JP2021194886A - Method for manufacturing fiber-reinforced resin structure - Google Patents

Abstract

To provide a new method for manufacturing a fiber-reinforced resin structure which can be formed into various shapes while having excellent strength.SOLUTION: A method for manufacturing a fiber-reinforced resin structure 100-4 includes a step of curving an aggregate 55 having a first columnar foam, a fiber body covering at least a part of a side face part of the first foam and a second columnar foam adjacent to the first foam through the fiber body, in which the fiber body is impregnated with an uncured thermosetting resin, so that a pillar axis of the foam is curved, and thermosetting the thermosetting resin contained in the aggregate, and 25% compressive loads of the first foam and the second foam are 1 to 2,000 kPa.SELECTED DRAWING: Figure 32-2

Description

The present invention relates to a method for manufacturing a fiber reinforced resin structure containing a fiber body and a resin.

Conventionally, a composite material composed of a reinforcing fiber body such as CFRP and a flexible body such as a foam has been proposed (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 63-31136

The method described in Patent Document 1 had excellent strength derived from fiber reinforced plastic while being partially curved, but could only produce a fiber reinforced resin structure having a fixed shape.

Therefore, it is an object of the present invention to provide a novel method for producing a fiber-reinforced resin structure, which can have various shapes while having a predetermined excellent strength. Further, the second object of the present invention is to provide a novel fiber-reinforced resin structure that can be manufactured by the manufacturing method.

Invention (I) is
A laminate having a columnar foam and a fiber that wraps around the side surface of the foam for one or more turns, and the fiber is impregnated with an uncured thermosetting resin. The present invention comprises a step of applying an external force to the laminate, deforming the cross-sectional shape of the foam contained in the laminate, and thermosetting the thermosetting resin contained in the laminate.
A method for producing a fiber-reinforced resin structure (secondary foaming is possible as the foam), wherein the 25% compression load measured in accordance with JIS K6400-2: 2012 of the foam is 1 to 2000 kPa. (Except for the method using the uncured thermosetting resin and the covering body having a bleed hole from which the gas can be exuded and covering the laminated body;).
The invention (I) is
The foam may be an olefin resin foam.
The invention (I) is
The foam may have a density of 1 to 800 kg / m ³ .
The invention (I) is
The deformation of the cross-sectional shape of the foam may be carried out in a reduced pressure atmosphere.
The invention (I) is
After the thermosetting step, the laminate is cooled to shrink the foam.
After the step of shrinking the foam, the step of removing the foam contained in the laminate may be included.

Invention (II) is
A laminate having a columnar foam and a fiber that covers at least a part of the side surface of the foam, and the fiber is impregnated with an uncured thermosetting resin. A step of preparing, bending the laminate so that the column axis of the foam is curved, and thermosetting the thermosetting resin contained in the laminate is included.
A method for producing a fiber-reinforced resin structure (secondary foaming is possible as the foam), wherein the 25% compression load measured in accordance with JIS K6400-2: 2012 of the foam is 1 to 2000 kPa. (Except for the method using the uncured thermosetting resin and the covering body having a bleed hole from which the gas can be exuded and covering the laminated body;).
The invention (II) is
In the laminated body, the fibrous body may be wound around the side surface portion of the foam for one or more turns.
The invention (II) is
The foam may be an olefin resin foam.
The invention (II) is
The foam may have a density of 1 to 800 kg / m ³ .
The invention (II) is
After the thermosetting step, the laminate is cooled to shrink the foam.
After the step of shrinking the foam, the step of removing the foam contained in the laminate may be included.

Invention (III)
A columnar first foam, a fiber that winds around the side surface of the first foam for one or more turns, and a columnar second foam that is close to the first foam via the fiber. A step of preparing an aggregate having a body and an aggregate in which the fibrous body is impregnated with an uncured thermosetting resin and thermally curing the thermocurable resin contained in the aggregate. Including
A method for producing a fiber-reinforced resin structure, wherein the 25% compressive load measured according to JIS K6400-2: 2012 of the first foam and the second foam is 1 to 2000 kPa. (As the first foam, a foam that can be secondarily foamed; and a coating body that has a bleed hole from which the uncured thermosetting resin and gas can be exuded and covers the aggregate; Except for the method used).
The invention (III) is
In the step, before the thermosetting resin contained in the aggregate is thermally cured, an external force is applied to the aggregate to deform the cross-sectional shapes of the first foam and the second foam. It may include a transformation process.
The invention (III) is
The aggregate includes the first foam, the fibrous body that winds around the side surface portion of the first foam one or more times, the second foam, and the side surface of the second foam. The fibrous body having a portion wound around one or more turns, and the fibrous body winding the side surface portion of the first foam one or more turns and the side surface portion of the second foam body. It may be in contact with the fiber body to be wound one or more turns.
The invention (III) is
The first foam and the second foam may be olefin resin foams.
The invention (III) is
The first foam and the second foam may have a density of 1 to 800 kg / m ³ .
The invention (III) is
The deformation process may be carried out in a reduced pressure atmosphere.
The invention (III) is
After the thermosetting step, the aggregate is cooled to shrink the first foam and the second foam.
It may include a step of removing the first foam and the second foam contained in the aggregate after the step of shrinking the first foam and the second foam.

Invention (IV)
A columnar first foam, a fiber covering at least a part of the side surface of the first foam, and a columnar second foam close to the first foam via the fiber. An aggregate having the above, in which the fiber body is impregnated with an uncured thermosetting resin, is prepared, and the aggregate is curved so that the column axis of the foam is curved. , Including a step of thermosetting the thermosetting resin contained in the aggregate.
A method for producing a fiber-reinforced resin structure, wherein the 25% compressive load measured according to JIS K6400-2: 2012 of the first foam and the second foam is 1 to 2000 kPa. (As the first foam, a foam that can be secondarily foamed; and a coating body that has a bleed hole from which the uncured thermosetting resin and gas can be exuded and covers the aggregate; Except for the method used).
The invention (IV) is
In the step, before the thermosetting resin contained in the aggregate is thermally cured, an external force is applied to the aggregate to deform the cross-sectional shapes of the first foam and the second foam. The transformation process may be further included.
The invention (IV) is
In the aggregate, the fibrous body may be wound around the side surface portion of the first foam for one or more turns.
The invention (IV) is
The aggregate includes the first foam, the fibrous body that winds around the side surface portion of the first foam one or more times, the second foam, and the side surface of the second foam. The fiber body having a portion wound around one or more turns, and the fiber body winding the side surface portion of the first foam one turn or more, and the side surface portion of the first foam body. It may be in contact with the fiber body to be wound one or more turns.
The invention (IV) is
The first foam and the second foam may be olefin resin foams.
The invention (IV) is
The first foam and the second foam may have a density of 1 to 800 kg / m ³ .
The invention (IV) is
The deformation process may be carried out in a reduced pressure atmosphere.
The invention (IV) is
After the thermosetting step, the aggregate is cooled to shrink the first foam and the second foam.
It may include a removal step of removing the first foam and the second foam contained in the aggregate after the step of shrinking the first foam and the second foam.

INDUSTRIAL APPLICABILITY According to the present invention, it is possible to provide a novel method for producing a fiber-reinforced resin structure, which has excellent strength and can be made into various shapes. Further, according to the present invention, it is possible to provide a novel fiber reinforced resin structure.

1A and 1B are views for explaining the first embodiment, and FIG. 1A is a perspective view for explaining a state in which a fiber sheet and a flexible body are directly laminated, and FIG. 1B is a perspective view. ) Is a perspective view showing the first multilayer laminated body. 2A and 2B are views for explaining the first embodiment, and FIG. 2A is a perspective view for explaining a state in which the fiber sheet and the flexible body are directly laminated, and FIG. 2B is a perspective view. ) Is a perspective view illustrating a state in which the fiber sheet is wound around the core material, and FIG. 2 (c) is a perspective view illustrating a state in which the fiber sheet is wound a plurality of times around the core material. FIG. 2D is a perspective view showing an uncured vortex laminate, and FIG. 2E is a perspective view showing a cured vortex laminate after curing. 3A and 3B are views for explaining the first embodiment, and FIG. 3A is a perspective view for explaining a state in which the fiber sheet and the flexible body are directly laminated, and FIG. 3B is a perspective view. ) Is a perspective view illustrating a state in which the fiber sheet is wound around the core material, and FIG. 3 (c) is a perspective view illustrating a state in which the fiber sheet is wound a plurality of times around the core material. FIG. 3D is a perspective view showing the uncured first cylindrical laminated body, and FIG. 2E is a perspective view showing the cured first cylindrical laminated body after curing. 4A and 4B are views for explaining the first embodiment, in particular, FIG. 4A is a perspective view showing the first multilayer laminate, and FIG. 4B is a view showing the first multilayer laminate. It is a perspective view explaining the state which is being cut, FIG. 4C is a perspective view for explaining a 2nd multilayer laminated body, and FIG. 4D is a fiber sheet wound around a core material. 4 (e) is a perspective view illustrating a state in which a fiber sheet is wound around a core material, and FIG. 4 (f) is a second perspective view illustrating a state in which a fiber sheet is wound around a core material. It is a perspective view which shows the cylindrical laminated body, and FIG. 4 (e) is a perspective view which shows the cured 2nd cylindrical laminated body after curing. 5A and 5B are views for explaining the first embodiment, in particular, FIG. 5A is a cross-sectional view for explaining a laminated state of a fiber sheet and a flexible body, and FIG. 5B is a cross-sectional view showing a fiber. FIG. 5 (c) is a cross-sectional view illustrating a state in which the energetic cured resin impregnated in the sheet is exuded into the flexible body, and FIG. 5 (c) shows the energetic cured resin impregnated in the fiber sheet exuding into the flexible body. FIG. 5 (d) is a cross-sectional view illustrating a state in which the energetic cured resin exuded into the flexible body is cured. 6A and 6B are views for explaining the first embodiment, and FIG. 6A is a perspective view for explaining a state in which a cured vortex laminate is cut to obtain a cut vortex laminate, and FIG. 6A is a perspective view. (B) is a perspective view explaining a state in which a cured first cylinder laminate is cut to obtain a cut first cylinder laminate. 7A and 7B are views for explaining the first embodiment, in particular, FIG. 7A is a perspective view showing a cured first multilayer laminate, and FIG. 7B is a cured first multilayer laminate. FIG. 7 (c) is a perspective view illustrating a state in which the body is cut, and FIG. 7 (c) is a perspective view illustrating a state in which the second cut laminates are arranged side by side on the plate member, FIG. 7 (d). Is a perspective view illustrating a state in which a plurality of second cut laminates are interposed between a pair of plate members. FIG. 8 is a diagram for explaining the first embodiment, and FIG. 8A is a perspective view for explaining a state in which a plurality of cutting vortex laminates are interposed between a pair of plate members. 8 (b) is a perspective view illustrating a state in which a plurality of cut first cylindrical laminates are interposed between a pair of plate members. 9A and 9B are views for explaining a modified example of the first embodiment, in particular, FIG. 9A is a perspective view showing a third multilayer laminate, and FIG. 9B is a third multilayer laminate. FIG. 9C is a perspective view illustrating a state in which the laminate is cut, and FIG. 9C is a perspective view illustrating a state in which a fourth multilayer laminate is obtained by directly laminating a fiber sheet on the third multilayer laminate. 9 (d) is a perspective view showing the cured fourth laminated body. FIG. 10 is a plan view showing a bent columnar laminated body according to the second embodiment. 11A and 11B are views for explaining the second embodiment, and FIG. 11A is a perspective view for explaining a state in which a fiber sheet is wound around a cylindrical foam to obtain a columnar laminated body. 11 (b) is a perspective view illustrating a state in which a columnar laminate group is obtained by arranging the columnar laminates in a row, and FIG. 11C is a first cut by cutting the columnar laminate group. 11 (d) is a perspective view illustrating a state of obtaining a columnar laminated body group, and FIG. 11 (d) is a perspective view illustrating a state of sandwiching the first cut columnar laminated body group between a pair of fiber sheets, and is FIG. 11 (e). ) Is a perspective view illustrating a state in which a cured special flat plate laminate is obtained by performing a curing step on the special flat plate laminate. FIG. 13 is a diagram illustrating a second embodiment, and FIG. 13A is a perspective view illustrating a state in which a fiber sheet is wound around a cylindrical foam to obtain a columnar laminate. 13 (b) is a perspective view illustrating a state in which the columnar laminated body groups are superposed on each other, and FIG. 13 (c) is a second cut by cutting a plurality of columnar laminated body groups superposed on each other. It is a perspective view explaining the state which obtains the columnar laminated body group, FIG. 13 (d) is a perspective view which shows the 2nd cut columnar laminated body group, and FIG. 13 (e) is with respect to the special block laminated body. It is a perspective view explaining the state which obtains the cured special block laminated body by performing the curing process. FIG. 15 is a diagram illustrating a second embodiment, and FIG. 15A is a perspective view illustrating a state in which a fiber sheet is wound around a cylindrical foam to obtain a cylindrical laminate. 15 (b) is a perspective view illustrating a state in which a group of cylindrical laminated bodies is bundled in a bundle, and FIG. 15 (c) shows a state in which a bundle of columnar laminated bodies is cut to obtain a cut columnar laminated body bundle. 15 (d) is a perspective view showing a bundle of cut cylindrical laminates, and FIG. 15 (e) is a cured special cylinder by performing a curing step on the special cylindrical laminate. It is a perspective view explaining the state which obtains the laminated body. FIG. 14 is a perspective view showing a fiber reinforced resin structure according to the first embodiment and a method for manufacturing the same. FIG. 15 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the first embodiment. FIG. 16 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the first embodiment. FIG. 17 is a perspective view showing a fiber reinforced resin structure according to the second embodiment and a method for manufacturing the same. FIG. 18 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the second embodiment. FIG. 19 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the second embodiment. FIG. 20 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 21 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 22 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 23 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 24-1 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 24-2 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 25 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 26 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 27 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 28 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 29 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 30 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 31 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for manufacturing the same. FIG. 32-1 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same. FIG. 32-2 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same. FIG. 33-1 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same. FIG. 33-1 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same. FIG. 34 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same. FIG. 35 is a perspective view showing the fiber reinforced resin structure according to the modified example 1. FIG. 36 is a perspective view showing the fiber reinforced resin structure according to the modified example 2. FIG. 37 is a perspective view showing the fiber reinforced resin structure according to the modified example 3. FIG. 38-1 is a perspective view showing the fiber reinforced resin structure according to the modified example 4. FIG. 38-2 is a perspective view showing the fiber reinforced resin structure according to the modified example 4. FIG. 39 is a perspective view showing the fiber reinforced resin structure according to the modified example 5. FIG. 40 is a perspective view showing the fiber reinforced resin structure according to the modified example 6. FIG. 41 is a perspective view showing the fiber reinforced resin structure according to the modified example 7. FIG. 42 is a perspective view showing the fiber reinforced resin structure according to the modified example 7. FIG. 43 is a perspective view showing the fiber reinforced resin structure according to the modified example 8. FIG. 44 is a perspective view showing the fiber reinforced resin structure according to the modified example 9. FIG. 45 is a perspective view showing the fiber reinforced resin structure according to the modified examples 10-1 to 3.

Hereinafter, the present invention will be specifically described, but the present invention is not limited to the following. The present invention also includes a configuration obtained by combining the matters disclosed in one embodiment and the matters disclosed in another embodiment to the extent that there is no particular contradiction.

Further, in the description of each embodiment, the matters already described in another embodiment may be omitted without particular explanation. For example, the description may be omitted or simplified by adding a similar reference numeral to a portion indicating a similar material. Further, in each figure, the description may be omitted or simplified for the matters having the same reference numerals. If the same reference numerals are given to the first and second embodiments described later and the I to IV embodiments described later, it may be determined that different members are disclosed. good.

In the present invention, the "circle" includes an ellipse.

In the present invention, when expressed as a "polygon" or the like, it has a structure different from that of a circle or an indeterminate form because it has a linear side in a part thereof, and it can be determined that the structure is similar to a polygon or a polygon as a whole. Anything is fine. Therefore, a shape in which some sides are rounded or a shape in which the sides are loosely connected is also included in the concept of "polygon". In addition, when it is simply referred to as a "polygon", it preferably indicates a regular polygon, but it also includes a configuration other than a regular polygon.

In the present specification, the vertical / horizontal direction as seen in the figure is referred to as “vertical / horizontal” as it is.

Hereinafter, the present invention will be described based on the two viewpoints of the first and second embodiments and the first and second embodiments.

The first to second embodiments and the first to IV embodiments have overlapping parts and different parts from each other. The matters described in the description of the first to second embodiments and not described in the description of the first to IV embodiments are carried out in the first to second embodiments to the extent that there is no contradiction. It is possible to incorporate it into the form of.

The method for producing the fiber-reinforced resin structure described below uses a foam that can be secondarily foamed as the foam, and has a coating having a thermosetting resin in an uncured state and a bleed hole from which gas can exude. A step of covering the laminated body with a body may be included, but it is preferable not to include such a step. When a secondary foamable foam is not used and a step of covering the laminate with a coating material having a bleed hole in which an uncured thermosetting resin or the like can be exuded is not provided, the foam 2 Since the unnecessary step of controlling the next foaming can be omitted and the necessary thermosetting resin can be prevented from flowing out from the bleed hole, it is possible to manufacture a fiber reinforced resin structure having higher strength and appearance. ..

<<<<<< Embodiments 1 and 2 >>>>>>
<<<<< First Embodiment >>>>>
First, the first embodiment will be described. In this first embodiment, the fibrous body impregnated with the energy curable resin and the flexible body are directly laminated to obtain an uncured laminated body, or the fibrous body and the flexible body are brought into direct contact with each other, and then the above-mentioned. A laminating process of impregnating a fiber body with an energy-curing resin to obtain an uncured laminated body,
The reinforced fiber body and the flexible body include a curing step of applying energy to the uncured laminated body to cure the energy-curable resin contained in the fiber body constituting the uncured laminated body. It is a method for manufacturing a composite material. Hereinafter, the raw materials, processes, and composite materials will be described in this order.

<< 1. Raw materials >>
(1-1. Fiber body)
The shape and size of the fiber body according to the present invention are not particularly limited, but for example, a sheet-shaped fiber sheet can be used. The fiber sheet is not particularly limited as long as it is a sheet in which fibers are aggregated, and examples thereof include woven fabrics (twill weave, double weave, triple weave, tatami weave, etc.) and non-woven fabrics.

The thickness of the fiber sheet is not particularly limited and can be appropriately selected. If the thickness of the fiber sheet is too thin, the mechanical properties such as the strength and elastic modulus of the fiber sheet may be lowered. Therefore, the thickness of the fiber sheet according to the present invention is, for example, preferably 20 μm to 500 μm, more preferably 30 μm to 300 μm, and particularly preferably 30 μm to 200 μm. Further, a plurality of such fiber sheets may be laminated. Needless to say, a fiber sheet having a thickness of several mm, such as a chopped strand mat or a core mat, may be used.

The fibers forming the fiber sheet are not particularly limited, and known ones can be used, and at least one of metal fibers, inorganic fibers and organic fibers can be used. Examples of the fiber include metal fibers such as stainless steel fiber, nickel fiber, copper fiber, aluminum fiber, silver fiber, gold fiber and titanium fiber; polyparaphenylene benzoxazole, polyethylene terephthalate (PET) resin and polyvinyl. Polyolefin resin such as alcohol (PVA), polyethylene, polypropylene, polyvinyl chloride resin, aramid resin, acrylic resin, polyimide resin, polyparaphenylene benzoxazole (PBO) fiber, cellulose, vinylon, nylon, rayon, aramid , Phenole fiber, Fluorine fiber, Pulp (fiber), Kenaf, Linen, Bamboo fiber and other organic fibers; Glass fiber, Carbon fiber, Silica fiber, Rock wool, Basalt fiber, Slag wool, Alumina fiber, Ceramic Inorganic fibers such as fibers; etc. can be mentioned. One or more of these can be used in combination. The fiber according to the present invention is preferably a fiber having a Young's modulus higher than the Young's modulus such as a resin or a matrix resin used for a sealing material, and more preferably a metal fiber or an inorganic fiber. The higher the Young's modulus of the fiber, the higher the rigidity of the fiber sheet, and when embedded in the resin, the rigidity of the resin can be effectively improved. Therefore, it is possible to obtain a sealing material having high rigidity and not easily damaged.

(1-1-1. Manufacturing method of fiber sheet)
As a method for producing the fiber sheet, a known method can be used. For example, as a method for producing a non-woven fabric which is a suitable example, a dry method such as a carding method and an air lace method, a wet papermaking method for forming by straining like paper, a fleece forming method such as a spunbond method and a melt blow method; thermal Examples include a fleece bonding method such as a bond method, a chemical bond method, a needle punch method, a spunlace method (water flow entanglement method), a stitch bond method, and a steam jet method. Of these, the manufacturing method by the wet papermaking method is suitable because the fiber sheet can be thinned and is excellent in terms of uniformity.

(1-2. Thermosetting resin)
Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, polyvinyl ester resin, phenol resin, polyurethane resin, acrylic resin, melamine resin, urea resin, benzoguanamine resin, rosin-modified maleic acid resin, and rosin-modified fumaric acid. Resin or the like can be used. These may be used alone or in combination of two or more.

The thermosetting resin can include an energy ray-curable resin as another curable resin. Examples of the energy ray-curable resin include epoxy resin, acrylic resin, silicone resin, polyester resin and the like. These may be used alone or in combination of two or more.

The volume ratio of the thermosetting resin to the fiber sheet shall be 15 to 85% by volume when the total volume of the thermosetting resin and the fiber sheet is 100% by volume and the volume fraction (fiber fraction) of the fiber sheet is 100% by volume. 25 to 85% by volume is preferable, and 45 to 80% by volume is more preferable. When the volume fraction (fiber fraction) of the fiber sheet is within the range, the fiber-reinforced resin structure after curing has few defects, is less likely to cause fracture such as buckling, and has excellent mechanical strength. It becomes.

(1-3. Flexible body)
As the flexible body, a columnar foam is used. The foam may be a closed cell foam, an open cell foam, or a foam containing both closed cells and open cells. The closed-cell foam shown here does not mean only those in which all the bubbles are completely independent, but some of the bubbles may communicate with the adjacent bubbles, and the closed cells as a whole may be used. It is sufficient that each bubble is independent to the extent that it can be understood as a foam.

