0 mm, and the resin layer thickness (C1). Is an example of 0.04 mm. In Example 3, the value of Φ1 / C1 is 15.00, the appearance is "◎", the resistance value in the thickness direction is 10Ω, the flexural modulus in the bending direction is 45 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

Example 4 is an example in which the diameter (Φ1) of the metal block in Example 3 is 1.0 mm. In Example 4, the value of Φ1 / C1 is 25.00, the appearance is "○", the resistance value in the thickness direction is 12Ω, the flexural modulus in the bending elasticity is 46 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

In Example 5, the diameter of the metal block in Example 4 is 0.6 mm, the total number of laminated carbon fiber reinforced layers (carbon fiber prepregs) is 6, the total thickness is 2.0 mm, and the resin layer thickness (C1). Is an example of 0.56 mm. In Example 5, the value of Φ1 / C1 is 1.07, the appearance is “◎”, the resistance value in the thickness direction is 42Ω, the flexural modulus in the bending direction is 40 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

In Example 6, the overall thickness in Example 2 is set to 0.8 mm, the resin layer thickness (C1) is set to 0.32 mm, and a metal block is placed at a predetermined position on the upper surface of the impregnated foam without slits. After that, it is an example of performing a compression heating step. In Example 6, the value of Φ1 / C1 is 3.13, the appearance is “◎”, the resistance value in the thickness direction is 12Ω, the flexural modulus in the bending direction is 46 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

Example 7 is an example in which other configurations are the same as those of Example 6 except that a slit is formed in the impregnated foam in Example 6 and a metal block is embedded. In Example 7, the value of Φ1 / C1 is 3.13, the appearance is “◎”, the resistance value in the thickness direction is 10Ω, the flexural modulus in the bending direction is 47 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity. The resistance value, flexural modulus, and appearance did not change between Example 6 and Example 7 regardless of the presence or absence of the slit.

Example 8 is an example in which the total thickness in Example 2 is 0.6 mm and the resin layer thickness (C1) is 0.12 mm. In Example 8, the value of Φ1 / C1 is 8.33, the appearance is “◎”, the resistance value in the thickness direction is 11Ω, the bending elasticity is 48 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

In Example 9, the diameter (Φ1) of the metal block in Example 2 is 2.0 mm, the total number of laminated carbon fiber reinforced layers (carbon fiber prepregs) is 10, the total thickness is 3.0 mm, and the resin layer thickness. This is an example in which (C1) is 0.6 mm. In Example 9, the value of Φ1 / C1 is 3.33, the appearance is “◎”, the resistance value in the thickness direction is 12Ω, the flexural modulus in the bending direction is 44 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. It has conductivity.

In Example 10, a carbon fiber reinforced layer (metal ratio 96.5/3 / 0.5), a diameter (Φ1) of 1.0 mm, and a length of 10 mm was used as the metal ingot. This is an example in which the total number of laminated carbon fibers (prepregs) is 2, the total thickness is 0.8 mm, and the resin layer thickness (C1) is 0.32 mm. In Example 10, the value of Φ1 / C1 is 3.13, the appearance is "○", the resistance value in the thickness direction is 25Ω, the flexural modulus in the bending direction is 45 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. Has conductivity.

In Example 11, a tin-lead alloy (metal ratio 10/90), a diameter (Φ1) of 1.0 mm, and a length of 10 mm are used as the metal ingots, and the carbon fiber reinforced layer (carbon fiber prepreg) is fully laminated (the carbon fiber prepreg). This is an example in which the number of ply) is 2, the total thickness is 0.8 mm, and the resin layer thickness (C1) is 0.32 mm. In Example 14, the value of Φ1 / C1 is 3.13, the appearance is "○", the resistance value in the thickness direction is 14Ω, the flexural modulus in the bending direction is 45 GPa, the resistance value in the thickness direction is small, and the resistance value in the thickness direction is good. Has conductivity.

Comparative Example 1 is an example in which the metal ingot is not embedded, and the total number of laminated carbon fiber reinforced layers (carbon fiber prepregs) is 2, the total thickness is 0.8 mm, and the resin layer thickness (C1) is 0.32 mm. Is. In the comparative example, the appearance is “⊚”, the resistance value in the thickness direction is 5.2 MΩ, the flexural modulus is 45 GPa, the resistance value in the thickness direction is large, and the conductivity in the thickness direction is low.