Here, when the foam contains closed cells and open cells, the average ratio of the closed cells and open cells (hereinafter referred to as the closed cell ratio) is not particularly limited, but for example, the closed cell ratio may be used. It can be 0.1 to 99.9%, preferably 10.0% to 99.9%, more preferably 30.0 to 99.9%, still more preferably 50.0 to 99.9%. Can be. The foam containing only closed cells is most preferable. When a large amount of closed cells are contained, there are many sealed air layers inside the foam, so when the foam is heated, in addition to the thermal expansion of the resin itself, the sealed air layer thermally expands. The force with which the foam presses the fibrous body can be increased. For this reason, when the foam is heated in the thermosetting step described later, thermal expansion occurs more strongly, and by pressing the fibrous body, formability (no wrinkles or twists, and the shape becomes a desired shape). It becomes possible to make it even more excellent, and it becomes easier to remove the foam from the laminate by shrinking during cooling after curing.

The closed cell ratio contained in the foam is determined by observing the cross section of the foam using a microscope or a scanning electron microscope and counting the number of closed cells and open cells per unit area in the captured image. It is assumed that the number is divided by the number of all bubbles (all of the independent bubbles and open bubbles) and multiplied by 100. The measurement of the closed cell ratio was repeated at 10 randomly selected cross sections of the same foam, and the average value of the closed cell ratios obtained for each was taken as the closed cell ratio of the foam.

The resin constituting the foam is not particularly limited, and an olefin resin, a urethane resin, a styrene resin, a phenol resin, a silicone resin, or the like may be appropriately selected depending on the intended use. In addition, natural rubber (NR), chloroprene rubber (CR), ethylene propylene diene rubber (EPDM), nitrile rubber (NBR) and the like are also used as constituents of the foam, and these are also appropriately selected according to the intended use. do it. Of these, olefin resins can be preferably used. With the olefin resin, it is easy to adjust the curing temperature of the fiber and the degree of thermal expansion of the foam at the curing temperature of the fiber, for example, by adjusting the composition of polyethylene and polypropylene. That is, when the foam is heated in the heat curing step described later and thermally expanded, the foam presses the fiber to formability (there is no wrinkles or twists, and the shape is a desired shape). However, the degree of thermal expansion can be adjusted by changing the mixing ratio of the olefin resin, for example, polyethylene and polypropylene, and the degree of thermal expansion can be adjusted. The moldability can be made excellent according to the shape. By adjusting the blending ratio of polyethylene and polypropylene, the presence or absence of cross-linking, and the degree of cross-linking, it becomes easy to adjust the flexibility (hardness), thermal expansion, wettability (affinity), softening point, etc. of the foam.

The resin constituting the foam can be freely selected in consideration of the affinity with the uncured resin contained in the fiber. If the affinity between the resin constituting the foam and the uncured resin contained in the fiber is high, the work of winding the laminate around the foam becomes easy, but it is difficult to remove the foam after heat curing. May become. Therefore, it is preferable to adjust the affinity between the resin constituting the foam and the uncured resin contained in the fiber.

In order to adjust the affinity between the resin constituting the foam and the uncured resin contained in the fiber, the wettability (for example, the contact angle) between the resin constituting the foam and the uncured resin contained in the fiber is used. Alternatively, the surface energy) may be adjusted, and in order to increase the affinity, the contact angle (or surface energy) between the resin constituting the foam and the uncured resin contained in the fiber may be selected. When increasing the affinity, the contact angle (or surface energy) of the resin constituting the foam and the uncured resin contained in the fiber may be close to each other, and when decreasing the affinity, the contact angle may be set to a close value. The contact angle and surface energy of the resin constituting the foam and the uncured resin contained in the fiber may be different from each other.

The difference in contact angle between the resin constituting the foam and the uncured resin contained in the fiber is not particularly limited, but may be more than 0 ° and less than ± 90 °. When the difference in contact angle between the resin constituting the foam and the uncured resin contained in the fiber is within the range, it is easy to wind the fiber around the foam and foam after heat curing. It also facilitates body removal.

The softening point of the resin constituting the foam is not particularly limited, and can be selected according to the curing temperature of the thermosetting resin used for the fiber. For example, the softening point of the resin constituting the foam can be set to a softening point that is 10 ° C. or higher higher than the curing temperature of the thermosetting resin used for the fiber body. For example, when the thermosetting resin is an epoxy resin, the softening point of the resin constituting the foam can be 60 to 200 ° C, preferably 80 to 160 ° C, more preferably 100 to 150 ° C. preferable. When the softening point of the resin constituting the foam is within such a range, the foam has sufficient thermal expansion as a foam and has sufficient strength (for example, tensile strength) when heated. Excellent moldability (without wrinkles or twists and making the shape a desired shape) becomes possible at the time of molding.

The foam is preferably a medium substance. The foam has a diameter of 1/2 or more, 1/3 or more, 1/4 or more, 1/5 or more, 1/10 or more, 1/15 or more, or 1/20 or more of the outer diameter of the foam. It is preferable that the hole (through hole / hollow portion) is not provided. That is, in the foam, the ratio of the inner diameter / outer diameter of the foam is 1/2 or less, 1/3 or less, 1/4 or less, 1/5 or less, 1/10 or less, 1/15 or less, 1/20. Hereinafter, it is preferably 1/50 or less, or 0/1 (that is, the foam is a medium substance). By forming the foam in such a configuration, it is possible to prevent buckling of the foam when the foam is deformed / curved.

The foam may contain known additive components such as thickeners, plasticizers, lubricants, fillers, flame retardants, colorants, antioxidants, reinforcing agents, conductive materials and the like.

The density of the foam is not particularly limited, but is, for example, 1 kg / m ³ or more, 2 kg / m ³ or more, 3 kg / m ³ or more, 4 kg / m ³ or more, 5 kg / m ³ or more, 10 kg / m ³ or more, 15 kg. / ^{m 3} may be a more, also, 800 kg / ^{m 3} or less, 700 kg / ^{m 3} or less, 600 kg / ^{m 3} or less, 500 kg / ^{m 3} or less, 250 kg / ^{m 3} or less, 100 kg / ^{m 3} or less, 50 kg / m ^It may be 3 or less. It should be noted that the upper limit value and the lower limit value can be arbitrarily combined to obtain a desired numerical range. For example, it is possible to 5~800kg / ^{m 3,} preferably ^{5~500kg / m 3, 10~250kg / m} 3 and more preferably. When the density of the foam is within such a range, it has sufficient thermal expansion as a foam when heated and has sufficient strength (for example, tensile strength), so that it has excellent moldability (wrinkles and wrinkles) during molding. It is possible to make the shape a desired shape without twisting. The density of the foam is the apparent density measured according to JIS K7222: 2005 "Foam plastics and rubber-How to determine the apparent density". The reciprocal of the density of the foam may be expressed as the expansion ratio.

The tensile elongation at break of the foam at 25 ° C. is more than 25% and less than 400%, preferably more than 50% and less than 350%, and more preferably more than 80% and less than 300%. If the tensile elongation at break at 25 ° C. of the foam is within such a range, it can be sufficiently deformed when the laminated body is deformed in the deformation step described later, and the coefficient of thermal expansion can be adjusted to an appropriate range. Therefore, when the foam is heated in the heat curing step described later, it is possible to strongly press the fibrous body, and the moldability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be considered.

The tensile elongation at break of the foam at 25 ° C. is measured by processing the foam into a No. 3 dumbbell test piece in accordance with JIS K6767 "Foam Plastic-Polyethylene-Test Method".

The tensile strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 0.05 MPa or more, preferably 0.1 MPa or more, and more preferably 0.2 MPa or more. The upper limit of the tensile strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 20 MPa or less. When the tensile strength of the foam at 25 ° C. is within such a range, the foam has sufficient strength in the deformation step described later, and the foam can uniformly press the fiber. Therefore, when the foam is heated in the thermosetting step, it is possible to strongly press the fibrous body, and the moldability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be.

The tensile strength of the foam at 25 ° C. can be measured by processing the foam into a No. 3 dumbbell test piece in accordance with JIS K6767 "Foam Plastic-Polyethylene-Test Method".

The tear strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 0.5 N / mm or more, preferably 0.8 N / mm or more, and more preferably 1.0 N / mm or more. Can be. The upper limit of the tear strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 50 N / mm or less. When the tear strength of the foam at 25 ° C. is within such a range, the foam has sufficient strength in the deformation step described later, and the foam can uniformly press the fiber. Therefore, when the foam is heated in the thermosetting step, it is possible to strongly press the fibrous body, and the moldability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be.

The tear strength of the foam at 25 ° C. can be measured according to JIS K6767 "Foam Plastic-Polyethylene-Test Method".

The 25% compressive load (hardness) of the foam at 25 ° C. is not particularly limited, but can be, for example, 1 to 2000 kPa, preferably 5 to 1000 kPa, more preferably 10 to 500 kPa, and further 10 to 200 kPa. preferable. When the 25% compressive load of the foam is within the applied range, it is easy to wind the fiber around the foam, and it can be sufficiently deformed when the laminate is deformed in the deformation step described later. Further, in the heat curing step described later, the repulsive force of the foam itself can act in addition to the thermal expansion. Therefore, when the foam is heated in the thermosetting step, it is possible to strongly press the fibrous body, and the formability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be.

The 25% compressive load of the foam at 25 ° C. is determined by the D method described in JIS K6400-2: 2012 "Soft foam material-Physical properties-Part 2: Hardness and compressive stress-How to determine strain characteristics". Can be done,

The thermal conductivity of the foam is not particularly limited, but can be, for example, 0.01 W / m · K or more, preferably 0.02 W / m · K or more, more preferably 0.03 W / m · K. It is K or more. The upper limit of the thermal conductivity of the foam is not particularly limited, but can be, for example, 0.2 W / m · K or less. When the thermal conductivity of the foam is within the range, when the foam is heated in the heat curing step described later, the foam can be uniformly heated in a short time, so that the foam is uniform. It becomes possible to thermally expand to. For this reason, the variation in the force with which the foam presses the fiber is reduced, and the moldability (without wrinkles or twists and having a desired shape) can be further improved.

The thermal conductivity of the foam shall be measured by the method described in JIS A1412-1: 2016 "Method for measuring thermal resistance and thermal conductivity of thermal insulating material-Part 1: Protective thermal plate method (GHP method)". Can be done.

The coefficient of linear thermal expansion of the foam is not particularly limited, but can be, for example, 0.01% or more, preferably 0.05% or more, more preferably 0.10% or more, and 1.00% or more. More preferred. The upper limit of the linear thermal expansion coefficient of the foam is not particularly limited, but can be 10.00% or less. When the linear thermal expansion coefficient of the foam is within the range, when the foam is heated in the heat curing step described later, it becomes possible to strongly press the fibrous body, resulting in moldability (wrinkles, twists, etc.). However, the shape can be made into a desired shape) to be further improved.

For the linear thermal expansion coefficient of the foam, the foam is processed to a width of 3 mm, a length of 25 mm, and a thickness of 2 mm. , 25 to 85 ° C., 1 ° C./min. After raising the temperature in 1 ° C., from 85 ° C. to 25 ° C. at 1 ° C./min. The temperature was lowered at 1 ° C./min. From 25 ° C. to 85 ° C. again. It can be measured by a method of measuring the linear thermal expansion coefficient at 85 ° C. at the time of the second temperature rise at this time.

Such foams can be produced by known methods. As a method for producing a foam, for example, a raw material preparation step which is a step of obtaining a liquid raw material mixture containing at least an aqueous liquid dispersion medium and an aqueous dispersible resin, and a foaming step of foaming the liquid raw material mixture to obtain a foamed mixture. And a drying step of evaporating the dispersion medium in the effervescent mixture. Further, before or after the foaming step, the liquid raw material mixture or the foamed mixture is coated with a doctor knife or a doctor roll, or the liquid raw material mixture or the foamed mixture is extruded or injection molded to form a sheet of the foamed mixture. It may be molded into a shape. In addition, a rubber sponge or the like can be molded into a desired shape, or a foam foam molded into a block shape can be formed into a desired shape such as a sheet, string, or columnar by slicing, cutting, polishing, or the like. May be. It should be noted that some or all of these steps may be executed at the same time.

As the foaming means in the foaming step, for example, a method of forming bubbles by blending a foaming agent that generates gas by a chemical reaction into the liquid raw material mixture, and a pressure after dissolving an appropriate gas in the liquid raw material mixture under high pressure. A method of forming bubbles by lowering or heating, a method of removing soluble substances mixed in the liquid raw material mixture and forming bubbles as voids, a method of forming the bubbles so that air or an appropriate gas is embraced. Examples thereof include a method of mechanically stirring (mechanical floss).

The foaming conditions (temperature, time, etc.) in the foaming step and the drying conditions (temperature, time, etc.) in the drying step can be appropriately changed depending on the raw material of the foam, the foaming means used, and the like.

The shape and size of the flexible body are not particularly limited, and in addition to the sheet-shaped flexible body sheet and the cylindrical flexible body, the columnar shape, the square columnar shape, the hexagonal columnar shape, or the cross-sectional shape is a star shape or a semicircle. A flexible body having a shape or the like can be appropriately selected, and the same applies when a foam is used as the flexible body.

<< 2. Process >>
(2-1. Laminating process)
In this laminating step, generally, the fiber sheet and the flexible body are directly laminated. In this laminating step, fibrous bodies and flexible bodies of various shapes and thicknesses can be used. The pattern of this laminating process is not particularly limited, and examples thereof include various patterns listed below.

(2-1-1. Laminating process pattern 1)
In this pattern 1, as shown in FIG. 1, a fiber sheet 1 in an uncured state impregnated with an energy curable resin in advance and a plate-shaped flexible body 3 are used. As a method of impregnating the fiber sheet 1 in advance with an energy-curable resin, for example, dipping in which the fiber sheet 1 is dipped in an uncured viscous liquid raw material of the energy-curable resin, or the fiber sheet 1 is sandwiched between a plurality of horizontal hard rolls. The roll coating method for applying the above-mentioned uncured viscous liquid raw material through the above-mentioned method, a so-called hand lay-up molding method, a RIMP (resin infusion) molding method, or the like can be mentioned, but the present invention is not limited thereto. As the fiber sheet 1, one sheet may be used, or a plurality of sheets may be stacked and used, and the present invention is not particularly limited. The same applies to this thereafter.

In this pattern 1, as shown in FIG. 1A, the lower surface of the flexible body 3 is directly superposed on the upper surface of the fiber sheet 1 placed on a flat surface, and another fiber sheet 1 is placed on the upper surface of the flexible body 3. After directly superimposing the lower surface of the fiber sheet 1, the upper surface of the other fiber sheet 1 and the lower surface of the other flexible body 3 are directly superposed repeatedly. As a result, each fiber sheet 1 and each flexible body 3 are in surface contact with each other, and the flexible body 3 is temporarily adhered to the fiber sheet 1 by the uncured energy-curing resin impregnated in the fiber sheet 1. It will be in the state of being done. By the pattern 1 of such a laminating step, as shown in FIG. 1 (b), a block-shaped first multilayer laminated body 5 in which the fiber sheet 1 and the flexible body 3 are stacked in multiple layers is obtained.

(2-1-2. Laminating process pattern 2)
In this pattern 2, the fiber sheet 1 and the flexible body 3 described in the above-mentioned pattern 1 are used. As shown in FIGS. 2A and 3A, a pair of fiber sheets 1 are directly superposed on the upper surface and the lower surface of the flexible body 3 (both sides of the flexible body 3), respectively. A single-layer laminated body 7 in a state where the flexible body 3 is interposed between 1 is obtained. The single-layer laminated body 7 may be a single-layer laminated body 7 in which the fiber sheet 1 is directly laminated only on one side of the flexible body 3.

(2-1-3. Laminating process pattern 3)
In this pattern 3, the first cut laminated body 5a obtained through the cutting step shown in FIG. 4 (b) (which will be described later) with respect to the above-mentioned first multilayer laminated body 5 shown in FIG. 4 (a). Is used. As shown in FIG. 4C, by directly laminating other fiber sheets 1A and 1B similar to the above-mentioned fiber sheet 1 on both sides of the first cut laminated body 5a along the cutting direction, respectively. , The second multilayer laminated body 8 shown in FIG. 4D is obtained.

The above-mentioned patterns 1 to 3 in the laminating process have been described by taking the case where the fiber sheet is impregnated with the energy curable resin in advance as an example, but instead of this, the fiber sheet 1 and the flexible body 3 are used. Needless to say, after the direct lamination, the fiber sheet 1 may be impregnated with the energy curable resin in the same manner as the impregnation method described in the above-mentioned pattern 1.

(2-2. Winding process)
In this winding step, the laminated bodies 7 and 8 obtained in the above patterns 2 and 3 are wound. Since these laminated bodies 7 and 8 are composed of the fiber sheet 1 and the flexible body 3, they are flexible even in this state, and can be easily deformed by bending, twisting, or the like. .. In the present embodiment, among these deformation processes, the winding process, which is a kind of bending process, is adopted as an example and described below, but it goes without saying that the present invention is not limited to this.

(2-2-1. Winding process pattern 1)
In this pattern 1, the single-layer laminated body 7 obtained in the pattern 2 of the above-mentioned laminating step is used (see FIG. 2A). As shown in FIGS. 2 (b) and 2 (c), the single laminated body 7 is wound a plurality of times around a core S composed of, for example, a metal pipe, a resin tube, and a foam formed in a cylindrical shape. Turn. Therefore, the length of the single-layer laminated body 7 of this pattern 1 is set to about several times the outer peripheral length of the core S (about according to the number of turns). By winding the single-layer laminated body 7 around the core S a plurality of times and then pulling out the core S (by removing the core S), as shown in FIG. 2D, a plurality of single-layer laminated bodies 7 are provided. A laminated spiral vortex laminate 9 is obtained.

(2-2-2. Winding process pattern 2)
Also in this pattern 2, the single-layer laminated body 7 obtained in the pattern 2 of the above-mentioned laminating step is used (see FIG. 3A). In this pattern 2, as shown in FIGS. 3 (b) and 3 (c), the single laminated body 7 is wound many times around the core S. That is, a single laminated body 7 having substantially the same length as the outer peripheral length of the core S is wound so that both end faces thereof are joined to each other, and further outside the single laminated body 7 is slightly longer than the above-mentioned single layer laminated body 7. The single laminated body 7 of the above is repeatedly wound a plurality of times so that both end faces thereof are joined to each other. Then, by pulling out the core S, as shown in FIG. 3D, a cylindrical first cylindrical laminated body 11 in which a plurality of single laminated bodies 7 are laminated is obtained.

(2-2-3. Winding process pattern 3)
In this pattern 3, the second multilayer laminate 8 obtained in the pattern 3 of the above-mentioned lamination step, and the length thereof is set to substantially the same length as the outer peripheral length of the core S, is used. Use. As shown in FIGS. 4 (d) and 4 (e), the second multilayer laminate 8 is wound around the core S. That is, the second multilayer laminate 8 is wound so that both end faces in the winding direction are joined to each other, and then the core S is pulled out to form the cylindrical second cylindrical laminate 13 shown in FIG. 4 (f). To get.

In the second cylindrical laminate 13, the outer peripheral surface of the other fiber sheet 1A directly laminated on one surface of the second multilayer laminate 8 forms the outer peripheral surface of the second cylindrical laminate 13. The outer peripheral surface of the other fiber sheet 1B directly laminated on the other surface of the second multilayer laminate 6 forms the inner peripheral surface of the second cylindrical laminate 13. Further, between these fiber sheets 1A and 1B, the fiber sheet 1 and the flexible body 3 of the first cut laminate 5a extend along the longitudinal direction of the second cylindrical laminate 13, and other fiber sheets. It has a positional relationship that intersects 1A and 1B. In other words, the fiber sheet 1 and the flexible body 3 each have a rib structure that stands up against the other fiber sheets 1A and 1B and extends along the longitudinal direction of the second cylindrical laminated body 13.

The inner diameter of the hollow portion along the central axis of each of the above-mentioned vortex laminated body 9, the first cylindrical laminated body 11 and the second cylindrical laminated body 13 can be appropriately adjusted by using cores S having different diameters. Needless to say, there is. Further, in the above-mentioned winding process patterns 1 to 3, the core S is used for winding the various laminated bodies 7 and 8, but the present invention is not limited to this, and various types are not used without using the core S. By directly winding the laminated bodies 7 and 8 in a spiral shape from the end thereof, a vortex laminated body 9 is obtained, or various laminated bodies 7 and 8 are directly bent so as to be wound, and the winding direction thereof. The first cylindrical laminate 11 and the second cylindrical laminate 13 may be obtained by temporarily adhering both end portions of the above to each other with an uncured energy-curable resin impregnated in the fiber sheet 1.

(2-3. Curing process)
In this curing step, the first multilayer laminate 5, the single-layer laminate 7, the second multilayer laminate 8 obtained in patterns 1 to 3 of the above-mentioned lamination step, and the vortex lamination obtained by patterns 1 to 3 in the winding step are laminated. Energy is applied to the body 9, the first cylindrical laminated body 11, and the second cylindrical laminated body 13 (hereinafter, these are collectively referred to as “laminated body 5 and the like”). The energy to be applied is due to heating of the laminated body 5 or the like, and may further include energy applied by irradiating the laminated body 5 or the like with energy rays. As shown in FIGS. 5A to 5C, the energy curable resin impregnated in the fiber sheet 1 of the laminated body 5 or the like in the temporarily bonded state by the lamination is impregnated by applying energy to the laminated body 5 or the like. It hardens while exuding (penetrating) into each of the flexible bodies 3.

The cured energy-curable resin becomes an adhesive portion G that adheres (anchor effect) the fiber sheet 1 and the flexible body 3, and the fiber sheet 1 and the flexible value 3 are integrated. Further, the fiber sheet 1 becomes a cured fiber sheet 1X by curing the impregnated energy curable resin. As a result, the first multilayer laminate 5 becomes the cured first multilayer laminate 5A (see FIG. 7A), the single-layer laminate 7 becomes the cured single-layer laminate (not shown), and the second multilayer laminate 8 becomes. Is a cured second multilayer laminate (not shown), the vortex laminate 9 is a cured vortex laminate 9A (see FIG. 2E), and the first cylinder laminate 11 is a cured first cylinder laminate 11A (FIG. 3). (E)), the second cylindrical laminate 13 becomes the cured second cylindrical laminate 13A (see FIG. 4 (g)) (hereinafter, these are collectively referred to as “cured laminate 5A and the like”). By going through the curing step in this way, a cured laminate 5A or the like as a composite material can be obtained. With respect to the cured laminated body 5A and the like thus obtained, since an adhesive or the like is not used for joining the fiber sheet 1 and the flexible body 3, it is possible to prevent damage due to deterioration of the adhesive or the like.

Next, among the cured laminates 5A and the like, the configuration of the cured laminate 5A shown in the figure will be described with reference to the drawings. That is, the cured first multilayer laminate 5A shown in FIG. 7A has a plurality of layers of the cured fiber sheet 1X and the flexible body 3 obtained by curing the impregnated energy-curable resin, and these cured fiber sheets 1X and the cured fiber sheet 1X. The flexible body 3 is integrated with the adhesive portion G.

Further, in the cured vortex laminate 9A shown in FIG. 2 (e), the cured fiber sheet 1X obtained by curing the impregnated energy-curable resin and the flexible body 3 are wound a plurality of times around the central axis, and also. A plurality of layers expanding in the radial direction with respect to the central axis are formed, and the cured fiber sheets 1X and 3 in these layers are integrated by the adhesive portion G.

Further, the cured first cylindrical laminate 11A shown in FIG. 3 (e) also has a cured fiber sheet 1X formed into a cylindrical shape and cured with an impregnated energy-curable resin, and an inner peripheral surface or an outer periphery of the fiber body. It has a cylindrical flexible body 3 bonded to at least one of the surfaces, and these cured fiber sheets 1X and the flexible body 3 are integrated by an adhesive portion G.

Further, as shown in FIG. 4 (g), the cured second cylindrical laminate 13A is formed into a cylindrical shape, and the first cylindrical fiber body 1Y obtained by curing the impregnated energy-curable resin and the first cylindrical fiber. It is formed in a cylindrical shape having a diameter smaller than that of the body Y, and is arranged in the hollow portion of the first cylindrical fiber body 1Y so as to be concentric with the first cylindrical fiber body 1Y, and the impregnated energy-curable resin is cured. It extends along the longitudinal direction of the first and second cylindrical fiber bodies 1Y and 1Z in a state of being interposed between the second cylindrical fiber body 1Z and the first and second cylindrical fiber bodies 1Y and 1Z, and is the first cylinder. An elongated plate-shaped intervening fiber 1K that is in contact with the inner peripheral surface of the fiber 1Y and the outer peripheral surface of the second cylindrical fiber 1Z and is obtained by curing the impregnated energy-curable resin, and the first and first cylinders. The two cylindrical fiber bodies 1Y and 1Z are arranged in an internal space formed by a pair of intervening fiber bodies 1K and 1K facing each other, and the inner peripheral surface of the first cylindrical fiber body 1Y and the second cylindrical fiber body 1Z. It is provided with a flexible body 3 in contact with the outer peripheral surface and the facing surfaces of the intervening fiber bodies 1K and 1K, respectively.

Further, the cured second cylindrical laminated body 13A is integrated with the contact portion between the first and second cylindrical fiber bodies 1Y and 1Z and the intervening fiber bodies 1K and 1K in the flexible body 3 by an adhesive portion G. It has become. Further, the contact portions between the first and second cylindrical fiber bodies 1Y and 1Z and the plurality of intervening fiber bodies 1K are also bonded and integrated by the adhesive portion G. In this example, since no adhesive or the like is used for joining the fiber sheet 1 and the flexible body 3 and for adhering the fiber sheets 1, 1A and 1B, it is possible to prevent damage due to deterioration of the adhesive and the like. Further, a plurality of intervening fibers 1K are arranged between the inner first cylindrical fiber body 1Y and the outer second cylindrical fiber body 1Z like ribs standing up against the respective fiber bodies 1Y and 1Z. Therefore, it is possible to obtain a cured second cylindrical laminate 13A whose strength is increased and which is less likely to be deformed as compared with a simple cylindrical one.

(2-4. Cutting process)
In this cutting step, the laminated body 5 or the like before curing obtained in the above-mentioned laminating step or winding step, the cured laminated body 5A after curing obtained in the curing step, or the like is cut smaller than these. In this cutting step, the laminated body 5 or the like or the cured laminated body 5A or the like may be cut into any shape or size, and the pattern thereof is not particularly limited, but some examples of these will be described below.

(2-4-1. Cutting process pattern 1)
In this pattern 1, the first multilayer laminated body 5 before curing obtained in pattern 1 of the laminating step is cut. As shown in FIG. 4B, the first multilayer laminated body 5 is vertically thinly cut in a state where the fiber sheet 1 and the flexible body sheet 3 are placed on a flat surface so as to be horizontal. The first cut laminated body 5a before curing used in the pattern 3 of the laminating step is obtained. As described above, the first cut laminated body 5a was designated as the second multilayer laminated body 8 in the pattern 3 of the laminating process, and was designated as the second cylindrical laminated body 13 in the pattern 3 of the winding process. After that, it undergoes a curing step to obtain a cured second cylindrical laminate 13A as a composite material.

(2-4-2. Cutting process pattern 2)
In this pattern 2, the cured first multilayer laminate 5A after the curing step shown in FIG. 7A is cut. As shown in FIG. 7B, the cured first multilayer laminated body 5A is vertically thinly cut in a state where the fiber sheet 1 and the flexible body sheet 3 are placed on a flat surface so as to be horizontal. , A cured second cut laminated body 5B after curing is obtained.

(2-4-3. Cutting process pattern 3)
In this pattern 3, the cured vortex laminate 9A and the cured first cylindrical laminate 11A that have been cured through the curing step are cut. As shown in FIGS. 6 (a) and 6 (b), the cured vortex laminate 9A and the cured first cylindrical laminate 11 are sliced (sliced) to a predetermined width in the longitudinal direction thereof to form a composite material. The hardened and cut vortex laminated body 9B and the hardened and cut first cylindrical laminated body 11B are obtained. Although not shown, it is needless to say that the cured second cylindrical laminate 13A may be similarly cut to obtain a cured cut second cylinder laminate as a composite material.

<< 3. Composite material >>
Here, the composite material obtained through each of the above steps will be described.
(3-1. Composite material pattern 1)
As shown in FIG. 7, this pattern 1 is an example of using the cured second cut laminate 5B, 5C, and 5D as the composite material obtained in the pattern 2 of the cutting step (note that in FIG. 7, it is complicated. In order to avoid this, only 5B, 5C, and 5D are added as the sign of the cured second cut laminate, and the entire mass composed of these is referred to as the cured second laminate group 5Z). As shown in FIG. 7, a plurality of second cut laminates 5B, 5C, and 5D are formed with respect to the upper surface of the lower first plate member 15 among the first plate members 15 and 17 such as resin plates and the like. The cured fiber sheet 1X and the flexible body 3 of the second cut laminated body 5B, 5C, and 5D stand up like ribs (in other words, the cured fiber sheet 1X with respect to the plate surfaces of the plate members 15 and 17). It is placed so that it extends in the direction in which the flexible body 3 and the flexible body 3 intersect (the vertical direction in FIG. 7C).

Further, at the time of this placement, the extension direction of the cured fiber sheet 1X and the flexible body 3 of the cured second cut laminate 5B and another cured second cut laminate adjacent to the cured second cut laminate 5B. One cured second cut laminated body 5C and another cured so that the extending directions of the cured fiber sheet 1X of 5C and 5D and the flexible body 3 intersect each other (orientated in FIG. 7 (c)). The second cut laminated body 5D is placed. This is repeated to obtain a cured second laminated body group 5Z formed by spreading the cured second cut laminated bodies 5B, 5C, and 5D over substantially the entire upper surface of the first plate member 15. After that, in a state where the upper surface of the first plate member 15 and the lower surface of the cured second laminated body group 5Z are adhered, the lower surface of the upper second plate member 17 and the upper surface of the cured second laminated body group 5Z are adhered to each other. , The plate members 15 and 17 can be reinforced. In this pattern 1, a pair of plate members 15 and 17 is used, but it is needless to say that the pattern 1 is not limited to this and only one of the plate members 15 and 17 may be used.

(3-2. Composite material pattern 2)
As shown in FIGS. 8 (a) and 8 (b), this pattern 2 has a plurality of cured cutting vortex laminates 9B or a plurality of cured products between the plate members 15 and 17 similar to the pattern 1 of the composite material. The cut first cylindrical laminated bodies 11B are arranged side by side so as to be adjacent to each other. After that, the upper surface of the plate member 15 and the lower surface of each of the plurality of cured cutting vortex laminates 9B or the plurality of cured cut first cylindrical laminates 11B are adhered to each other, and the lower surface of the plate member 17 and the plurality of cured cut vortex laminates 9B are bonded. Alternatively, the upper surface of each of the plurality of hardened and cut first cylindrical laminates 11B is adhered. As a result, the plate members 15 and 17 can be reinforced.

In this pattern 2, the cut laminate 9B or the cut first cylindrical laminate 11B and the plate members 15 and 17 are bonded to each other, but the present invention is not limited to this, and the plate members 15 and 17 are penetrated, for example. The plate member may be reinforced by forming a hole and fitting the cut laminated body 9B or the cut first cylindrical laminated body 11B into the through hole. Further, the same foam as the flexible body 3 is used as the plate members 15 and 17, and after forming the same through holes as described above in the plate members 15 and 17, the uncured vortex laminated body 9 and the first are formed in the through holes. A cured plate member may be obtained by performing a curing step after fitting the 1-cylindrical laminate 11 and the second cylindrical laminate 13. In this case, if a plate member having no through hole is desired, for example, by winding various laminated bodies 7 and 8 directly from the end thereof in a spiral shape without using the core S, there is no hollow portion. The vortex laminate 9 may be provided and fitted into the through hole of the plate member.

The present invention is not limited to the above-mentioned first embodiment, and various modifications can be made without departing from the gist thereof. In this modification, the description thereof shall be omitted or simplified by adding the same reference numerals to the parts similar to those in the first embodiment described above.

In the above-mentioned first embodiment, in the pattern 1 of the laminating step, as shown in FIG. 1 (b) and the like, the flexible bodies 3 having the same width (thickness) are used, but the flexible bodies 3 are not limited to this, and they are not limited to each other. Flexible bodies having different widths, hardnesses, densities, etc. may be used. As an example of this specific example, the one shown in FIG. 9 can be mentioned, and this will be described below while interweaving the above-mentioned various steps.

In the example shown in FIG. 9, the laminating step is performed using the fiber sheet 1, the flexible body 3a having a predetermined width, and the flexible body 3b having a width smaller than this. As shown in FIG. 9A, a block-shaped third multilayer laminated body 19 in which the fiber sheet 1 and the flexible bodies 3a and 3b are stacked in multiple layers is obtained. That is, the central portion of the third multilayer laminate 19 extending vertically is formed by alternately stacking the relatively thin flexible body 3b and the fiber sheet 1, and the upper and lower portions of the third multilayer laminate 19 are relative to each other. The thick flexible body 3a and the fiber sheet 1 are alternately stacked.

Next, as shown in FIG. 9B, the third cut laminate 23 is obtained by performing a cutting step of vertically thinly cutting the third multilayer laminate 19. Then, as shown in FIG. 9 (c), a fourth multilayer laminate 25 is obtained by further performing a lamination step of directly laminating another fiber sheet 24 on one side of the third cut laminate 23. Since the fourth multilayer laminate 25 is composed of the uncured fiber sheet 1 and the flexible body 3, it has flexibility even in this state, and can be easily deformed by bending, twisting, or the like. Can be done. Therefore, the bending step of lightly bending the fourth multilayer laminated body 25 around the central portion thereof can be performed (see FIG. 9D). Then, the above-mentioned curing step is performed on the bent fourth multilayer laminate 25.

Here, in the fourth multilayer laminated body 25, as shown in FIG. 9C, each fiber sheet 1 extends in a state of being substantially vertically upright with respect to the fiber sheet 24 like a rib. Further, the flexible body 3 that stands up from the fiber sheet 24 and is interposed between the fiber sheets 1 and 1 adjacent to each other is in surface contact with these fiber sheets 1, 1 and 24 and is in a temporarily bonded state. It has become. Therefore, as shown in an enlarged manner in FIG. 9E, when the curing step is performed, the energetic cured resin exuded from the fiber sheets 1, 1 and 24 exudes into the flexible body 3 as described above. And harden. That is, the fiber sheets 1, 1 and 24 become the cured fiber sheets 1X, 1X and 24X, respectively, by the curing step, and the energetic cured resin exuded into the flexible body 3 and cured is the flexible body 3 and the cured fiber sheet 1X. It becomes an adhesive portion G with 1X and 24X, and these are integrated. Similarly, the contact portions of the fiber sheets 1, 1 and 24 are also bonded and integrated by the adhesive portion G made of the energy-curable resin that has exuded and hardened. Thereby, the cured fourth multilayer laminated body 25A as a composite material can be obtained. Instead of the uncured fiber sheets 1, 1 and 24, at least one of these may be the cured fiber sheets 1X, 1X and 24X, and even in this case, the same effect is exhibited.

In other words, the cured fourth multilayer laminate 25A is arranged in an upright state with respect to the cured fiber sheet 24X, which is the first fiber body obtained by curing the impregnated energy-curable resin, and the cured fiber sheet 24X. A plurality of cured fiber sheets 1X and 1X, which are second fibers obtained by curing the impregnated energy-curable resin, and a flexible body 3 in contact with the cured fiber sheets 24X and adjacent cured fiber sheets 1X and 1X, respectively. When the energy-curable resin impregnated in the cured fiber sheets 1X, 1X, 24X is applied with energy to be cured at the contact portion with the cured fiber sheets 1X, 1X, 24X in the flexible body 3. In addition, it can be said that the adhesive portion G made of the energy-curable resin impregnated in at least one of the cured fiber sheets 1X, 1X, and 24X is exuded and cured.

The cured fourth multilayer laminate 25A thus obtained has a cured fiber sheet 24C and a plurality of cured fiber sheets 1C standing up against the cured fiber sheet 24C, and thus has a simple plate shape. Higher strength than the hardened fiber sheet of. Further, as described above, in the state before curing, deformation processing such as bending and twisting can be easily performed, so that it is easy to obtain a composite material having a desired shape. In addition, in the above-mentioned pattern 1 of the composite material, when the curing step is performed using the fiber sheet 1 impregnated with the energetic curing resin instead of the plate members 15 and 17, the same action and effect can be obtained. Needless to say.

Here, in the example shown in FIG. 9, the width of the central flexible body 3a is larger than the width of the upper and lower flexible bodies 3b, but is not limited to this, and for example, the upper and lower flexible bodies 3b. The width of the flexible body 3a in the central portion may be larger than the width of the flexible body 3a, and the bendable angle can be adjusted to some extent by these widths. In short, it is sufficient to use the flexible body 3 having a width according to the intended use, and the width and the like can be appropriately set.

Further, in the example shown in FIG. 9, the cured fourth multilayer laminate 25 was subjected to a curing step to obtain a cured fourth multilayer laminate as a composite material, but the present invention is not limited to this, and for example, FIG. 9 By performing the curing step on the third multilayer laminate 19 shown in (a), a cured third multilayer laminate of the composite material can be obtained, or the third cut laminate 23 shown in FIG. 9B can be obtained. Needless to say, the cured third cut laminate as a composite material may be obtained by performing the curing step. In this case, for example, a composite material can be obtained based on laminating the fiber sheet 24 on a mold that can be releasable having a curved surface and arranging the cured third cut laminate therein. Further, the cured third cut laminate may be used instead of the plurality of second laminates 5b, 5c, and 5d (see FIG. 7) described in the above-mentioned pattern 1 of the composite material.

In the above-mentioned first embodiment, in the laminating step, the fiber sheet 1 in the horizontal state and the flexible body 3 are laminated alternately with each other. For example, the fiber sheet is laminated with respect to the core S shown in FIG. A cylindrical laminate is obtained by repeatedly winding 1 once or multiple times, winding the flexible body 3 on the outside thereof, and further winding the fiber sheet 1 on the outside thereof once or multiple times. You may do so. Further, the fiber sheet 1 may be laminated on at least one of each side surface of the first multilayer laminated body 5. In short, it is not particularly limited as long as the fiber sheet 1 and the flexible body 3 are directly laminated. Further, the fiber sheet 1 may be cured after laminating the fiber sheet 1 on at least one of the upper surface, the lower surface, and each side surface of the cured second laminated body group 5Z shown in FIG. 7, and the laminating after curing. The body and the uncured fiber sheet may be combined as appropriate.

<<<<< Second Embodiment >>>>>
Next, the second embodiment will be described.
This second embodiment is
The fiber body impregnated with the energy-curable resin and the flexible body are directly laminated to obtain an uncured laminated body, or the fiber body and the flexible body are brought into direct contact with each other, and then the fiber body is impregnated with the energy-curable resin. And the laminating process to obtain an uncured laminated body,
The deformation step of deforming the uncured laminate and
A curing step of applying energy to the uncured laminate deformed in the deformation step to cure the energy curable resin contained in the fiber body constituting the uncured laminate.
It is a method of manufacturing a reinforcing fiber body including.
Hereinafter, the raw materials and the process will be described in this order, but in the description thereof, the same parts as those in the above-mentioned first embodiment are designated by the same reference numerals, and the description thereof will be omitted or simplified.

<< 1. Raw materials >>
Since the raw materials in the second embodiment are the same as those in the first embodiment described above, the description thereof will be omitted.

<< 2. Process >>
(2-1. Laminating process)
This laminating step is performed by directly laminating the fibrous body and the flexible body. In this laminating step, fibrous bodies and flexible bodies of various shapes and thicknesses can be used. Specifically, as shown in FIGS. 11 (a), 12 (a), and 13 (a), the fiber sheet 1 in an uncured state impregnated with an energy curable resin in advance serves as a core material. A columnar flexible body 31 is used. By directly winding the fiber sheet 1 around the flexible body 31, a columnar laminated body 33 in which the fiber sheet 1 and the flexible body 31 are directly laminated is obtained. In the cylindrical laminated body 33, the length of the flexible body 31 is longer than the vertical width of the fiber sheet 1, and the fiber sheet 1 is wound around the flexible body 31 to form a cylindrical shape from both ends in the longitudinal direction. , Both ends of the flexible body 31 are in a protruding state. Needless to say, as in the first embodiment, the fiber sheet 1 may be directly laminated on the flexible body 31 and then impregnated with the energy curable resin.

(2-2. Deformation process)
This deformation step is a step of variously deforming the uncured cylindrical laminate 33, which is easily deformed, and the deformation is not particularly limited, but the patterns listed below can be mentioned.

(2-2-1. Deformation process pattern 1)
In this pattern 1, as shown in FIG. 10, one columnar laminated body 33 is deformed by bending it into a curved line as it is. Needless to say, the curvature is not particularly limited here. Further, in addition to bending into a curved shape such as an L-shape, a U-shape, an S-shape, etc., the deformation may be performed by bending at a predetermined angle (30 degrees, 90 degrees, etc.) according to the intended use. As a result, a bent columnar laminated body 35 having a special shape bent into various shapes is obtained.

(2-2-2. Deformation process pattern 2)
In this pattern 2, as shown in FIG. 11 (b), after forming a columnar laminated body group 33a in which a plurality of cylindrical laminated bodies 33 are arranged in a row, they protrude from the fiber sheet 1 as shown in FIG. 11 (c). By performing a cutting step of cutting the vicinity of both ends of the flexible body 3, the first cut columnar laminated body group 33b in which both end faces of the respective columnar laminated bodies 33 are flush with each other is obtained. The cutting step shown in FIG. 11C may be omitted. This also applies to the subsequent cutting steps.

Then, as shown in FIG. 11D, the cut columnar laminated body group 33b is sandwiched between the other pair of fiber sheets 35, 37, and pressure is applied. As a result, as shown in FIG. 11 (e), the cross-sectional shape of the fiber sheet 1 of the first cut columnar laminated body group 33b is deformed into a hollow square column shape, and is located in each of these hollow portions. The cross-sectional shape of each flexible body 31 is deformed into a square column shape, and as a whole, a special flat plate laminated body 39 having a special shape deformed into a flat plate shape is obtained. The method of applying pressure may be performed by directly applying a load, or may be performed by depressurizing the first cut columnar laminated body group 33b in a sealed state, and is not particularly limited. This also applies to the subsequent deformation steps.

In this pattern 2, the shape is formed into a square pillar shape, but the present invention is not limited to this, and the special flat plate laminate 39 having a pentagonal or hexagonal cross section can be formed by adjusting the direction in which pressure is applied to the columnar laminate group 33a. You may try to get it. Further, without using the other pair of fiber sheets 35, 37, the pressure is directly applied to the first cut columnar laminated body group 33b, or the pressure is directly applied to the columnar laminated body group 33a. Even in this case, the same effect is obtained.

(2-2-3. Deformation process pattern 3)
In this pattern 3, as shown in FIG. 12B, a plurality of columnar laminated body groups 33a described in pattern 2 of the above-mentioned deformation step are prepared, and these columnar laminated body groups 33a are overlapped with each other in a parallel state. After that, as shown in FIG. 12 (c), by performing a cutting step of cutting the vicinity of both ends of the flexible body 3 protruding from the fiber sheet 1, as shown in FIG. 12 (d), the columnar laminated body group. A second cut columnar laminated body group 33c in which both end faces of 33a are flush with each other is obtained.

Then, as shown in FIG. 12 (e), by applying pressure to the second cut columnar laminated body group 33c, the cross-sectional shape of the fiber sheet 1 of the second cut columnar laminated body group 33c becomes a hollow hexagonal column shape. Along with the deformation, the cross-sectional shape of each of the flexible bodies 33 located in each of these hollows is deformed into a hexagonal column shape, and a block-shaped special block laminated body 41 is obtained as a whole. Needless to say, also in this pattern 3, similarly to the above-mentioned pattern 2, the special block laminated body 41 having various cross-sectional shapes can be obtained by adjusting the direction of applying pressure and the like.

(2-2-4. Deformation process pattern 4)
In this pattern 4, as shown in FIG. 13 (b), a plurality of cylindrical laminated bodies 33 are bundled into a bundle to form a columnar laminated body bundle 43, and as shown in FIG. 13 (c), the cylindrical laminated body 33 protrudes from the fiber sheet 1. As shown in FIG. 13 (d), by performing a cutting step of cutting the vicinity of both ends of the flexible body 3, the cut columnar laminated body 33d in which both end faces of the respective columnar laminated bodies 33 are in a flush state. A cut columnar laminated body bundle 43a composed of bundles is obtained.