In Comparative Example 2, a tin-lead alloy (metal ratio 60/40), a diameter (Φ1) of 0.6 mm, and a length of 10 mm were used as the metal ingots, and the carbon fiber reinforced layer (carbon fiber prepreg) was fully laminated (the carbon fiber prepreg). This is an example in which the number of ply) is 2, the total thickness is 1.2 mm, and the thickness of the resin layer (C1) is 0.72 mm. In Comparative Example 2, the value of Φ1 / C1 was 0.83, the appearance was “⊚”, the resistance value in the thickness direction was 2.9 MΩ, the flexural modulus was 42 GPa, and the resistance value in the thickness direction was high. In Comparative Example 2, the thickness of the resin layer after molding was larger than the diameter of the metal block before molding, and even when the compression heating step was performed, the resin layer did not substantially come into contact with the carbon fibers.

As described above, the fiber-reinforced molded product of the present invention has conductivity in the thickness direction, and has no protrusions or deformations due to the metal lumps embedded in the resin layer on the surface, and is conductive in the thickness direction. It is suitable for applications that require aesthetics and surface aesthetics.

10 Fiber reinforced plastic 11 Resin layer 11A Foam 11B Thermosetting resin 11C Impregnated foam 21 Carbon fiber reinforced layer 21A Carbon fiber 21B Thermosetting resin 21C Carbon fiber prepreg 31 Metal ingot 41 Press molding lower mold 43 Press molding Top type

Claims (7)

It is a fiber reinforced molded product in which carbon fiber reinforced layers are laminated and integrated on both sides of the resin layer.
A metal block penetrates and is embedded in the resin layer in the thickness direction of the resin layer.
A fiber-reinforced molded product, wherein the metal lump is in contact with the carbon fiber reinforced layer on both sides of the resin layer. The fiber-reinforced molded product according to claim 1, wherein the metal ingot is an alloy containing tin and is provided at at least one position in the resin layer. The fiber-reinforced molded product according to claim 1 or 2, wherein the resin layer is formed by curing a foam impregnated with a thermosetting resin in a compressed state. By arranging carbon fiber prepregs on both sides of the foam impregnated with the thermosetting resin and compressing and heating, both sides of the resin layer formed by curing the foam impregnated with the thermosetting resin in a compressed state. In addition, in the method for producing a fiber-reinforced molded body in which a carbon fiber-reinforced layer formed by curing the carbon fiber prepreg is laminated and integrated.
When the carbon fiber prepreg is arranged on both sides of the foam impregnated with the thermosetting resin to be compressed and heated,
A metal block is placed at least one place between one side of the foam impregnated with the thermosetting resin and the carbon fiber prepreg.
By performing the compression and heating, the metal ingot was pushed into the foam impregnated with the thermosetting resin, and the metal ingot and the carbon fiber prepreg came into contact with each other on both sides of the foam impregnated with the thermosetting resin. A method for producing a fiber-reinforced molded product, which comprises curing a foam impregnated with the thermosetting resin and the carbon fiber prepreg in a state. By arranging carbon fiber prepregs on both sides of the foam impregnated with the thermosetting resin and compressing and heating, both sides of the resin layer formed by curing the foam impregnated with the thermosetting resin in a compressed state. In addition, in the method for producing a fiber-reinforced molded body in which a carbon fiber-reinforced layer formed by curing the carbon fiber prepreg is laminated and integrated.
When the carbon fiber prepreg is arranged on both sides of the foam impregnated with the thermosetting resin to be compressed and heated,
A metal block is embedded in at least one place of the foam impregnated with the thermosetting resin.
By performing the compression and heating, the metal ingot and the carbon fiber prepreg are brought into contact with each other on both sides of the foam impregnated with the thermosetting resin, and the foam impregnated with the thermosetting resin and the carbon are brought into contact with each other. A method for producing a fiber-reinforced molded body, which comprises curing a fiber prepreg. The method for producing a fiber-reinforced molded product according to claim 5, wherein a notch is provided in at least one position of the foam impregnated with the thermosetting resin, and the metal block is inserted and embedded in the notch. The method for producing a fiber-reinforced molded product according to any one of claims 4 to 6, wherein the metal ingot is made of an alloy containing tin.

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