Then, as shown in FIG. 13 (e), by applying pressure to the cut columnar laminated body bundle 43a, among the cut columnar laminated body bundles 43a, the peripheral cut columnar laminated body 33d surrounding the central cut cylindrical laminated body 33d is formed. Each fiber sheet 1 of the above is transformed into a hollow pentagonal column shape. Along with this, each of the flexible bodies 33 located in the hollow of these cut columnar laminated bodies 33d is deformed into a pentagonal column shape. Further, the central cut columnar laminated body 33d is deformed into a hollow hexagonal column shape, and the flexible body 33 located in the hollow is deformed into a hexagonal column shape. As a result, a special columnar laminated body 45 having a special shape deformed into a columnar shape is obtained as a whole. Needless to say, also in this pattern 4, similarly to the above-mentioned pattern 2, the special block laminated body 45 having various cross-sectional shapes can be obtained by adjusting the direction of applying pressure and the like. Further, in FIG. 13E, in order to clearly indicate that the fiber sheet 1 of the central cut columnar laminate 33d has a hexagonal cross-sectional shape, the hollow portion of the central cut columnar laminate 33d is intentionally formed. Although the flexible body 33 is shown in a removed state, the hollow portion is actually filled with the flexible body 33.

(2-3. Curing process)
In this curing step, the first bending columnar laminate 35, the special flat plate laminate 39, the special block laminate 41, and the second columnar laminate 41, which are uncured laminates deformed in each of the above-mentioned deformation steps, are first. By applying energy in the same manner as in the embodiment, the energy-curable resin impregnated in the sheet fibers is cured. As a result, the bent columnar laminate 35 becomes the first reinforcing fiber (not shown), the special flat plate laminate 39 becomes the second reinforcing fiber 39A (see FIG. 11E), and the special block laminate 41 becomes the first. The 3 reinforcing fiber body 41A becomes (see FIG. 12 (e)), and the special columnar laminated body 45 becomes the 4th reinforcing fiber body 45A (see FIG. 13 (e)). In each of the reinforcing fiber bodies 39A, 41A, and 45A, a removal step of removing the flexible body 33 by punching out or melting the respective flexible body 33 may be performed.

As described above, in the second embodiment, the uncured laminate obtained in the laminating step is easily deformed, and in this state, it is extremely deformed into a desired special shape and then the curing step is performed. A reinforcing fiber having a desired special shape can be obtained by a simple method.

The present invention is not limited to the above-mentioned second embodiment, and various modifications can be made without departing from the gist thereof. For example, in the cutting steps shown in FIGS. 11 (c), 12 (c), and 13 (c), as shown in FIGS. 11 (b), 12 (b), and 13 (b), respectively, The operation was performed after the columnar laminate 33 was formed into the columnar laminate group 33a or the columnar laminate bundle 43, but the present invention is not limited to this, and after the columnar laminate group 33a or the columnar laminate bundle 43 is formed, pressure is applied to them as they are. It may be performed after the deformation, and the timing of the cutting process is not particularly limited as long as it is before the curing process.

<<<< Summary of the first and second embodiments >>>>>
The first and second embodiments described above can be summarized as follows.

The invention (1-1) is
The fiber body impregnated with the energy-curable resin and the flexible body are directly laminated to obtain an uncured laminate, or the fiber body and the flexible body are brought into direct contact with each other, and then the energy-curable resin is applied to the fiber body. The laminating process of impregnating and obtaining an uncured laminate,
The reinforced fiber body and the flexible body include a curing step of applying energy to the uncured laminated body to cure the energy-curable resin contained in the fiber body constituting the uncured laminated body. It is a method for manufacturing a composite material.
Invention (1-2)
The manufacturing method of the invention (1-1), wherein the flexible body is a foam.
Invention (1-3)
The method according to the invention (1-1) or (1-2), further comprising a winding step of winding the uncured laminate after the laminating step.
The invention (1-4) further includes a step of cutting the uncured laminate or the cured laminate cured by the curing step to a size smaller than the cured laminate, according to the inventions (1-1) to (1-). It is the method according to any one of 3).

According to the above invention, it is possible to prevent the composite material (composite material of the reinforcing fiber body and the flexible body) from being damaged due to deterioration of the pressure-sensitive adhesive, the adhesive, etc., and it is easy to manufacture the composite material having a desired shape. be able to.

Invention (2-1)
The fiber body impregnated with the energy-curable resin and the flexible body are directly laminated to obtain an uncured laminate, or the fiber body and the flexible body are brought into direct contact with each other, and then the energy-curable resin is applied to the fiber body. The laminating process of impregnating and obtaining an uncured laminate,
The deformation step of deforming the uncured laminate and
A curing step of applying energy to the uncured laminate deformed in the deformation step to cure the energy curable resin contained in the fiber body constituting the uncured laminate.
It is a method of manufacturing a reinforcing fiber body including.
Invention (2-2)
The manufacturing method of the invention (2-1), wherein the flexible body is a foam.

According to the above invention, a reinforcing fiber body having a special shape can be easily manufactured.

Invention (3-1)
The first fiber body obtained by curing the impregnated energy-curable resin and
The second fiber body, which is arranged in an upright state with respect to the first fiber body and has the impregnated energy curable resin cured, and the second fiber body.
The first fiber body and the flexible body in contact with the second fiber body adjacent to each other are provided.
The contact portions of the flexible body with the first and second fibrous bodies are said to be cured by applying energy to the energy-curable resin impregnated by the first and second fibrous bodies. It is a composite material characterized by having an adhesive portion made of an energy-curable resin in which the energy-curable resin impregnated in at least one of the first and the second fibers is exuded and cured.

According to the above invention, it is possible to prevent the composite material from being damaged due to deterioration of the adhesive, the adhesive and the like.

The invention (4-1) is
A first cylindrical fiber body formed in a cylindrical shape and cured with an impregnated energy-curable resin, and
It is formed in a cylindrical shape having a diameter smaller than that of the first cylindrical fiber body, is arranged so as to be concentric with the first cylindrical fiber body in the hollow portion of the first cylindrical fiber body, and is impregnated with energy curing. The second cylindrical fiber body which hardened the sex resin and
It extends along the longitudinal direction of the first and second cylindrical fibers in a state of being interposed between the first and second cylindrical fibers, and the inner peripheral surface of the first cylindrical fiber and the second cylindrical fiber. The intervening fibers that are in contact with the outer peripheral surfaces of the above and have the impregnated energy-curable resin cured,
It is arranged in an internal space formed by the pair of intervening fibers facing each other with the first and second cylindrical fibers, and the inner peripheral surface of the first cylindrical fibers and the second cylindrical fibers. A flexible body in contact with the outer peripheral surface of the body and one surface of the intervening fiber body, respectively.
The contact portion between the first and second cylindrical fibers and the intervening fibers in the foam has the energy curability impregnated by the first and second cylindrical fibers and the intervening fibers. When the resin is cured by applying energy, the energy-curable resin impregnated in at least one of the first and second fibers and the intervening fibers is exuded from the cured energy-curable resin. It is a composite material characterized by having an adhesive portion.

According to the above invention, it is possible to prevent the composite material from being damaged due to deterioration of the adhesive, the adhesive and the like.

<<<<<< Embodiments I to IV >>>>>>
Next, the first to second embodiments will be described from the viewpoint different from the first and second embodiments. It should be noted that the embodiments of the first I to IV can be considered to be an arrangement of the fiber reinforced resin structure obtained by using, applying, changing, etc. the concept explained in the second embodiment and the manufacturing method thereof. can.

In the embodiments of I to IV, the members corresponding to the flexible bodies described in the first to second embodiments are specifically described as foams, but flexible bodies other than foams are described. Does not preclude the use of.

The size of the fiber-reinforced resin structure described below, the thickness of the thick portion of the fiber-reinforced resin structure, the diameter of the communication hole H of the fiber-reinforced resin structure, etc. are not limited at all and can be appropriately adjusted according to the application. Is.

<<<<<< Embodiment I >>>>>
<<< Structure >>>
The fiber-reinforced resin structure 100-1 according to the first embodiment is a tubular fiber-reinforced resin structure containing at least a fiber body 10 and a resin 20 impregnated in the fiber body 10 (FIG. 14). (C)).

More specifically, the resin 20 impregnated in the tubular fiber body 10 becomes a thick portion, and the tubular fiber reinforced resin structure 100-1 is formed as a whole.

In the fiber reinforced resin structure 100-1, the foam 30 may be inserted inside the cylinder. In each of the following embodiments and modifications, each fiber reinforced resin structure may or may not contain the foam 30.

<<< Raw materials >>
<< Fiber body 10 >>
The shape and size of the fiber body 10 are not particularly limited, but for example, a sheet-shaped fiber sheet is preferable. This fiber sheet is not particularly limited as long as it is a sheet in which fibers are aggregated, and is, for example, a woven fabric (plain weave, twill weave, double weave, triple weave, tatami weave, etc.), a non-woven fabric, and a unidirectional reinforcing material (UD). Material) and the like.

The thickness of the fiber sheet is not particularly limited and can be appropriately selected. If the thickness of the fiber sheet is too thin, the mechanical properties such as the strength and elastic modulus of the fiber sheet may be lowered. Therefore, the thickness of the fiber sheet according to the present invention is preferably, for example, 20 μm to 500 μm, more preferably 30 μm to 200 μm. Needless to say, a fiber sheet having a thickness of several mm, such as a chopped strand mat or a core mat, may be used.

The fibers forming the fiber sheet are not particularly limited, and known ones can be used, and at least one of metal fibers, inorganic fibers and organic fibers can be used.

Examples of the fibers constituting the fiber body 10 include, for example.
Metallic fibers such as stainless steel fiber, nickel fiber, copper fiber, aluminum fiber, silver fiber, gold fiber, titanium fiber;
Polyparaphenylene benzoxazole, polyethylene terephthalate (PET) resin, polyvinyl alcohol (PVA), polyethylene, polyolefin resins such as polypropylene, polyvinyl chloride resin, aramid resin, acrylic resin, polyimide resin, polyparaphenylene benz Organic fibers such as oxazole (PBO) fiber, cellulose, vinylon, nylon, rayon, aramid, phenolic fiber, fluorine fiber, pulp (fiber), kenaf, hemp, bamboo fiber;
Inorganic fibers such as glass fiber, carbon fiber, silica fiber, rock wool, slag wool, alumina fiber, ceramic fiber;
And so on.
As the fiber, one or a plurality of these can be used in combination. For example, non-crimp fiber (NCF) having a two-layer structure containing carbon fiber and polyester fiber can also be used.

The fiber is preferably a fiber having a Young's modulus higher than the Young's modulus such as a resin or a matrix resin used for a sealing material, and more preferably a metal fiber or an inorganic fiber. The higher the Young's modulus of the fiber, the higher the rigidity of the fiber sheet, and when embedded in the resin, the rigidity of the resin can be effectively improved. Therefore, it is possible to obtain a sealing material having high rigidity and not easily damaged.

The fiber sheet may be one in which fibers are woven into a cylinder.

The fiber sheet may be partially punched or the like to form pores as long as the effect of the present invention is not impaired.

The fiber sheet may be a bias sheet (bias-cut sheet).

<Manufacturing method of fiber sheet>
As a method for producing the fiber sheet, a known method can be used. For example, as a method for producing a non-woven fabric which is a suitable example, a dry method such as a carding method and an air lace method, a wet papermaking method for forming by straining like paper, a fleece forming method such as a spunbond method and a melt blow method; thermal Examples include a fleece bonding method such as a bond method, a chemical bond method, a needle punch method, a spunlace method (water flow entanglement method), a stitch bond method, and a steam jet method. Of these, the manufacturing method by the wet papermaking method is suitable because the fiber sheet can be thinned and is excellent in terms of uniformity.

When the fiber sheet has a tubular shape, it can be manufactured in the same manner as that of a braid, for example.

The method for producing a fiber sheet may include a step of performing bias cutting.

<< Resin 20 >>
As the resin 20, a known resin used as a fiber reinforced resin can be used, and a thermoplastic resin or the like can also be used, but in order to improve workability, it is preferable to use an energy curable resin.

<Energy curable resin>
The energy curable resin is a thermosetting resin, and may further include an energy ray curable resin and the like.

Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, polyvinyl ester resin, phenol resin, polyurethane resin, acrylic resin, melanin resin, melamine resin, urea resin, benzoguanamine resin, rosin-modified maleic acid resin, and rosin. A modified fumaric acid resin or the like can be used. These may be used alone or in combination of two or more.

Examples of the energy ray-curable resin include epoxy resin, acrylic resin, silicone resin, polyester resin and the like. These may be used alone or in combination of two or more.

In the following description, the resin 20 will be described as a thermosetting resin, but as long as there is no particular contradiction, "thermosetting" can be read as "curing" in the following description.

<< Foam 30 >>
The foam may be a closed cell foam, an open cell foam, or a foam containing both closed cells and open cells. The closed-cell foam shown here does not mean only those in which all the bubbles are completely independent, but some of the bubbles may communicate with the adjacent bubbles, and the closed cells as a whole may be used. It is sufficient that each bubble is independent to the extent that it can be understood as a foam.

Here, when the foam contains closed cells and open cells, the average ratio of the closed cells and open cells (hereinafter referred to as the closed cell ratio) is not particularly limited, but for example, the closed cell ratio may be used. It can be 0.1 to 99.9%, preferably 10.0% to 99.9%, more preferably 30.0 to 99.9%, still more preferably 50.0 to 99.9%. Can be. The foam containing only closed cells is most preferable. When a large amount of closed cells are contained, there are many sealed air layers inside the foam, so when the foam is heated, in addition to the thermal expansion of the resin itself, the sealed air layer thermally expands. The force with which the foam presses the fibrous body can be increased. For this reason, when the foam is heated in the thermosetting step described later, thermal expansion occurs more strongly, and by pressing the fibrous body, formability (no wrinkles or twists, and the shape becomes a desired shape). It becomes possible to make it even more excellent, and it becomes easier to remove the foam from the laminate by shrinking during cooling after curing.

The closed cell ratio contained in the foam is determined by observing the cross section of the foam using a microscope or a scanning electron microscope and counting the number of closed cells and open cells per unit area in the captured image. It is assumed that the number is divided by the number of all bubbles (all of the independent bubbles and open bubbles) and multiplied by 100. The measurement of the closed cell ratio was repeated at 10 randomly selected cross sections of the same foam, and the average value of the closed cell ratios obtained for each was taken as the closed cell ratio of the foam.

The resin constituting the foam is not particularly limited, and an olefin resin, a urethane resin, a styrene resin, a phenol resin, a silicone resin, or the like may be appropriately selected depending on the intended use. In addition, natural rubber (NR), chloroprene rubber (CR), ethylene propylene diene rubber (EPDM), nitrile rubber (NBR) and the like are also used as constituents of the foam, and these are also appropriately selected according to the intended use. do it. Of these, olefin resins can be preferably used. With the olefin resin, it is easy to adjust the curing temperature of the fiber and the degree of thermal expansion of the foam at the curing temperature of the fiber, for example, by adjusting the composition of polyethylene and polypropylene. That is, when the foam is heated in the heat curing step described later and thermally expanded, the foam presses the fiber to formability (there is no wrinkles or twists, and the shape is a desired shape). However, the degree of thermal expansion can be adjusted by changing the mixing ratio of the olefin resin, for example, polyethylene and polypropylene, and the degree of thermal expansion can be adjusted. The moldability can be made excellent according to the shape. Further, by adjusting the compounding ratio of polyethylene and polypropylene, the presence or absence of cross-linking, and the degree of cross-linking, it becomes easy to adjust the flexibility (hardness), thermal expansion, wettability (affinity), softening point, etc. of the foam.

The resin constituting the foam can be freely selected in consideration of the affinity with the uncured resin contained in the fiber. If the affinity between the resin constituting the foam and the uncured resin contained in the fiber is high, the work of winding the laminate around the foam becomes easy, but it is difficult to remove the foam after heat curing. May become. Therefore, it is preferable to adjust the affinity between the resin constituting the foam and the uncured resin contained in the fiber.

In order to adjust the affinity between the resin constituting the foam and the uncured resin contained in the fiber, the wettability (for example, the contact angle) between the resin constituting the foam and the uncured resin contained in the fiber is used. Alternatively, the surface energy) may be adjusted, and in order to increase the affinity, the contact angle (or surface energy) between the resin constituting the foam and the uncured resin contained in the fiber may be selected. When increasing the affinity, the contact angle (or surface energy) of the resin constituting the foam and the uncured resin contained in the fiber may be close to each other, and when decreasing the affinity, the contact angle may be set to a close value. The contact angle and surface energy of the resin constituting the foam and the uncured resin contained in the fiber may be different from each other.

The difference in contact angle between the resin constituting the foam and the uncured resin contained in the fiber is not particularly limited, but may be more than 0 ° and less than ± 90 °. When the difference in contact angle between the resin constituting the foam and the uncured resin contained in the fiber is within the range, it is easy to wind the fiber around the foam and heat it after heating and curing. It is also possible to remove the foam after curing.

Further, the softening point of the resin constituting the foam is not particularly limited, and can be selected according to the curing temperature of the thermosetting resin used for the fiber. For example, the softening point of the resin constituting the foam can be set to a softening point that is 10 ° C. or higher higher than the curing temperature of the thermosetting resin used for the fiber body. For example, when the thermosetting resin is an epoxy resin, the softening point of the resin constituting the foam can be 60 to 200 ° C, preferably 80 to 160 ° C, and 100 to 150 ° C. Is more preferable. When the softening point of the resin constituting the foam is within such a range, the foam has sufficient thermal expansion property as a foam when heated, and has sufficient strength (for example, tensile strength). Therefore, excellent moldability (without wrinkles or twists and making the shape a desired shape) becomes possible at the time of molding.

The foam is preferably a medium substance. The foam has a diameter of 1/2 or more, 1/3 or more, 1/4 or more, 1/5 or more, 1/10 or more, 1/15 or more, or 1/20 or more of the outer diameter of the foam. It is preferable that the hole (through hole / hollow portion) is not provided. That is, the foam is a medium substance, or when the foam is a hollow body, the ratio of the inner diameter / outer diameter of the foam is 1/2 or less, 1/3 or less, 1/4 or less, 1 It is preferably / 5 or less, 1/10 or less, 1/15 or less, or 1/20 or less. By forming the foam in such a configuration, it is possible to prevent buckling of the foam when the foam is deformed / curved.

The foam may contain known additive components such as thickeners, plasticizers, lubricants, fillers, flame retardants, colorants, antioxidants, reinforcing agents, conductive materials and the like.

The density of the foam is not particularly limited, but is, for example, 1 kg / m ³ or more, 2 kg / m ³ or more, 3 kg / m ³ or more, 4 kg / m ³ or more, 5 kg / m ³ or more, 10 kg / m ³ or more, 15 kg. / ^{m 3} may be a more, also, 800 kg / ^{m 3} or less, 700 kg / ^{m 3} or less, 600 kg / ^{m 3} or less, 500 kg / ^{m 3} or less, 250 kg / ^{m 3} or less, 100 kg / ^{m 3} or less, 50 kg / m ^It may be 3 or less. It should be noted that the upper limit value and the lower limit value can be arbitrarily combined to obtain a desired numerical range. For example, it is possible to 5~800kg / ^{m 3,} preferably ^{5~500kg / m 3, 10~250kg / m} 3 and more preferably. When the density of the foam is within such a range, it has sufficient thermal expansion as a foam when heated and has sufficient strength (for example, tensile strength), so that it has excellent moldability (wrinkles and wrinkles) during molding. It is possible to make the shape a desired shape without twisting. The density of the foam is the apparent density measured according to JIS K7222: 2005 "Foam plastics and rubber-How to determine the apparent density". The reciprocal of the density of the foam may be expressed as the expansion ratio.

The tensile elongation at break of the foam at 25 ° C. is more than 25% and less than 400%, preferably more than 50% and less than 350%, and more preferably more than 80% and less than 300%. If the tensile elongation at break at 25 ° C. of the foam is within such a range, it can be sufficiently deformed when the laminated body is deformed in the deformation step described later, and the coefficient of thermal expansion can be adjusted to an appropriate range. Therefore, when the foam is heated in the heat curing step described later, it is possible to strongly press the fibrous body, and the moldability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be considered.

The tensile elongation at break of the foam at 25 ° C. is measured by processing the foam into a No. 3 dumbbell test piece in accordance with JIS K6767 "Foam Plastic-Polyethylene-Test Method".

The tensile strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 0.05 MPa or more, preferably 0.1 MPa or more, and more preferably 0.2 MPa or more. The upper limit of the tensile strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 20 MPa or less. When the tensile strength of the foam at 25 ° C. is within such a range, the foam has sufficient strength in the deformation step described later, and the foam can uniformly press the fiber. Therefore, when the foam is heated in the thermosetting step, it is possible to strongly press the fibrous body, and the moldability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be.

The tensile strength of the foam at 25 ° C. can be measured by processing the foam into a No. 3 dumbbell test piece in accordance with JIS K6767 "Foam Plastic-Polyethylene-Test Method".

The tear strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 0.5 N / mm or more, preferably 0.8 N / mm or more, and more preferably 1.0 N / mm or more. Can be. The upper limit of the tear strength of the foam at 25 ° C. is not particularly limited, but can be, for example, 50 N / mm or less. When the tear strength of the foam at 25 ° C. is within such a range, the foam has sufficient strength in the deformation step described later, and the foam can uniformly press the fiber. Therefore, when the foam is heated in the thermosetting step, it is possible to strongly press the fibrous body, and the moldability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be.

The tear strength of the foam at 25 ° C. can be measured according to JIS K6767 "Foam Plastic-Polyethylene-Test Method".

The 25% compressive load (hardness) of the foam at 25 ° C. is not particularly limited, but can be, for example, 1 to 2000 kPa, preferably 5 to 1000 kPa, more preferably 10 to 500 kPa, and further 10 to 200 kPa. preferable. When the 25% compressive load of the foam is within the applied range, it is easy to wind the fiber around the foam, and it can be sufficiently deformed when the laminate is deformed in the deformation step described later. Further, in the heat curing step described later, the repulsive force of the foam itself can act in addition to the thermal expansion. Therefore, when the foam is heated in the thermosetting step, it is possible to strongly press the fibrous body, and the formability (there is no wrinkle or twist, and the shape is a desired shape) is further excellent. Can be.

The 25% compressive load of the foam at 25 ° C. is determined by the D method described in JIS K6400-2: 2012 "Soft foam material-Physical properties-Part 2: Hardness and compressive stress-How to determine strain characteristics". Can be done,

The thermal conductivity of the foam is not particularly limited, but can be, for example, 0.01 W / m · K or more, preferably 0.02 W / m · K or more, more preferably 0.03 W / m · K. It is K or more. The upper limit of the thermal conductivity of the foam is not particularly limited, but can be, for example, 0.2 W / m · K or less. When the thermal conductivity of the foam is within the range, when the foam is heated in the heat curing step described later, the foam can be uniformly heated in a short time, so that the foam is uniform. It becomes possible to thermally expand to. For this reason, the variation in the force with which the foam presses the fiber is reduced, and the moldability (without wrinkles or twists and having a desired shape) can be further improved.

The thermal conductivity of the foam shall be measured by the method described in JIS A1412-1: 2016 "Method for measuring thermal resistance and thermal conductivity of thermal insulating material-Part 1: Protective thermal plate method (GHP method)". Can be done.

The coefficient of linear thermal expansion of the foam is not particularly limited, but can be, for example, 0.01% or more, preferably 0.05% or more, more preferably 0.10% or more, and 1.00% or more. More preferred. The upper limit of the linear thermal expansion coefficient of the foam is not particularly limited, but can be 10.00% or less. When the linear thermal expansion coefficient of the foam is within the range, when the foam is heated in the heat curing step described later, it becomes possible to strongly press the fibrous body, resulting in moldability (wrinkles, twists, etc.). However, the shape can be made into a desired shape) to be further improved.

For the linear thermal expansion coefficient of the foam, the foam is processed to a width of 3 mm, a length of 25 mm, and a thickness of 2 mm. , 25 to 85 ° C., 1 ° C./min. After raising the temperature in 1 ° C., from 85 ° C. to 25 ° C. at 1 ° C./min. The temperature was lowered at 1 ° C./min. From 25 ° C. to 85 ° C. again. It can be measured by a method of measuring the linear thermal expansion coefficient at 85 ° C. at the time of the second temperature rise at this time.

<Manufacturing method of foam>
The foam can be produced by a known method. As a method for producing a foam, for example, a raw material preparation step which is a step of obtaining a liquid raw material mixture containing at least an aqueous liquid dispersion medium and an aqueous dispersible resin, and a foaming step of foaming the liquid raw material mixture to obtain a foamed mixture. And a drying step of evaporating the dispersion medium in the effervescent mixture. Further, before or after the foaming step, the liquid raw material mixture or the foamed mixture is coated with a doctor knife or a doctor roll, or the liquid raw material mixture or the foamed mixture is extruded or injection molded to form a sheet of the foamed mixture. It may be molded into a shape. Further, a rubber sponge or the like may be molded into a desired shape, or a foam foam molded into a block shape may be sliced into a desired shape such as a sheet shape, a string shape, or a columnar shape. It should be noted that some or all of these steps may be executed at the same time.

As the foaming means in the foaming step, for example, a method of forming bubbles by blending a foaming agent that generates gas by a chemical reaction into the liquid raw material mixture, and a pressure after dissolving an appropriate gas in the liquid raw material mixture under high pressure. A method of forming bubbles by lowering or heating, a method of removing soluble substances mixed in the liquid raw material mixture and forming bubbles as voids, a method of forming the bubbles so that air or an appropriate gas is embraced. Examples thereof include a method of mechanically stirring (mechanical floss).

The foaming conditions (temperature, time, etc.) in the foaming step and the drying conditions (temperature, time, etc.) in the drying step can be appropriately changed depending on the raw material of the foam, the foaming means used, and the like.

The shape, size, etc. of the foam are not particularly limited, and in addition to the cylindrical foam, a columnar, square columnar, hexagonal columnar, or a foam having a star-shaped or semi-circular cross-sectional shape can be used as appropriate. It is selectable. Further, the foam is not only foam-molded to have a desired shape, but also a block-shaped one formed by cutting or carving, a sheet-shaped foam wound up, and the like. You may.

<<< Manufacturing method >>>
The method for producing the fiber reinforced resin structure 100-1 is, for example,
A laminated body 50 having a columnar foam 30 and a fibrous body 10 that covers at least a part of a side surface portion of the foam 30, and the fibrous body 10 is a thermosetting resin (uncured resin) in an uncured state. A preparatory step for preparing the laminate 50 impregnated with 25) and
This method includes a curing step of thermally curing the resin (uncured resin 25) impregnated in the fiber body 10 to obtain the resin 20.

The method for producing the fiber-reinforced resin structure 100-1 includes a cutting step of cutting the foam 30, a cooling step of cooling the foam 30 and the resin 20 after the curing step, a removing step of pulling out the foam 30 after the curing step, and the like. May include.

Further, although not particularly described, the method for producing the fiber-reinforced resin structure 100-1 may be provided with a shaving step or a polishing step for treating the surface of the fiber-reinforced resin structure 100-1 after the curing step.

<< Preparation process >>
The preparatory step has a columnar foam 30 and a fibrous body 10 that covers at least a part of the side surface portion of the foam 30, and the fibrous body 10 has an uncured thermosetting resin (uncured resin 25). Is a step of preparing the laminated body 50 impregnated with.

The preparation step may be carried out by purchasing the laminated body 50 from the outside or the like.

Further, the preparation step may include an impregnation step and a laminating step.

<Immersion process>
In the impregnation step, the uncured resin 25 and the fiber body 10 are brought into contact with each other to impregnate the fiber body 10 with the uncured resin 25.

The impregnation method is not particularly limited, and may be, for example, roll coating, hand lay-up molding method, infusion molding method, VaRTM molding method, RTM molding method, or the like, and the fiber body 10 is placed in a tank containing the uncured resin 25. It may be used as a method of submerging (dipping) or the like.

The impregnation conditions can be adjusted according to the type of the fiber body 10 and the uncured resin 25. When it is difficult to impregnate the fiber body 10 with the uncured resin 25, the impregnation time may be lengthened or the fiber body 10 may be impregnated while being pressurized.

The volume ratio of the uncured resin 25 to the fiber body 10 may be such that the volume fraction (fiber fraction) of the fiber body 10 is 15 to 85% by volume when the volume of the laminated body 50 is 100% by volume. It is possible, preferably 25 to 85% by volume, more preferably 45 to 80% by volume. When the volume fraction (fiber fraction) of the fiber body 10 is within the range, the cured fiber-reinforced resin structure has few defects, is less likely to cause fracture such as buckling, and has excellent mechanical strength. It becomes a thing.

<Laminating process>
In the laminating step, at least a part of the side surface of the foam 30 is covered with the fiber body 10 (see FIGS. 14 (a) and 14 (c)).

The method of covering the side surface of the foam 30 with the fiber 10 is not particularly limited. For example, when the fiber body 10 is a fiber sheet, the fiber body 10 may be wound around the foam 30. The number of windings is preferably one or more, and may be two or more.

Further, in the laminating step, the fibrous body 10 after covering the foam 30 may be temporarily fastened. For example, when the fiber body 10 is impregnated with the uncured resin 25, the fiber body 10 can be temporarily adhered to the side surface of the foam 30 due to the adhesiveness of the uncured resin 25.

In the laminating step, as shown in FIG. 14, it is not necessary to cover the entire side surface of the foam 30 from the upper end to the lower end with the fiber body 10, but the entire side surface of the foam 30 is covered with the fiber body 10. Is also possible.

It is possible to adjust the thickness of the fiber body 10 in the laminating step. For example, when the fiber body 10 is a fiber sheet, the thickness of the fiber body 10 can be increased by increasing the number of times the fiber body 10 is wound. Further, the fiber sheet may be a single sheet or may be used as a stack of a plurality of sheets, and is not particularly limited. The fiber body 10 may be used in combination of two or more kinds. When the fiber body 10 is a woven fabric or a UD material, the orientation of the fibers (bias, etc.) is taken into consideration in consideration of thermal expansion of the foam, or in consideration of the deformation step, bending step, etc. in another embodiment. ) May be adjusted to perform winding. Further, when a fiber body 10 having an adjusted fiber orientation is used, the fiber body 10 may be configured so that the fiber orientation is adjusted over the entire fiber body 10. It may be configured so that the fiber orientation is adjusted only in a part of the region (for example, the fiber orientation is adjusted only in the easily deformable region).

When the fiber body 10 is long, the laminating step can be carried out by winding the fiber body 10 around the side surface of the foam body 30 while moving the fiber body 10 in the axial direction. For example, the laminating step may be carried out based on a filament winding method, a braiding method, or the like.

Further, the fiber body 10 may be formed in a tubular shape in advance, and the foam 30 may be inserted into the cylinder.

In the laminating step, the side surface of the foam 30 is covered with the fiber body 10, but when the fiber body 10 is arranged on the side surface of the foam body 30, the foam body 30 is flexibly deformed. Therefore, for example, when the fiber body 10 is used as a fiber sheet and the fiber body 10 is wound around the foam body 10, distortions and the like that may occur in the fiber body 10 are absorbed by the deformation of the foam body 30 and are in a somewhat natural state. The fibrous body 10 can be retained.

Here, the impregnation step may be carried out before the laminating step, at the same time as the laminating step, or after the laminating step. When the fiber body 10 is a fiber sheet, the fiber body 10 is impregnated with a resin (uncured resin 25) before the laminating step in order to surely impregnate the fiber body 10, and the fiber body 10 is not impregnated. It is preferable to carry out the laminating step in a state where the cured resin 25 is impregnated. In the description of each embodiment, the preparation step is described as a step of carrying out the laminating step after carrying out the impregnation step, but is not limited thereto.

<< Curing process >>
By carrying out the curing step, the uncured resin 25 impregnated in the fiber body 10 is cured, and the resin 20 is obtained (see FIG. 14 (c)).

In the curing step, the curing method and the curing conditions may be selected so that the uncured resin 25 is sufficiently cured according to the type of the resin (uncured resin 25) used. For example, in the case of a thermosetting resin, heat can be applied to the uncured resin 25 to cure it.

In order to improve the shape retention of the laminate 50 (foam 30), the curing step is carried out in a state where the laminate 50 is fitted into a mold or a shrink tape is arranged around the laminate 50. You may.

<< Cooling process >>
The cooling step is a step of cooling the resin 20 and the foam 30 obtained by thermosetting before carrying out the foam removing step and the like.

It is considered that the foam 30 is thermally expanded by the thermosetting in the curing step, and a force in the direction of pushing the fiber body 10 is generated. By cooling the foam 30 after the uncured resin 25 is thermally cured, the foam 30 shrinks, promoting the separation between the resin 20 and the foam 30, and facilitating the removal step described later. It is thought that it can be done.

The cooling method is not particularly limited, and any method such as natural cooling, ventilation, and leaving in a cold air atmosphere may be used. The temperature after cooling may be set to room temperature or higher, room temperature, or room temperature or lower. As an example, the cooling step can be carried out by cooling the temperature at 10 ° C. or higher, 20 ° C. or higher, 30 ° C. or higher, 40 ° C. or higher, or 50 ° C. or higher from the temperature at the time of thermosetting.

<< Cutting process >>
The cutting step may be a step of cutting only the foam 30 protruding from the fiber body 10, or may be a step of cutting the foam body 30 and the fiber body 10 at the same time. For example, the laminated body 50 may be adjusted to a desired length by a cutting step.

The cutting step may be carried out before the curing step or after the curing step.

<< Removal process >>
By removing the foam 30 contained in the laminate 50, a hollow fiber-reinforced resin structure 100-1 containing no foam 30 can be obtained (see FIG. 14 (c)).

By carrying out the preparation step (for example, laminating step, impregnation step) and the curing step, the uncured resin 25 is cured in a state where the foam 30 and the uncured resin 25 are in contact with each other. When the foam 30 is a foam or the like, the uncured resin 25 may invade the bubbles existing on the surface of the foam. By carrying out the curing step in this state, the foam and the resin 20 can be fixed. Therefore, when carrying out the removal step, the material of the foam and the density of the foam (foaming ratio) are adjusted so that the foam and the resin 20 are difficult to be fixed, or the foam and the resin 20 are fixed. Even if it is done, it may be easy to remove the foam.

In addition to physically removing the foam 30, the removal step may be carried out by dissolving the foam 30.

<<< Modification example of the first embodiment >>>
The fiber reinforced resin structure 100-1 is not limited to a cylindrical one. Hereinafter, the fiber-reinforced resin structure 100-1 other than the cylindrical shape will be described as an example of modification of the first embodiment.

<< Structure >>
The fiber-reinforced resin structure 100-1 may have a polygonal tubular structure (a cylindrical structure having a polygonal cross section perpendicular to the tubular axis) instead of the cylindrical structure shown in FIG. .. For example, the fiber reinforced resin structure 100-1 may have a square cylinder shape as shown in FIG. 15 (c) or a hexagonal cylinder shape as shown in FIG. 16 (c). Further, the polygonal cylinder of the fiber body 10 may be a triangular cylinder or a hexagonal cylinder or more.

Further, the fiber-reinforced resin structure 100-1 does not need to have the same outer shape (shape of the outer surface of the cylinder) and inner shape (shape of the inner side surface of the cylinder). For example, the fiber-reinforced resin structure 100-1 may have a cylindrical outer shape and a cylindrical inner shape.

<< Manufacturing method >>
The method for manufacturing the fiber reinforced resin structure 100-1 according to the modified example is, for example,
A laminated body 50 having a columnar foam 30 and a fibrous body 10 that covers at least a part of a side surface portion of the foam 30, and the fibrous body 10 is a thermosetting resin (uncured resin) in an uncured state. A preparatory step for preparing the laminate 50 impregnated with 25) and
A deformation step of applying an external force to the laminated body 50 to deform the cross-sectional shape of the foam 30 and
This method includes a curing step of thermally curing the resin (uncured resin 25) impregnated in the fiber body 10 to obtain the resin 20.

The preparation process, curing process, etc. are as described above. Further, as described above, the cooling step, the cutting step and the removing step may be carried out.

<Transformation process>
In the deformation step, an external force is applied to the laminated body 50 to deform the cross-sectional shape of the foam 30 (see FIGS. 15 (a), 15 (b), 16 (a), and 16 (b)). More specifically, for example, by applying an external force to the side surface portion of the laminated body 50, the laminated body 50 can be deformed into a prismatic shape.

The foam 30 and the fiber 10 are deformed by applying an external force to the side surface portion of the laminate 50, but the fiber 10 is not crushed by the foam 30 and retains a predetermined shape (for example, a tubular shape). can do.

The deformation step can be carried out, for example, by fitting the laminated body 50 into a formwork or the like having a predetermined shape.

In the deformation step, the shape of the laminated body 50 can be freely changed by adjusting the direction in which the external force is applied and the position in which the external force is applied.

For example, as shown in FIG. 15A, when an external force is evenly applied to the side surface of the laminated body 50 (foam 30) from four directions, the laminated body 50 may be a square cylinder. As shown in FIG. 16A, when an external force is evenly applied to the side surface of the laminate 50 (foam 30) from six directions, the laminate 50 can be a hexagonal cylinder. can.

Further, the external force applied to one surface of the laminated body 50 and the external force applied to the other surface may be different, or the direction and strength of the external force applied between the upper side of the laminated body 50 and the lower side of the laminated body 50 may be changed. By doing so, it is possible to make the laminated body 50 asymmetric with respect to the vertical direction (axial direction) of the laminated body 50 or the left-right front-rear direction (direction perpendicular to the axis) of the laminated body 50. be.

The fiber-reinforced resin structure 100-1 is formed into a fiber-reinforced resin structure 100-1 having a different shape by changing the outer diameter of the foam 30 according to the axial direction (for example, providing a taper). Is also possible.

The fiber-reinforced resin structure 100-1 having a polygonal tubular shape can also be obtained by forming the foam 30 into a prismatic shape in advance and then carrying out the same manufacturing method as in the first embodiment. In this case, the fiber is likely to be loaded, and the strength may be inferior.

<<<<<< Embodiment II >>>>>
<<< Structure >>>
The fiber reinforced resin structure 100-2 according to the second embodiment is as shown in FIG. 17 (d).
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fiber body 10 is a fiber reinforced resin structure having a curved tubular shape (or the tubular shaft B is curved).

In other words, the fiber reinforced resin structure 100-2 has a curved portion 60 in which at least a part of the structure of the fiber reinforced resin structure 100-2 is curved. Further, the fiber reinforced resin structure 100-2 has a tubular structure held in the curved portion 60. Further, when the fiber reinforced resin structure 100-2 has a curved portion 60 and a non-curved portion, the curved portion 60 and the non-curved portion are smoothly connected. Further, the fiber-reinforced resin structure 100-2 may have the same shape in the curved portion 60 and the non-curved portion when the cross section perpendicular to the cylinder axis B is observed.

The fiber reinforced resin structure 100-2 may have a plurality of curved portions 60. In this case, the direction of bending, the degree of bending, and the like can be designed for each curved portion 60.

The degree of curvature of the cylinder shaft B or the curvature of the curved portion 60 is not particularly limited. The degree of curvature of the cylinder shaft B or the curvature of the curved portion 60 can be bent into a curved shape such as L-shaped, U-shaped, S-shaped, bow-shaped, etc., or at a predetermined angle (30) depending on the application. It may be curved to degrees, 45 degrees, 90 degrees, etc.).

The fiber body 10 is not limited to a cylindrical shape, and may be a polygonal tubular shape.

The structure according to the fiber reinforced resin structure 100-2 can be expressed as the fiber reinforced resin structure 100-1 being curved in a predetermined direction while maintaining the cross-sectional shape along the axis.

<<< Manufacturing method >>>
The method for manufacturing the fiber reinforced resin structure 100-2 is, for example,
A laminated body 50 having a columnar foam 30 and a fibrous body 10 that covers at least a part of a side surface portion of the foam 30, and the fibrous body 10 is a thermosetting resin (uncured resin) in an uncured state. A preparatory step for preparing the laminate 50 impregnated with 25) and
The bending step of bending the laminated body 50 so that the column axis A of the foam is curved, and
This method includes a curing step of curing the resin (uncured resin 25) impregnated in the fiber body 10 to obtain the resin 20.

The preparation process, curing process, etc. are as described above. Further, as described above, the cutting step, the cooling step and the removing step may be carried out.

<< Curving process >>
In the bending step, an external force is applied to the laminated body 50 so that the column shaft A of the foam 30 is curved. As a result, the axis A of the foam 30 is curved, so that the axis of the entire laminated body 50 is curved. Therefore, when the laminated body 50 includes the tubular fiber body 10, the tubular axis of the fiber body 10 is formed. B will be curved in the same manner.

The foam 30 and the fiber 10 are deformed by applying an external force to the side surface portion of the laminate 50, but the fiber 10 is not crushed by the foam 30 and retains a predetermined shape (for example, a tubular shape). can do.

As a method of bending, an external force may be applied to the laminated body 50 from a predetermined direction (see FIGS. 17 (b) and 17 (c)). The magnitude of the external force may be appropriately set in consideration of the material of the laminated body 50, the degree of bending, and the like.

The bending step can be carried out, for example, by fitting the laminated body 50 into a predetermined formwork or the like having a curved structure. If it is desired to have a complicated curved shape, the formwork may be divisible.

The laminated body 50 includes a fibrous body 10 and a foam 30. Therefore, the laminated body 50 is unlikely to break even if it is curved. In particular, when the fiber body 10 is a fiber sheet and the foam 30 is a foam, the fiber sheet and the foam are flexibly deformed, so that the laminated body 50 is smoothly curved (it is difficult to have a buckled portion). can do.

At the time of bending, the density of the fibrous body 10 becomes dense in the compressed portion, and the density of the fibrous body 10 becomes sparse in the pulled portion. In consideration of this point, the thickness of the fiber body 10 at the portion where the curved portion 60 can be formed may be adjusted in advance in the laminating step.

In the case of the fiber reinforced resin structure 100-2 having a plurality of curved portions, a mold having a shape having a plurality of curved portions may be used, or the bending step may be performed a plurality of times.

<<< Modification of the second embodiment >>>
In the second embodiment, as shown in FIG. 17, the fiber-reinforced resin structure 100-2 having an overall cylindrical shape has been described, but the fiber-reinforced resin structure 100-2 is shown in FIG. It may be configured to have a polygonal cylinder as a whole.

In the structure according to the modified example of the fiber reinforced resin structure 100-2, the structure according to the modified example of the fiber reinforced resin structure 100-1 is curved in a predetermined direction while maintaining the cross-sectional shape along the axis. It can also be expressed as being done.

The fiber-reinforced resin structure 100-2 according to the modified example of the second embodiment can be manufactured by carrying out the above-mentioned deformation step and the above-mentioned bending step on the laminated body 50 (Fig.). 18). In FIG. 18, the display of the foam 30 is omitted for the sake of simplicity.

The cross-sectional shape of the laminated body 50 (foam 30) is deformed into a prismatic shape by the deformation step, and the column axis A of the laminated body 50 is curved by the bending step.

In these steps, the foam 30 and the fibrous body 10 are deformed by applying an external force to the side surface portion of the laminated body 50, but the fibrous body 10 is not crushed by the foam 30 and has a predetermined shape (for example, for example). Can hold a tubular shape).

The deformation step and the bending step may be carried out in a state where the laminated body 50 contains the foam 30 and before the resin is cured (in other words, a state containing the uncured resin 25), and the deformation step may be performed. It may be any of a form in which the bending step is carried out after the bending step, a form in which the deformation step is carried out after the bending step, and a form in which the deformation step and the bending step are carried out at the same time.

When the deformation step and the bending step are carried out at the same time, for example, it can be carried out by fitting the laminated body 50 into a mold having a predetermined bending structure and a predetermined cross-sectional shape.

Further, in manufacturing the fiber reinforced resin structure 100-2, as shown in FIG. 19, the plurality of laminated bodies 50 are in a state before the resin is cured (a state in which the laminated body 50 contains the uncured resin 25). ) May further include a step of providing a step of bringing them into contact with each other (see FIG. 19 (b)).

For example, in the manufacturing method shown in FIG. 19, first, a plurality of laminated bodies 50 having a curved structure obtained by carrying out a bending step are prepared (see FIG. 19A), and these plurality of laminated bodies 50 are mutually arranged. By arranging them so as to be in contact with each other, performing a deformation step in that state (see FIG. 19B), and finally curing the particles, a plurality of communication holes are provided, and these communication holes are parallel to each other. It is possible to manufacture a fiber-reinforced resin structure 100-2 that does not become.

In addition, in FIG. 19A and FIG. 19B, the foam 30 is omitted for the sake of simplicity.

The contact step, the deformation step, and the bending step can be carried out in any order, and a part or all of them may be carried out at the same time.

When the contact step, the deformation step, and the bending step are carried out at the same time, for example, a formwork having a predetermined bending structure, a predetermined cross-sectional shape, and a plurality of laminated bodies 50 can be arranged at a predetermined position. It can be carried out by fitting a plurality of laminated bodies 50 into the structure.

In this way, after the resin is brought into contact with the plurality of laminated bodies 50 in a state before being cured (a state in which the laminated body 50 contains the uncured resin 25), other members or the like containing the uncured resin 25 are brought into contact with each other. By curing the resin, it is also possible to obtain a structure integrated with the resin 20. The concept that a plurality of laminated bodies 50 and the like are brought into contact with each other in a state before the resin is cured and integrated can be similarly applied in all embodiments. That is, with respect to the combination of all the structures described in each embodiment and the combination of all the structures described in each embodiment with known structures, each structure is integrated via a resin. The structure is understood to be within the scope of the present invention.

<<<<<< Embodiment III >>>>>
<<< Structure >>>
The fiber reinforced resin structure 100-3 according to the third embodiment is, for example,
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
At least a first communication hole H, a second communication hole H parallel to the first communication hole H, and a wall portion defining the first communication hole H and the second communication hole H are provided.
The wall contains the fibrous body 10,
It is a fiber reinforced resin structure.

The fiber-reinforced resin structure 100-3 includes a plurality of communication holes H arranged in parallel with each other so that the hole axes C are arranged perpendicularly to a predetermined direction (for example, a certain straight line). The number of communication holes H of the fiber reinforced resin structure 100-3 may be two or more. For example, in FIG. 20 (f), a structure having four communication holes H, in FIG. 21 (f), a structure having 13 communication holes H, and in FIG. 22 (f), twelve pieces. A structure having communication holes H, FIG. 23 (f) shows a structure having seven communication holes H.

The first communication hole H and the second communication hole H are provided so as to be parallel to each other. The fact that the first communication hole H and the second communication hole H are parallel means that, as a whole, the hole axis C of the communication hole H on one side and the hole axis C of the communication hole H on the other side are used. Indicates that is regularly arranged to the extent that is understood to be parallel.

The wall portion (for example, the thick resin 20) that defines each communication hole H includes the fiber body 10. It is preferable that the fiber body 10 is present on the entire wall portion around each communication hole H, in other words, the fiber body 10 is provided so as to continuously surround the communication hole H at least one round.

In the present embodiment, the fiber body 10 is included in the wall portion (the wall portion existing between the one communication hole H and another communication hole H) that separates one communication hole H and another communication hole H. With this configuration, the strength of the fiber reinforced resin structure 100-3 in the thickness direction (direction perpendicular to the direction in which the communication holes H are lined up) can be increased.

In the fiber reinforced resin structure 100-3, the foam 30 may be inserted through a part or all of the communication holes (see FIG. 20 (e) and the like).

The fiber reinforced resin structure 100-3 has a structure as shown in FIG. 20 (c), and a plurality of cylindrical fiber bodies 10 are arranged in a state where they are close to each other via the resin. It may be cured. On the other hand, in the fiber reinforced resin structure 100-3, as shown in FIG. 21 (f), a plurality of polygonal tubular fiber bodies 10 are arranged, and these are in close proximity to each other via the resin. It may be hardened with. Further, the fiber reinforced resin structure 100-3 may be obtained by combining a cylindrical fiber body 10 and a polygonal tubular fiber body 10.

According to another expression, the fiber reinforced resin structure 100-3 according to the third embodiment is described.
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fibrous body 10 includes at least a first tubular fibrous body 10 and a second tubular fibrous body 10, which are polygonal tubular fibrous bodies.
It is a fiber reinforced resin structure in which a flat surface portion constituting the outer surface of the first tubular fiber body and a flat surface portion constituting the outer surface of the second tubular fiber body are in contact with each other or in close contact with each other.

From this point of view, the fiber reinforced resin structure 100-3 includes a plurality of polygonal tubular fiber bodies 10. Further, the plurality of fiber bodies 10 are regularly arranged so that the side surfaces of the plurality of fiber bodies 10 are in contact with each other or close to each other.

The number of polygonal tubular fiber bodies 10 contained in the fiber reinforced resin structure 100-3 is not particularly limited, and may be two or more.

In the fiber reinforced resin structure 100-3, the foam 30 may be inserted into all the cylinders of each tubular fiber body (for example, the first tubular fiber body and the second tubular fiber body). The foam 30 may not be inserted inside all the cylinders, or the foam 30 may not be inserted inside some of the cylinders, but the foam 30 may not be inserted inside the remaining cylinders. You may.

As a method of arranging the communication holes H (or the fiber body 10), as shown in FIG. 20, a method of arranging the plurality of communication holes H (or the plurality of fiber bodies 10) so as to be arranged in a single layer, FIG. 21. As shown in FIG. 22, a method of stacking a plurality of layers in which a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged and arranging them in a honeycomb shape, as shown in FIG. 22, a plurality of communication holes H. A method of stacking layers in which (or a plurality of fiber bodies 10) are arranged in a plurality of stages and arranging them in a grid pattern, as shown in FIG. 23, a plurality of communication holes H (or a plurality of fiber bodies 10) are formed in a circle. Examples thereof include a method of arranging them so as to be arranged in a pattern.

As shown in FIG. 24, the fiber-reinforced resin structure 100-3 has a plurality of layers in which a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged, and has a layer and another layer. And, the direction of the hole axis C of the communication hole H (or the tube axis direction of the fiber body 10) may be arranged so as to be different.

The wall portion (or the cylindrical shape of the fiber body 10) that defines the communication hole H is not particularly limited, and may be a square cylinder shape, a pentagonal cylinder shape or more, or a plurality of shapes. (For example, as shown in FIG. 21, a combination of a pentagonal cylinder and a hexagonal cylinder) may be used.

In the fiber reinforced resin structure 100-3, as shown in FIG. 25 (1), a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged so that the hole axes are arranged perpendicularly to a certain curve. They may be arranged parallel to each other.

As shown in FIG. 25 (2), in the fiber reinforced resin structure 100-3, the end portion (opening surface) of the communication hole H may be sealed (or may be crushed). For example, the fiber reinforced resin structure 100-3 may have a shape in which the upper end portion and / or the lower end portion thereof are crushed. The end portion crushed in this way can be used, for example, as a surface for installing a fixing member such as a screw.

In the fiber reinforced resin structure 100-3, only one end (opening surface) of the communication hole H may be sealed (or may be crushed), or both of the communication holes H may be sealed. The end (opening surface) may be sealed (or may be crushed).

In this case, the fiber reinforced resin structure 100-3 may or may not contain the foam 30.

Similarly, the fiber-reinforced resin structure described in each embodiment may have a structure in which the end portion of the communication hole H is sealed (or crushed).

As shown in FIGS. 26 (f) and 31 (f), the fiber-reinforced resin structure 100-3 has holes at locations where the plurality of communication holes H (or the plurality of fiber bodies 10) are close to each other. You may be doing it.

As shown in FIG. 27 (f), the fiber reinforced resin structure 100-3 may have the reinforcing member 15. The reinforcing member 15 is impregnated with a resin (resin 20) and integrated as a fiber reinforced resin structure 100-3. By having the reinforcing member 15, it is possible to reinforce the portion where the fiber body 10 is insufficient and improve the strength of the fiber reinforced resin structure 100-3.

The place where the reinforcing member 15 is arranged is not particularly limited, and can be appropriately arranged in a place where the strength may be insufficient due to the lack of the fiber body 10. For example, as shown in FIG. 27, the reinforcing member 15 may be arranged at a location where a plurality of communication holes H (or a plurality of fiber bodies 10) are close to each other, or at an end portion of the fiber reinforced resin structure 100-3. can.

The material of the reinforcing member 15 is not particularly limited, but may be the same material as the fibers constituting the fiber body 10. That is, the reinforcing member 15 may be made of fibers. The shape of the reinforcing member 15 is not limited, and may be an appropriate shape. For example, as the reinforcing member 15, a one-way reinforcing material (UD material), a twisted material thereof, or the like may be used, or a sheet shape, a rod shape obtained by rolling the sheet, or the like may be used, and the portion to be reinforced may be used. It can be changed according to the shape. The content of the reinforcing member 15 can be appropriately used according to the strength of the desired fiber reinforced resin structure 100-3 and the like.

As shown in FIG. 28 (f), the fiber-reinforced resin structure 100-3 may have different hole diameters (or cylinder inner diameters of the plurality of fiber bodies 10) of the plurality of communication holes H.

As shown in FIGS. 29 (e) and 30 (e), the fiber reinforced resin structure 100-3 has the thickness of the wall portion surrounding the communication hole H (or the tubular fiber body 10 and the resin 20). The fiber thickness of the fiber body 10 (or the tubular fiber body 10) may be different for each communication hole H. Further, in this case, as shown in FIGS. 29 (e) and 30 (e), the hole diameters of the plurality of communication holes H (or the inner diameters of the cylinders of the plurality of fiber bodies 10) are different for each communication hole H. You may.

As the structure according to the fiber reinforced resin structure 100-3, the structure according to the fiber reinforced resin structure 100-1 and / or the structure according to the modified example of the fiber reinforced resin structure 100-1 are regularly used. It can also be expressed as having a structure that is arranged side by side and integrated via a resin.

<<< Manufacturing method >>>
The method for manufacturing the fiber reinforced resin structure 100-3 is, for example,
A columnar first foam 30, a fibrous body 10 that covers at least a part of the side surface of the first foam 30, and a columnar second foam that is close to the first foam 30 via the fibrous body 10. A preparatory step for preparing an aggregate 55 having the foam 30 and at least the aggregate 55 having the fibrous body 10 impregnated with an uncured heat-curable resin (uncured resin 25).
This method includes a curing step of thermally curing the thermosetting resin (uncured resin 25) contained in the aggregate 55.

The curing process and the like are as described above. As shown in FIG. 20 (e), by carrying out the curing step, the plurality of fibrous bodies 10 and the like contained in the aggregate 55 are integrated via the thermosetting resin.

Further, as described above, the cooling step, the cutting step and the removing step may be carried out.

Further, in the method for manufacturing the fiber reinforced resin structure 100-3, a sealing step (crushing step) for crushing the end portion (opening surface) of the aggregate 55 may be provided before the curing step.

When the sealing step (crushing step) is carried out, the length of the fiber body 10 may be made longer than the length of the foam body 30 (configured so that the fiber body 10 protrudes from the foam body 30).

The sealing step (crushing step) may be performed only on one end (opening surface) of the aggregate 55, or may be performed on both ends (opening surface) of the aggregate 55. May be good.

When the sealing step (crushing step) is performed, the removing step may or may not be carried out. The sealing step (crushing step) is preferably carried out in a state where the aggregate 55 contains the foam 30.

The sealing step (crushing step) may be carried out so that the end portion (opening surface) of the aggregate 55 is completely closed, or may be carried out within the range where the end portion of the aggregate 55 has an opening.

<< Preparation process >>
In the preparatory step, there is at least a fibrous body 10 that covers at least a part of the side surface portion of the first foam 30 and a columnar second foam 30 that is close to the first foam 30 via the fibrous body 10. Then, the aggregate 55 impregnated with the thermosetting resin (uncured resin 25) in an uncured state is prepared for the fiber body 10.

More specifically, in the preparation step, an aggregate 55 in which a plurality of laminated bodies 50 are arranged so as to be in contact with or close to each other is prepared (see FIGS. 20 (a) to 20 (c) and the like). According to another expression, the foam 30 contained in the laminated body 50 is arranged so as to be close to each other via the fiber body 10.

The number of laminated bodies 50 included in the aggregate 55 and the arrangement of the laminated bodies 50 are not particularly limited, and may be adjusted according to the desired structure of the fiber reinforced resin structure 100-3.

The aggregate 55 is, for example, one in which a plurality of laminated bodies 50 are arranged so as to be arranged in one layer as shown in FIG. 20, and a layer in which a plurality of laminated bodies 50 are arranged as shown in FIG. 21. A plurality of layers arranged in a honeycomb shape, as shown in FIG. 22, a layer in which a plurality of laminated bodies 50 are arranged are arranged in a grid pattern, as shown in FIG. 23. , Such as those in which a plurality of laminated bodies 50 are arranged so as to be arranged in a circle.

As shown in FIG. 24, the aggregate 55 includes a layer in which a plurality of laminates 50 are arranged so that the hole axes C of the communication holes H (or the plurality of fibrous bodies 10) face a certain direction. The plurality of laminates 50 are arranged so as to have another layer in which the plurality of laminates 50 are arranged so that the hole axes C of the communication holes H (or the plurality of fiber bodies 10) face different directions. It may have been done.

Here, as shown in FIG. 20 (d), the aggregate 55 may have a plate-shaped outer peripheral body 70 provided so as to be in contact with the side portion of the laminated body 50.

The outer peripheral body 70 includes, for example, a fiber similar to the fiber constituting the fiber body 10 and an uncured resin 25. By using such an outer peripheral body 70, the strength of the fiber reinforced resin structure can be improved.

The thickness of the outer peripheral body 70 and the like can be appropriately used according to the strength of the desired fiber reinforced resin structure 100-3 and the like.

The shape of the outer peripheral body 70 is not particularly limited, but may be, for example, a flat plate.

Further, the outer peripheral body 70 may be configured to orbit the entire side surface of the aggregate 55 by one or more rounds. With such a configuration, since the outer peripheral body 70 after curing becomes the outer wall of the fiber reinforced resin structure 100-3, it becomes easy to improve the strength of the fiber reinforced resin structure 100-3.

The outer peripheral body 70 may be provided so as to come into contact with the plurality of laminated bodies 50. When the outer peripheral body 70 comes into contact with the plurality of laminated bodies 50, the laminated body 50 is arranged along the outer peripheral body 70.

Other members may or may not be present between the laminated bodies 50. For example, as shown in FIG. 27, the assembly 55 may include a reinforcing member 15. In the fiber reinforced resin structure 100-3, the reinforcing member 15 is integrated with the fiber body 10 and the like via the resin 20. Therefore, it is preferable that the reinforcing member 15 is impregnated with the uncured resin 25 at any timing. The uncured resin 25 contained in the laminate 50 may be moved to the reinforcing member 15 by bringing the laminate 50 containing the uncured resin 25 into contact with the reinforcing member 15 not containing the uncured resin 25, or the uncured resin 25 may be moved to the reinforcing member 15. After forming the aggregate 55 including the laminate 50 and the reinforcing member 15 which does not contain the resin 25, the aggregate 55 may be subjected to the impregnation step, but the reinforcing member 15 is impregnated with the uncured resin 25 in advance. It is preferable to keep it.

The shape, material, and the like of the foam 30 and the fibrous body 10 may be different between one laminated body 50 and another laminated body 50. For example, as shown in FIG. 28, the aggregate 55 may include a plurality of foams 30 (laminated body 50) having different diameters.

Further, as shown in FIGS. 29, 30, and 31, the aggregate 55 includes a plurality of laminated bodies 50 and one or more foams 30 (foams 30 that are not previously covered with the fiber 10). May be arranged. When configured in this way, the thickness of the fiber body 10 contained in the wall portion of the obtained fiber reinforced resin structure 100-3 may differ depending on the location. Further, when configured in this way, the diameter of the communication hole H of the fiber reinforced resin structure 100-3 may differ greatly depending on the location. Further, in this configuration, the pitch between the walls (dense / sparse communication holes H) can be adjusted. As described above, when it is desired to adjust the required wall thickness (amount of fiber 10), the size of the communication hole H, etc. in consideration of design, strength, cost, weight, etc., further, specify. Such a method can be adopted when it is desired to design the region to have high strength.

<< Deformation process >>
In the deformation step, an external force is applied to the plurality of laminated bodies 50 in a state where the plurality of laminated bodies 50 are arranged as an aggregate 55.

Further, since the laminated body 50 contains the foam 30, the axis of the laminated body 50 (the pillar axis A of the foam 30) is unlikely to shift when the deformation step is performed. Therefore, before and after the deformation step, the method of arranging the plurality of laminated bodies 50 as a whole (particularly, the method of arranging the column axes A of the foam 30) is maintained almost unchanged. As a result, in the obtained fiber-reinforced resin structure 100-3, the hole axes C of the communication holes H can be made parallel to each other.

Further, since the laminated body 50 contains the foam 30, the side surfaces of the laminated body 50 are in contact with each other or close to each other, or a surface different from the side surface of the laminated body 50 (for example, an inner surface of a predetermined mold). When an external force is applied to the laminated body 50 in a state of contact with the fixed surface and the outer peripheral body 70), a compressive force and a repulsive force act on the foam 30. As a result, the side surface of the laminated body 50 is deformed so as to be flattened, and a prismatic laminated body 50 is formed. When the fibrous body 10 is provided in a tubular shape in the laminated body 50, it constitutes a flat surface portion constituting an outer surface of one tubular fibrous body 10 and an outer surface of another tubular fibrous body 10. It is possible to form a fiber-reinforced resin structure such that the flat surface portions thereof are in contact with or close to each other (that is, such flat surface portions are parallel to each other).

The method of applying an external force in the deformation step is not particularly limited.

The application of the external force can be carried out, for example, by fitting the aggregate 55 into a predetermined mold.

The application of the external force may be carried out by sandwiching the aggregate 55 with the outer peripheral body 70. Further, by carrying out the curing step with the aggregate 55 sandwiched between the outer peripheral bodies 70, the fiber reinforced resin structure 100-3 having the outer peripheral body 70 as an outer shell can be manufactured. When the aggregate 55 is sandwiched from the front and back by using two outer peripheral bodies 70, the laminated body 50 existing at the left end and the right end is open because there is no adjacent member (laminated body 50 or outer peripheral body 70). Will have the side surface. When the deformation step is carried out in a situation where such an open side surface exists, there is no force for suppressing the deformation in the side surface direction of the assembly 55, so that the end side surface (stacking existing at the end portion) of the assembly 55 is present. The side surface of the body 50) may form a curved structure along the expansion of the foam 30.

When the outer peripheral body 70 is applied to the aggregate 55, the outer peripheral body 70 may be cured first, the cured outer peripheral body 70 may be brought into contact with the aggregate 55, and the uncured resin contained in the aggregate 55 may be cured. However, it is preferable that the outer peripheral body 70 containing the uncured resin is brought into contact with the aggregate 55 to simultaneously cure the uncured resin contained in the aggregate 55 and the outer peripheral body 70.

The application of the external force may be carried out by tying the entire assembly 55 with a string or the like.

The application of the external force is carried out by enclosing the whole or a part of the aggregate 55 in a flexible material such as a bag, sealing it, and then sucking the air in the flexible material to create a reduced pressure atmosphere. Is preferable. In this case, the uncured resin in the fiber body 10 contained in the aggregate 55 is subjected to the action of the suction force for sucking air and the compressive force due to the reduced pressure, and the inside of the fiber body 10 is densely filled. Therefore, the fiber-reinforced resin structure after curing can form a dense priority structure, and defects are significantly reduced. This improves physical properties such as mechanical strength of the fiber reinforced resin structure. In the heat curing step, there is an effect that the fiber body 10 can be uniformly pressed against the outer peripheral body 70 by the differential pressure from the atmospheric pressure, and an effect that the fiber body 10 can be strongly pressed against the outer peripheral body 70 by further expanding the foam. , The moldability (there is no wrinkle or twist, and the shape is a desired shape) can be further improved. The conditions for depressurization are not particularly limited, and may be conditions that are normally carried out.

By adjusting the direction in which the external force is applied when the external force is applied, fiber-reinforced resin structures 100-3 having various structures can be obtained.

By applying an external force to the aggregate 55 from the front-rear direction (or the front-back direction and the left-right direction), the fiber-reinforced resin structure 100- as a whole is rectangular parallelepiped as shown in FIG. 3 can be obtained.

By applying an external force to the aggregate 55 substantially evenly from the peripheral direction of the aggregate 55, a fiber-reinforced resin structure 100-3 having a cylindrical shape as a whole as shown in FIG. 23 (f) or the like is formed. Obtainable.

By changing the shape of the surface (for example, the inner surface of the mold to be used) that comes into contact with the aggregate 55 when an external force is applied, a plurality of communication holes H (or) as shown in FIG. 25 (1) are used. Can obtain a fiber-reinforced resin structure 100-3 in which a plurality of fiber bodies 10) are arranged in parallel with each other so that the hole axes are arranged perpendicularly to a certain curve.

In the deformation step, the degree of deformation of the foam 30 and the degree of deformation of the laminated body 50 can be adjusted by adjusting the external force. For example, when the external force on the aggregate 55 is weakened, the deformation of the laminated body 50 is suppressed, and a region (vacancy region) in which the external force does not sufficiently contribute to the laminated body 50 can be formed. As a result, as shown in FIG. 26, the curved surface shape can be maintained at the portion corresponding to the corner portion of the laminated body 50. Similarly, when the formwork is used when applying an external force, a region (non-following region) in which the deformation of the laminated body 50 does not follow the corners of the formwork or the like may be formed. When it is not preferable to have such a hole region or a non-following region, it is preferable to arrange the reinforcing member 15 in advance at a position corresponding to these regions.

In the method shown in FIG. 20, a laminate 50 including a foam 30, a fiber 10, and an uncured resin 25 is prepared (FIG. 20A), and the plurality of laminates 50 are brought into contact with or close to each other. (FIG. 20 (b)), a plurality of laminated bodies 50 arranged by the two outer peripheral bodies 70 are sandwiched to form an aggregate 55 (FIG. 20 (c)), and an external force is applied to the aggregate 55. The entire body is compressed to deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then cured to form the fiber-reinforced resin structure 100-3 (FIG. 20 (e)). The foam 30 is removed from the fiber reinforced resin structure 100-3 (FIG. 20 (f)).

In the method shown in FIGS. 21 and 22, a laminate 50 including the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIGS. 21 (a) and 22 (a)), and the plurality of laminates 50 are prepared. Are arranged in a row so that the fiber bodies 10 are in contact with each other or close to each other, and the rows of the plurality of laminated bodies 50 are arranged in a plurality of rows to form an aggregate 55 (FIGS. 21 (b) to 21 (d)). 22 (b) to 22 (d)), an external force is applied to the aggregate 55 to compress the whole, deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then cure. As a result, the fiber-reinforced resin structure 100-3 is formed (FIGS. 21 (e) and 22 (e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 21 (f). ), FIG. 22 (f)).

In the method shown in FIG. 23, a laminate 50 including the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIG. 23 (a)), and the periphery of the laminate 50 is surrounded by the plurality of laminates 50. In addition, the laminated bodies 50 are arranged so that the fiber bodies 10 are in contact with each other or close to each other to form an aggregate 55 (FIGS. 23 (b) to 23 (d)), and an external force is applied to the aggregate 55 to make the whole. The fiber-reinforced resin structure 100-3 is formed by compressing, deforming the cross-sectional shape perpendicular to the axis of the laminated body 50 (foam 30), and then curing (FIG. 23 (e)), and the fiber-reinforced resin. The foam 30 is removed from the structure 100-3 (FIG. 23 (f)).

In the method shown in FIG. 24, a laminate 50 including the foam 30, the fiber body 10, and the uncured resin 25 is prepared (FIG. 24 (a)), and the fiber body 10 comes into contact with or is close to the plurality of laminates 50. The rows of the plurality of laminated bodies 50 are arranged in one row in this manner, and the rows of the plurality of laminated bodies 50 are stacked so as to have different orientations to form an aggregate 55 (FIGS. 24 (b) to 24 (d)), and the aggregate 55 is formed. A fiber-reinforced resin structure 100-3 is formed by applying an external force to the body to compress the whole body, deforming the cross-sectional shape perpendicular to the axis of the laminated body 50 (foam 30), and then curing the laminated body 50 (foam 30) (FIG. 24). (E)), the foam 30 is removed from the fiber reinforced resin structure 100-3 (FIG. 24 (f)).

In the method shown in FIG. 26, a laminate 50 containing a foam 30, a fiber 10, and an uncured resin 25 is prepared (FIG. 26A), and the plurality of laminates 50 are brought into contact with or close to each other. (FIGS. 26 (b) to (c)), an external force is applied to the aggregate 55, and the whole is compressed until the portions where the ends of the three or more laminated bodies 50 are aggregated do not come into close contact with each other. The fiber-reinforced resin structure 100-3 is formed by deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 26 (d)) and then curing the laminate 50 (foam 30) (FIG. 26 (e)). ), The foam 30 is removed from the fiber reinforced resin structure 100-3 (FIG. 26 (f)).

In the method shown in FIG. 27, a laminate 50 including a foam 30, a fiber body 10, and an uncured resin 25 and a reinforcing member 15 are prepared (FIG. 27 (a)), and a plurality of laminates 50 are made into fibers. The bodies 10 are arranged so as to be in contact with each other or close to each other, and the reinforcing member 15 is arranged between the plurality of laminated bodies 50 (FIGS. 27 (b) to (c)), and an external force is applied to the aggregate 55 as a whole. Is compressed to deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 27 (d)), and then cured to form the fiber-reinforced resin structure 100-3 (FIG. 27). (E)), the foam 30 is removed from the fiber reinforced resin structure 100-3 (FIG. 27 (f)).

In the method shown in FIG. 28, the laminate 50 having a relatively large diameter including the foam 30, the fiber 10, and the uncured resin 25, and the relatively large diameter including the foam 30, the fiber 10, and the uncured resin 25 are included. (FIG. 28 (a)), and a plurality of relatively large-diameter laminates 50 are arranged so as to surround the relatively small-diameter laminate 50 (FIGS. 28 (b) to (b)). (C)) By applying an external force to the aggregate 55 to compress the whole, deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) ((FIG. 28 (d)), and then curing the laminate 50 (FIG. 28 (d)). , The fiber reinforced resin structure 100-3 is formed (FIG. 28 (e)), and the foam 30 is removed from the fiber reinforced resin structure 100-3 (FIG. 28 (f)).

In the method shown in FIG. 29, a laminate 50 including a foam 30, a fiber 10, and an uncured resin 25 and a foam 30 to which the fiber 10 is not arranged are prepared, and the laminate 50 and the foam are prepared. 30 and 30 are alternately arranged (FIG. 29 (a)), and the laminated body 50 and the foam 30 arranged by the two outer peripheral bodies 70 are sandwiched to form an aggregate 55 (FIG. 29 (b)), and the aggregate 55 is formed. A fiber-reinforced resin structure 100-3 is formed by applying an external force to compress the entire body, deforming the cross-sectional shape perpendicular to the axis of the laminated body 50 (foam 30) (FIG. 29 (c)), and then curing the laminated body 50 (foam 30). (FIG. 29 (d)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 29 (e)).

In the method shown in FIG. 30, a laminate 50 including a foam 30, a fiber 10, and an uncured resin 25 and a foam 30 to which the fiber 10 is not arranged are prepared, and the laminate 50 and the foam are prepared. The foams 30 are arranged so as to be lined up with 30 and the foams 30 are arranged so as to be continuously arranged (FIG. 30A), and the laminated body 50 and the foams 30 arranged by the two outer peripheral bodies 70 are sandwiched and aggregated. 55 (FIG. 30 (b)), an external force is applied to the aggregate 55 to compress the whole, and the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) is deformed (FIG. 30 (c)). After that, the fiber-reinforced resin structure 100-3 is formed by curing (FIG. 30 (d)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 30 (e)).

In the method shown in FIG. 31, a laminate 50 of the foam 30, the fiber 10, and the uncured resin 25, and the foam 30 to which the fiber 10 is not arranged are prepared (FIG. 31 (a)). A plurality of laminated bodies 50 are arranged so as to surround the foam 30 (FIGS. 31 (b) to (c)), and an external force is applied to the aggregate 55 to compress the whole and the shaft of the laminated body 50 (foam 30). By deforming the vertical cross-sectional shape ((FIG. 31 (d)) and then curing it to form the fiber reinforced resin structure 100-3 (FIG. 31 (e)), the fiber reinforced resin structure 100-3 is formed. The foam 30 is removed from the body (FIG. 31 (f)).

<<<<<< Embodiment IV >>>>>
<<< Structure >>>
The fiber reinforced resin structure 100-4 according to the IV embodiment is
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
At least a first communication hole H, a second communication hole H parallel to the first communication hole H, and a wall portion defining the first communication hole H and the second communication hole H are provided.
The hole axis C of the first communication hole H and the second communication hole H is curved.
The wall contains the fibrous body 10,
It is a fiber reinforced resin structure.

Further, the first communication hole H and the second communication hole H may have a polygonal cross-sectional shape in a cross section perpendicular to the hole axis C.

The number of communication holes H included in the fiber reinforced resin structure 100-4 may be two or more.

The fiber reinforced resin structure 100-4 has a plurality of communication holes H, has a plurality of communication holes H in which the hole axis C is curved, and the communication holes H are arranged so as to be parallel to each other. ing. As described above, the fiber-reinforced resin structure can be provided with the characteristics of the modified example of the fiber-reinforced resin structure 100-1 and the characteristics of the fiber-reinforced resin structure 100-3. Therefore, all the matters described for each embodiment can be applied to the fiber reinforced resin structure 100-4.

According to other expressions, the fiber reinforced resin structure 100-4 according to the IV embodiment is described.
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fibrous body 10 includes at least a first tubular fibrous body 10 and a second tubular fibrous body 10.
The first tubular fiber body 10 has a curved polygonal tubular structure in which the tubular shaft B is curved, and has an outer surface parallel to the tubular shaft B.
The second tubular fiber body has a curved polygonal tubular structure in which the tubular axis B is curved, and has an outer surface parallel to the tubular axis B.
It is a fiber reinforced resin structure in which the outer surface of the first tubular fiber body and the outer surface of the second tubular fiber body are in contact with or in close contact with each other.

In yet another expression, the fiber reinforced resin structure 100-4 includes a plurality of polygonal tubular fiber bodies 10 which are regularly arranged and provided in contact with each other or in close proximity to each other, and a plurality of fibers. It has a curved portion 60 that is curved in a predetermined direction and is present over the body 10.

The degree of curvature of the hole axis C of the communication hole H (or the curvature of the curved portion of the fiber body 10) can be freely designed as appropriate. Further, the degree of curvature may be the same or different in the plurality of communication holes H.

The direction in which the fiber reinforced resin structure 100-4 is curved is not particularly limited. For example, as shown in FIG. 32 (g), a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged and formed in the front direction of the fiber reinforced resin structure 100-4, in other words, a plurality of communication holes H (or a plurality of fiber bodies 10). It may be curved in a direction perpendicular to the virtual plane, or as shown in FIG. 33 (g), the side surface direction of the fiber reinforced resin structure 100-4, in other words, a plurality of communication holes H. (Or a plurality of fiber bodies 10) may be curved in the same direction as the arrangement direction.

Further, as shown in FIG. 33, the fiber reinforced resin structure 100-4 may have a plurality of curved portions 60.

As shown in FIG. 34, the fiber reinforced resin structure 100-4 may have a form in which a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged in a plurality of rows.

A form in which the entire fiber-reinforced resin structure 100-4 is twisted is also within the scope of the present invention.

In the structure according to the fiber reinforced resin structure 100-4, the structures according to the modified example of the fiber reinforced resin structure 100-2 and / or the fiber reinforced resin structure 100-2 are regularly arranged, and the resin is formed. It can also be expressed as having an integrated structure via. Further, in the structure according to the fiber reinforced resin structure 100-4, the structure according to the fiber reinforced resin structure 100-3 is curved in a predetermined direction as a whole while maintaining the cross-sectional shape along the axis. It can also be expressed as a thing.

<<< Manufacturing method >>>
The method for manufacturing the fiber reinforced resin structure 100-4 is, for example,
A columnar first foam 30, a fibrous body 10 that covers at least a part of the side surface of the first foam 30, and a columnar second foam that is close to the first foam 30 via the fibrous body 10. A preparatory step for preparing an aggregate 55 having a foam 30 and an aggregate 55 in which the fibrous body 10 is impregnated with an uncured heat-curable resin (uncured resin 25).
A deformation step of applying an external force to the aggregate 55 to deform the cross-sectional shapes of the first foam 30 and the second foam 30.
A bending step of bending the aggregate 55 so that the column axis A of the foam 30 is curved, and
This method includes a curing step of thermally curing the thermosetting resin (uncured resin 25) contained in the aggregate 55.

Even if the method for manufacturing the fiber-reinforced resin structure 100-4 is a method in which the assembly 55 as shown in FIG. 20C is not subjected to the deformation step and the bending step is carried out. Although it is good, it is preferable to carry out the deformation step and the bending step. That is, the method for manufacturing the fiber-reinforced resin structure 100-4 may further include a deformation step of applying an external force to the aggregate 55 to deform the cross-sectional shapes of the first foam 30 and the second foam 30. preferable.

The preparation step can be carried out in the same manner as the manufacturing method of the fiber reinforced resin structure 100-3.

Regarding the bending step, the above-mentioned contents can be referred to except that the object to be curved is changed from the laminated body 50 to the aggregate 55. That is, in the bending step, an external force is applied to the plurality of laminated bodies 50 so that the pillar axes A of the plurality of foams 30 included in the aggregate 55 are curved in a state where the plurality of laminated bodies 50 are arranged as the aggregate 55. Is added. As a method of applying an external force, as described above, the assembly 55 can be fitted into the mold.

For the deformation process, the above-mentioned contents can be referred to. That is, in the deformation step, in a state where the plurality of laminated bodies 50 are arranged as an aggregate 55, an external force is applied to the plurality of laminated bodies 50 to deform the cross-sectional shape of the plurality of foams 30. As a method of applying an external force, as described above, the assembly 55 can be fitted into the mold.

As described above, the deformation step and the bending step may be carried out at the same time or separately.

The curing process is as described above. As shown in FIG. 32 (f), by carrying out the curing step, the plurality of fibrous bodies 10 and the like contained in the aggregate 55 are integrated via the thermosetting resin.

Further, as described above, the cooling step, the cutting step and the removing step may be carried out.

In the method shown in FIGS. 32 and 33, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIGS. 32 (a) and 33 (a)), and the plurality of laminates 50 are prepared. Is arranged so that the fibrous bodies 10 are in contact with each other or close to each other, and a plurality of laminated bodies 50 arranged by the two outer peripheral bodies 70 are sandwiched therein to form an aggregate 55 (FIGS. 32 (b) to 32 (d), FIGS. 32 (b) to 32 (d). 33 (b) to 33 (d)), an external force is applied to the aggregate 55 to compress the whole, deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and the side surface of the aggregate 55. An external force is applied from the portion so as to bend the axis of the laminated body 50 (foam 30) (FIGS. 32 (e) and 33 (e)), and then the cured portion is cured to have the curved portion 60 (communication hole H). The fiber reinforced resin structure 100-4 (in which the hole axis C is curved) is formed (FIGS. 32 (f) and 33 (f)), and the foam 30 is removed from the fiber reinforced resin structure 100-4. (FIG. 32 (g), FIG. 33 (g)).

In the method shown in FIG. 34, although details are not shown, a laminate 50 containing the foam 30, the fiber body 10, and the uncured resin 25 is prepared so that the fiber body 10 comes into contact with or is close to the plurality of laminates 50. And arranged in one row, the rows consisting of the plurality of laminated bodies 50 are arranged so as to form a plurality of rows to form an aggregate 55, and an external force is applied to the aggregate 55 to compress the whole and the laminated body 50 (foam 30). ), While deforming the cross-sectional shape perpendicular to the axis, an external force is applied from the side surface portion of the aggregate 55 so as to bend the axis of the laminated body 50 (foam 30), and then the curved portion 60 is cured. The fiber-reinforced resin structure 100-4 having (the hole axis C of the communication hole H is curved) is formed, and the foam 30 is removed from the fiber-reinforced resin structure 100-4.

In each embodiment, the pillar shaft A, the cylinder shaft B, and the hole shaft C can be considered to exist at substantially the same positions, so that the pillar shaft A, the cylinder shaft B, and the cylinder shaft B are used. It is also possible to read and explain each of the hole axis C.

Next, a modification of each of the above-described embodiments will be described with reference to FIGS. 35 to 45.

In explaining the modification of the fiber reinforced resin structure shown in FIGS. 35 to 45, the description thereof will be omitted or simplified by assigning the same reference numerals to the same components as described above. In addition, the fiber-reinforced resin structures described in the various modifications described below include those manufactured in the same manner as any of the manufacturing methods described in the above-described examples of embodiments. Therefore, the manufacturing method of the above-described embodiment will be cited as appropriate.

First, a modified example of the fiber reinforced resin structure shown in FIGS. 35 to 40 will be described.

In the following description, the fiber-reinforced resin structure shown in FIGS. 35 (a), 36 (a), 37 (a), 38 (a) and 39 (a) is referred to as a fiber-reinforced resin structure A. , FIG. 35 (b), FIG. 36 (b), FIG. 37 (b), FIG. 38 (b), FIG. 39 (b) and FIG. 40 (c) are the fiber reinforced resin structures B. That is.

The method for manufacturing the fiber reinforced resin structure A is as follows.
A laminated body 50 having a columnar foam 30 and a fiber body 10 in which a side surface portion of the foam body 30 is wound around once or more, and the fiber body 10 is a thermosetting resin (uncured) in an uncured state. A laminated body 50 impregnated with resin) is prepared, the laminated body 50 is curved so that the column axis A of the foam 30 is curved, and an external force is applied to the laminated body 50 to have thermosetting properties contained in the laminated body 50. Including the process of thermosetting the resin
A method for producing a fiber-reinforced resin structure (secondary foaming is possible as the foam 30), wherein the 25% compressive load measured according to JIS K6400-2: 2012 of the foam is 1 to 2000 kPa. Except for the method using a foam; a thermosetting resin (uncured resin) in an uncured state and a coating body having a bleed hole from which gas can exude and covering the laminated body 30;).

The method for manufacturing the fiber reinforced resin structure B is as follows.
A laminated body 50 having a columnar foam 30 and a fiber body 10 in which a side surface portion of the foam body 30 is wound around once or more, and the fiber body 10 is a thermosetting resin (uncured) in an uncured state. A laminated body 50 impregnated with resin) is prepared, the laminated body 50 is curved so that the column axis A of the foam 30 is curved, and an external force is applied to the laminated body 50 to have thermosetting properties contained in the laminated body 50. A step of thermosetting the resin, cooling the laminate 50 to shrink the foam 30, shrinking the foam 30, and then removing the foam 30 contained in the laminate 50 is included.
A method for producing a fiber-reinforced resin structure (secondary foaming is possible as the foam 30), wherein the 25% compressive load measured according to JIS K6400-2: 2012 of the foam is 1 to 2000 kPa. Except for the method using a foam; a thermosetting resin (uncured resin) in an uncured state and a coating body having a bleed hole from which gas can exude and covering the laminated body 30;).

The fiber reinforced resin structure A is
It contains at least a columnar foam 30, a fiber 10 surrounding the foam 30, and a resin 20 impregnated in the fiber 10.
The foam 30 is preferably a medium entity extending from one end to the other end of the fibrous body 10, preferably at least.
The fiber body 10 is a fiber reinforced resin structure in which a part or all of the fiber body 10 is curved.

The fiber reinforced resin structure B is
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fiber body 10 is a fiber reinforced resin structure in which a part or all of the fiber body 10 is curved.

Comparing the fiber-reinforced resin structure A and the fiber-reinforced resin structure B, the fiber-reinforced resin structure A is mainly different in that it contains the foam 30 and the fiber-reinforced resin structure B does not contain the foam 30.

In the following description, the step of preparing the laminate 50 is the "preparation step", the step of bending the laminate 50 is the "curving step", and the step of curing the uncured resin impregnated in the fiber 10 is the "curing step". The step of cooling the laminate 50 to shrink the foam 30 after the curing step is referred to as a "cooling step", and the step of removing the foam 30 contained in the laminate 50 after the cooling step is referred to as a "removal step". Although the description is omitted here, each manufacturing method can further carry out the above-mentioned deformation step (see, for example, FIG. 38 (b)).

The fiber-reinforced resin structure A has a structure in which the foam 30 extends from one end to the other end of the fiber body 10, but the structure is not limited to this, and for example, the foam body 30 is one end of the fiber body 10. It may be configured to extend from the to the front of the other end. That is, the foam 30 may be configured so as to extend from one end of the fiber body 10 and not reach the other end of the fiber body 10. Similarly, foaming is performed only between the first position separated from one end of the fiber body 10 toward the center by a predetermined distance and the second position separated from the other end of the fiber body 10 toward the center by a predetermined distance. The body 30 may be extended.

<Modification 1>
FIG. 35 is a perspective view showing the fiber reinforced resin structure according to the modified example 1. As shown in FIG. 35 (a), the fiber reinforced resin structure 100-5 according to the first modification is manufactured by the method described with reference to FIG. Here, FIG. 17 exemplifies a fiber reinforced resin structure having one curved portion, but Modification 1 shown in FIG. 35 exemplifies a fiber reinforced resin structure having a plurality of curved portions. ..

In the method for manufacturing the fiber-reinforced resin structure 100-5 according to the first modification, the bending step includes a plurality of steps. Specifically, at a step of bending the laminated body 50 at a first position separated from one end of the laminated body 50 toward the center by a predetermined interval, and at a second position separated from the other end of the laminated body 50 toward the center by a predetermined interval. The laminated body 50 is formed so that the column axis A of the foam 30 existing between the first position and the second position has a predetermined shape (for example, a V shape or a rectangular shape) in the step of bending the laminated body 50. Including the step of bending. In the present modification 1, the laminated body 50 is curved so that the pillar axis A of the foam 30 existing between the first position and the second position is U-shaped or inverted U-shaped.

In the fiber reinforced resin structure 100-5 according to the first modification, the cylindrical fiber body 10 has an opening 10a, an opening 10b, a plurality of curved portions 60a to 60c, and a plurality of non-curved portions 60d to 60 g. And have.

The opening 10a is open in the X1 direction, and the opening 10b is open in the X2 direction. The opening direction of the openings 10a and 10b can be arbitrarily set. For example, the opening direction of the openings 10a and 10b can be set to the X1 direction.

The curved portion 60a bends in an inverted U shape when viewed from the front (viewed in the Y direction). Similarly, when viewed from the front (viewed in the Y direction), the curved portion 60b is bent in an L shape, and the curved portion 60c is bent in an L-shaped enantiomer shape. The fiber body 10 may have a structure in which at least one of the curved portions 60a to 60c is curved.

The non-curved portion 60d extends linearly in the X2 direction from the opening 10a to the curved portion 60c. The non-curved portion 60e extends linearly in the X1 direction from the opening 10b to the curved portion 60b. The non-curved portion 60f extends linearly in the Z direction so as to connect the curved portion 60c and the curved portion 60a. The non-curved portion 60 g extends linearly in the Z direction so as to connect the curved portion 60b and the curved portion 60a.

<Modification 2>
FIG. 36 is a perspective view showing the fiber reinforced resin structure according to the modified example 2. As shown in FIG. 36 (a), the fiber reinforced resin structure according to the modified example 2 has a plurality of laminated bodies 50. Here, FIG. 17 illustrates a fiber-reinforced resin structure in which one laminated body 50 is curved, but in the second modification, a bundle of a plurality of (for example, four) laminated bodies 50 is curved. The fiber reinforced resin structure which has been made is illustrated.

The method for manufacturing the fiber-reinforced resin structure 100-5 according to the second modification includes an arrangement step of assembling a plurality of laminated bodies (laminated bodies 50a to 50d) into an aggregate (also referred to as a laminated body group). The bending step is a step of bending a part of the aggregate. The bending process is also referred to as a twisting process.

The arrangement step is a step of arranging a plurality of laminated bodies 50 so as to extend the pillar axis A of the foam 30 in the X direction to form an aggregate 55. At this time, the plurality of laminated bodies 50 are aligned in the Y direction. Specifically, the laminated body 50b is aligned with the laminated body 50a, the laminated body 50c is aligned with the laminated body 50b, and the laminated body 50d is aligned with the laminated body 50c.

The bending step is a step of bending a predetermined position located between one end and the other end of the aggregate 55. In the example shown in FIG. 36 (a), the predetermined position is curved by changing the arrangement state of the laminated body at one end (right side in the drawing) of both ends of the aggregate 55. More specifically, one end of the laminated body 50c and the laminated body 50d is lifted upward, and these are stacked on one end of the laminated body 50a and the laminated body 50b to bend the predetermined position. The bending step may be a step of bending at least one of one end and the other end of the aggregate 55. That is, one end and / or the other end of the assembly 55 may be curved.

As shown in FIG. 36 (b), the fiber reinforced resin structure 100-5 according to the modified example 2 includes a plurality of fiber bodies 10 (fiber bodies 10a to 10d), and the plurality of fiber bodies 10 are curved portions. It has 60 (twisted portion 60) and a non-curved portion (non-twisted portion), respectively. The non-curved portions of the fiber bodies 10a to 10d all extend linearly in the X direction.

The fiber reinforced resin structure 100-5 according to the second modification has an end portion 70, an end portion 80, and communication holes H1 to H4.

The end 70 has four openings 10a1, 10b1, 10c1, 10d1. These openings 10a1 to 10d1 are arranged in a row in the Y direction along a plane perpendicular to the X direction.

The end 80 has four openings 10a2, 10b2, 10c2, and 10d2. These four openings 10a2 to 10d2 are arranged in two rows in the Y direction along a plane perpendicular to the X direction. Specifically, the opening 10a2 and the opening 10b2 are arranged in the first row of the lower layer of the two rows, and the opening 10c2 and the opening 10d2 are arranged in the second row of the upper layer. In other words, the end portion 80 has a lower layer 80a composed of an opening 10a2 and an opening 10b2, and an upper layer 80b composed of an opening 50c2 and an opening 50d2.

The communication hole H1 communicates the opening 10a1 and the opening 10a2 of the fiber body 10a. The communication hole H2 communicates between the opening 10b1 and the opening 10b2 of the fiber body 10b. The communication hole H3 communicates the opening 10c1 and the opening 10c2 of the fiber body 10c. The communication hole H4 communicates the opening 10d1 and the opening 10d2 of the fiber body 10d.

The communication holes H1 to H4 extend linearly in the X direction from the end 70 to the front of the curved portion 60, and are curved at the curved portion 60. The communication holes H1 and H2 are curved at the curved portion 60 and then extend linearly in the X direction to the lower layer 80a of the end portion 80. On the other hand, the communication holes H3 and H4 are curved by the curved portion 60 and then extend linearly in the X direction to the upper layer 80b of the end portion 80.

In the bending step (twisting step) in the modification 2, the column axis of the foam contained in the laminated body or the aggregate is set in a plurality of directions (in FIG. 36A, 2 in the Y direction and the Z direction). It is different from the above-mentioned bending process in that it is curved with respect to the direction).

<Modification 3>
FIG. 37 is a perspective view showing the fiber reinforced resin structure according to the modified example 3. As shown in FIG. 37 (a), in the fiber-reinforced resin structure according to the modified example 3, a plurality of laminated bodies 50 are aggregated to form an aggregate 55, and the aggregate 55 is curved, as in the modified example 2. ing.

Comparing the fiber-reinforced resin structure according to the modified example 3 and the fiber-reinforced resin structure according to the modified example 2, the morphology of one end and the morphology of the curved portion are mainly different. Therefore, in explaining the fiber-reinforced resin structure according to the modified example 3, the points different from the fiber-reinforced resin structure according to the above-mentioned modified example 2 will be described, and the common points will be omitted as appropriate.

In the method for manufacturing a fiber-reinforced resin structure according to the third modification, three steps are included in the placement step. Specifically, a step of adjoining the laminated bodies 50a and 50b so as to extend the column axis A of the foam 30 in the X direction to form a single layer first aggregate, and a step of forming the column axis A of the foam 30 in the X direction. The steps of placing the laminated bodies 50c and 50d adjacent to each other to form a second aggregate, and the step of placing the second aggregate on the first aggregate to form a two-layer aggregate 55. included.

In the method for manufacturing a fiber-reinforced resin structure according to the third modification, the bending step includes two steps. Specifically, the column axis direction (X direction) of the foam 30 is set as the rotation axis so that the predetermined portion located between one end and the other end of the aggregate 55 becomes the curved portion 60, and the one end is set. On the other hand, a step of twisting the aggregate 55 by rotating the other end by 180 degrees and a step of interposing a cylindrical guide material C in the curved portion 60 are included.

In the bending step, when the guide material C is interposed, the first aggregate composed of the laminated bodies 50a and 50b and the second aggregate composed of the laminated bodies 50c and 50d are separated from each other by the curved portion 60. As such, the guide material C is interposed between the first aggregate and the second aggregate.

After the bending step, the uncured resin impregnated in the fiber body 10 is cured with the guide material C interposed between the first aggregate and the second aggregate. Then, the aggregate 55 is cooled and the guide material C is removed to obtain the fiber reinforced resin structure 100-5 shown in FIG. 37 (a). When the foam 30 is removed from the fiber-reinforced resin structure 100-5 shown in FIG. 37 (a), the fiber-reinforced resin structure 100-5 shown in FIG. 37 (b) is obtained.

In the bending step of the modification 3, the other end is rotated by 180 degrees to twist the aggregate 55, but this rotation angle can be arbitrarily set. For example, the other end may be rotated 45 degrees or 360 degrees with respect to one end.

Further, in the manufacturing method of Modification 3, the curved portion 60 has an opening that opens in the Z direction by interposing a cylindrical guide material C between the first aggregate and the second aggregate. However, the configuration is not limited to this, and the curved portion 60 may have a configuration having no opening. That is, in the manufacturing method of the modified example 3, the cylindrical guide material C is not interposed between the first aggregate and the second aggregate. After this, the other end is rotated by a predetermined angle (for example, 1 degree to 360 degrees, or 360 degrees or more) with respect to one end so that the aggregate 55 is twisted.

The fiber-reinforced resin structure according to the third modification has an end portion 70, an end portion 80, and communication holes H1 to H4.

The end 70 has four openings 10a1, 10b1, 10c1, 10d1. These openings 10a1 to 10d1 are arranged in two rows in the Y direction along a plane perpendicular to the X direction. Specifically, the opening 10c1 and the opening 10d1 are arranged in the first row of the lower layer of the two rows, and the opening 10a1 and the opening 10b1 are arranged in the second row of the upper layer. In other words, the end 70 has a lower layer 70a composed of an opening 10c1 and an opening 10d1, and an upper layer 70b composed of an opening 10a1 and an opening 10b1.

The end 80 has four openings 10a2, 10b2, 10c2, and 10d2. These four openings 10a2 to 10d2 are arranged in two rows in the Y direction along a plane perpendicular to the X direction. Specifically, the opening 10b2 and the opening 10a2 are arranged in the first row of the lower layer of the two rows, and the opening 10c2 and the opening 10d2 are arranged in the second row of the upper layer. In other words, the end portion 80 has a lower layer 80a composed of an opening 10b2 and an opening 10a2, and an upper layer 80b composed of an opening 10c2 and an opening 10d2.

The communication hole H1 communicates the opening 10a1 and the opening 10a2 of the fiber body 10a. The communication hole H2 communicates between the opening 10b1 and the opening 10b2 of the fiber body 10b. The communication hole H3 communicates the opening 10c1 and the opening 10c2 of the fiber body 10c. The communication hole H4 communicates the opening 10d1 and the opening 10d2 of the fiber body 10d.

The communication holes H1 and H2 extend linearly in the X direction from the upper layer 70b of the end 70 to the front of the curved portion 60, bend in the curved portion 60, and then extend linearly in the X direction to the lower layer 80a of the end 80. ing. On the other hand, the communication holes H3 and H4 extend linearly in the X direction from the lower layer 70a of the end 70 to the front of the curved portion 60, bend at the curved portion 60, and then linearly extend in the X direction to the upper layer 80b of the end 80. Extends to.

<Modification example 4>
FIG. 38-1 is a perspective view showing the fiber reinforced resin structure according to the modified example 4. The fiber-reinforced resin structure 100-5 according to the modified example 4 shown in FIG. 38 (c) is manufactured by the method described in FIG. 19, but here, the main difference is from the method described in FIG. I will explain to.

First, as shown in FIG. 38-1 (a), a plurality of laminated bodies 50 (formed in an L shape) having a curved structure obtained by carrying out a bending step, and a plurality of columnar laminated bodies. Prepare 50 and. In the L-shaped laminate 50, one side portion of the L-shape is installed, while the other side portion of the L-shape is made to stand upright, and one side of each L-shaped laminate 50 stands upright. Arrange the parts so that they are in contact with each other. Further, one end surface of the columnar laminated body 50 is arranged so as to be joined to the side surface side of the L-shaped laminated body 50. Note that FIGS. 38-1 (a) and 38-1 (b) show a state in which the laminated bodies 50 are slightly separated from each other so that the shapes of the laminated bodies 50 can be easily understood, but in reality, they are separated from each other as described above. It should be added that they are in contact with each other.

As shown in FIG. 38-1 (b), in a state where the L-shaped laminated body 50 and the columnar laminated body 50 are in contact with each other, a deformation step is performed, and finally curing is performed to form an L-shape. The portion of the laminated body 50 having a shape becomes a plurality of communication holes (a plurality of communication holes having an L-shaped cross section) that are not parallel to each other, and the portion of the columnar laminated body 50 has a plurality of extending in a straight line. The fiber-reinforced resin structure 100-5 having a bottomed hole can be manufactured (see FIG. 38-1 (c)). In FIGS. 38-1 (a) and 38-1 (b), the foam 30 is omitted for the sake of simplicity.

<Modification 4-1>
The fiber-reinforced resin structure 100-5 is not limited to the one shown in FIG. 38-1 (c), but is, for example, the fiber-reinforced resin structure 100-5 shown in FIG. 38-2 (e). It is also good (this is referred to as modification 4-1). Specifically, as described in FIG. 38-1 (a), the upright side portions of the L-shaped laminated bodies 50 are arranged so as to be in contact with each other, and the columnar laminated body 50 is arranged so as to be in contact with each other. One end surface of the above is arranged so as to be joined to the side surface side of the L-shaped laminated body 50 to form an upper portion (see reference numeral 50U in FIG. 38-2 (d)). Further, under the upper portion 50U, one plurality of cylindrical laminates (see reference numeral 50D1 in FIG. 38-2 (d)) and another on the side surface of the one cylindrical laminate 50, respectively. A lower portion (see reference numeral 50D in FIG. 38-2 (d)) arranged so as to join one end faces of a plurality of cylindrical laminated bodies (see reference numeral 50D2 in FIG. 38-2 (d)) is prepared. In a state where the lower surface of the upper portion is in contact with the upper surface of the lower portion, the deformation step is carried out as described above, and finally the curing is performed. The portion 50D is integrated to obtain the fiber reinforced resin structure 100-5 shown in FIG. 38-2 (e). In addition, in FIG. 38-2, for the sake of simplicity, the illustration of the columnar laminate 50 and the like shown in FIG. 38-1 (a) is omitted, and the fiber reinforced resin structure 100-shown in FIG. 38-2 (e) is omitted. Only 5 and FIG. 38-2 (d), which is a disassembled state thereof, are shown.

In this modification 4-1: the upper surface of the lower portion 50D, which was one or more cylindrical laminates before curing, and the upper portion 50U, a plurality of cylindrical laminates before curing. Since the lower surface of the 50U1 is in contact with each other and cured, it is possible to improve the strength of the 50D1 and the 50U1. Further, the upper surface of the lower portion 50D, which was a plurality of other cylindrical laminates before curing, and the lower surface of the upper portion 50U, which was an L-shaped laminate before curing. Can be brought into contact with each other and cured, so that the strength with these 50D2 and 50U2 can be improved. As a result, it is possible to improve the strength of the entire fiber-reinforced resin structure 100-5.

<Modifications 5 and 6>
39 and 40 are perspective views showing the fiber reinforced resin structure according to the modified examples 5 and 6. The fiber reinforced resin structure 100-6 according to the modified examples 5 and 6 is manufactured by the method described with reference to FIG.

Comparing the fiber-reinforced resin structure according to the modified examples 1 to 4 with the fiber-reinforced resin structure according to the modified examples 5 and 6, the fiber-reinforced resin structure according to the modified examples 1 to 4 is one of the fiber bodies 10. While the portion is curved, the fiber-reinforced resin structure according to the modified examples 5 and 6 is different in that the entire fiber body 10 is curved. In other words, the fiber reinforced resin structure according to the modified examples 1 to 4 has a non-curved portion, but the fiber reinforced resin structure according to the modified examples 5 and 6 does not have a non-curved portion.

As shown in FIG. 39, in the method for manufacturing the fiber reinforced resin structure 100-6 according to the modified example 5, in the bending step, the column shaft A of the foam 30 is laminated so as to be wound in a plane in a spiral shape. The body 50 is curved.

After the bending step, the uncured resin impregnated in the fiber body 10 is cured, and then the laminated body 50 is cooled to obtain the fiber reinforced resin structure 100-6 shown in FIG. 39 (a). Then, when the foam 30 is removed from the fiber reinforced resin structure 100-6 shown in FIG. 39 (a), the fiber reinforced resin structure 100-6 shown in FIG. 39 (b) is obtained.

As shown in FIG. 39 (b), the fiber reinforced resin structure 100-6 according to the modified example 5 contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10, and the fiber body 10 includes the fiber body 10. The tubular shaft B has a tubular shape that is spirally formed in a plane. In other words, the fiber-reinforced resin structure 100-6 is formed in a spiral shape by being bent in a plurality of planes so that the diameter from the virtual center M shown in FIG. 39 (b) gradually increases.

As shown in FIG. 40, in the method for manufacturing the fiber reinforced resin structure 100-6 according to the modified example 6, in the bending step, the laminated body 50 is wound so that the column shaft A of the foam 30 winds like a spiral spring. Curve.

In the bending step, a cylindrical guide material C is prepared, and the laminated body 50 is wound around the outer peripheral surface of the guide material C.

After the bending step, the uncured resin impregnated in the fiber body 10 is cured in a state where the laminated body 50 is wound around the outer peripheral surface of the guide material C. After that, the laminated body 50 is cooled and the guide material C is removed to obtain the fiber reinforced resin structure 100-6 shown in FIG. 40 (a). When the foam 30 is removed from the fiber-reinforced resin structure 100-6 shown in FIG. 40 (a), the fiber-reinforced resin structure 100-6 shown in FIG. 40 (b) is obtained.

As described above, by bending one laminated body 50 or bending an aggregate 55 composed of a plurality of laminated bodies 50, fiber reinforced resin structures having various shapes can be formed. Further, by combining a laminated body 50 having a predetermined shape and a laminated body 50 having a shape different from the predetermined shape, such as a laminated body 50 having a curved structure and a laminated body 50 having a columnar shape, fibers having various shapes can be used. It is possible to manufacture a reinforced resin structure. Although illustration and description are omitted, a fiber-reinforced resin structure may be manufactured by combining laminated bodies 50 having different sizes, or the number, shape, and size of the laminated bodies 50 may be determined. By appropriately combining these, it is possible to produce a desired fiber-reinforced resin structure. Further, various lightweight and high-strength products are obtained by fitting the uncured laminate 50 and the aggregate 55 into a predetermined mold to apply an external force and curing the uncured resin impregnated in the fiber 10. Parts and the like can be obtained. For example, an oar used for a boat such as a boat or a canoe is obtained from the aggregate 55 shown in FIG. 36 (a) (not shown). For example, a propeller for propelling an aircraft or a ship is obtained from the assembly 55 shown in FIG. 37 (a) (not shown). For example, from the laminate 50 shown in FIG. 39 (a), a manhole cover, a receiving portion of a parabolic antenna, or a lid of a container for containing a predetermined liquid or solid can be obtained (not shown). For example, from the laminate 50 shown in FIG. 40 (a), a container for containing a predetermined liquid, solid, or the like is obtained (not shown). The fiber-reinforced resin structure 100-5 shown in FIGS. 38-1 (c) and 38-2 (f) is a protective member that protects the harness by passing a harness or the like through the through hole, or a through hole. Use as a container that supports and stores a rod-shaped object in an upright position by inserting a rod-shaped object (for example, if the rod-shaped object is an umbrella, the container becomes an umbrella stand, etc.). Can be done.

<Modification 7>
41 and 42 are perspective views showing the fiber reinforced resin structure according to the modified example 7. As shown in FIG. 42 (a), the fiber reinforced resin structure 100-7 according to the modified example 7 is manufactured by the method described with reference to FIGS. 32 and 33. That is, in the present modification 7, the methods described in FIGS. 32 (a) to 32 (d) and 33 (a) to 33 (d) are used in FIGS. 32 (e) and 33 (e). The aggregate 55 shown is provided. Here, FIGS. 32 and 33 illustrate an example in which four laminated bodies 50 are sandwiched between two outer peripheral bodies 70, but in the present modification 7, for example, nine laminated bodies 50 are sandwiched between two outer peripheral bodies 70. It is sandwiched between 70 to form a rectangular plate-shaped aggregate 55.

An external force is applied to the aggregate 55 to compress the whole, and both sides of the aggregate 50 are centered on the central laminate 50 (the fifth laminate 50 from the left when viewed in FIG. 41) among the nine laminates 50. By applying an external force so as to bend the ends toward each other (in other words, applying an external force so as to bend the central laminated body 50), the aggregate 55 is deformed so as to have an L-shape in cross-sectional shape. , Then cure. As a result, the fiber reinforced resin structure 100-7 having a bent portion 60W and having an L-shaped cross section is formed, and the foam 30 is removed from the fiber reinforced resin structure 100-7.

Then, the fiber-reinforced resin structure 100-7 is cut in the vertical direction (vertical direction as seen in FIG. 41) along the “A1, A1” shown in FIG. 41 (a), whereby in FIG. 41 (b). A fiber reinforced resin structure 100-7A having an L-shaped cross section can be obtained. Further, by cutting the fiber reinforced resin structure 100-7 in the vertical direction along "A2, A2" and "A3, A3" shown in FIG. 41 (a), the cross section shown in FIG. A (b) can be obtained. An H-shaped fiber reinforced resin structure 100-7B can be obtained.

The fiber-reinforced resin structure 100-7A has a corner portion 90 in which a communication hole H is formed, a pair of wall portions 92 extending outward from the corner portion 90 and facing each other, and a pair of wall portions from the corner portion 90. It has a pair of wall portions 93 that extend outward and face each other in a direction different from that of 92. In this modification, the pair of wall portions 92 and 93 extend so as to be perpendicular to each other. Needless to say, the angle formed by the pair of wall portions B and C is not limited to vertical, and an appropriate angle can be set.

In this fiber-reinforced resin structure 100-7A, for example, as shown in FIG. 42, by inserting the end portion of the glass plate 95 between each of the pair of wall portions 92 and 93, the edge (side surface) of the glass plate 95 is inserted. ) Can function as a glass frame (sometimes referred to as "glass plate corner", "edge seal", "glass edge projector", "corner block", "corner piece", etc.). can. In this case, after inserting the end portion of the glass plate 95 between each of the pair of wall portions 92 and 93, the glass plate 95 may be fixed to the glass frame by a fixing tool 97 such as a pin or a screw. can. The glass plate 95 may be fixed to the fiber reinforced resin structure 100-7A by adhesive or the like instead of being fixed by the fixing tool 97 described above, and the fixing method thereof is not particularly limited.

By inserting the glass plate 95 into the pair of wall portions 92, 93 in this way, the edges of the glass plate 95 are covered by the pair of wall portions 92, 93, so that the pair of wall portions 92 , 93 can protect the edges of the glass plate 95. Further, since the corner portion 90 in which the communication hole H is formed is provided between the pair of wall portions 92 and 93 as described above, even if an external force is applied to the corner portion 90 (). Even if another structure collides with the corner 90), the impact can be mitigated by the communication hole H.

Here, the fiber-reinforced resin structure 100-7A is used as a glass frame for protecting the edge of the glass plate 95, but instead of this, a pair of plate-shaped members such as a panel (not shown) is used. It may be inserted between the wall portions 92 and 93 and used as a frame member for protecting the plate members other than the glass plate 95. In short, it suffices as long as it can be inserted into the pair of wall portions 92, 93 of the fiber reinforced resin structure 100-7A, and the object to be inserted into the pair of wall portions 92, 93 is not particularly limited.

Further, in the case of the glass plate 95, the fiber-reinforced resin structure 100-7A functions as a glass frame for protecting the edge of the glass plate 95, but is not particularly necessary to protect the panel made of metal or the like. In the case of such an object, it also functions as a connecting member in which one object and another object are connected so as to be at right angles to each other. From this point of view, even in the case of the glass plate 95, as shown in FIG. 42, one glass plate 95 (the leftmost glass plate 95 in FIG. 42) and another glass plate 95 (FIG. 42). It can be said that the central glass plate 95) is connected so as to form an angle perpendicular to each other.

Here, it is preferable that the distance between the pair of wall portions 92, 93 is slightly larger than the thickness of the object to be inserted into the pair of wall portions 92, 93, and in this case, the pair of these wall portions 92, 93. The object can be easily inserted into the wall portions 92 and 93, and when the object to be inserted is inserted between the pair of wall portions 92 and 93, the object and the inner surface of the wall portions 92 and 93 rub against each other. It is possible to prevent damage to the object due to this.

On the other hand, in the fiber reinforced resin structure 100-7B, a pair of wall portions 92 that face each other and extend in a straight line, and a pair of wall portions 93 that extend in a straight line in the direction opposite to the pair of wall portions 92 and face each other. And a connecting plate 94 connecting the pair of wall portions 92 and 93. Similar to the above-mentioned fiber-reinforced resin structure 100-7B, the fiber-reinforced resin structure 100-7B also has an object such as a glass plate 95 inserted into the pair of wall portions 92 and 93, and the object is formed. It functions as a protective member for protection and a connecting member for connecting objects. Needless to say, the object may be fixed to the fiber reinforced resin structure 100-7B by the above-mentioned fixing tool 97 (see FIG. 42 (b)) or by adhesion or the like. stomach.

<Modification 8>
FIG. 43 is a perspective view showing the fiber reinforced resin structure according to the modified example 8. As shown in FIG. 43, the fiber reinforced resin structure 100-8 according to the modified example B is manufactured by the method described with reference to FIGS. 32 and 33. That is, in the present modification A, the methods described in FIGS. 32 (a) to 32 (d) and 33 (a) to 33 (d) are used in FIGS. 32 (e) and 33 (e). The aggregate 55 shown is provided. Here, in FIGS. 32 and 33, an outer peripheral body 70 having the same size is illustrated, but in the present modification 8, one outer peripheral body 70 (FIGS. 32 (e) and 33 (e)) is illustrated. Then, the outer peripheral body 70) on the left side is flush with the side surface of the outermost laminated body 50 in the aggregate 55 (the side surface of the rightmost laminated body 50 in FIGS. 32 (e) and 33 (e)). For the other outer peripheral body 70 (the outer peripheral body 70 on the right side in FIGS. 32 (e) and 33 (e)), the outer peripheral body 70 is further from the side surface of the endmost laminated body 50 in the laminated body 50. The one with a length that protrudes outward is used. Specifically, in FIGS. 32 (e) and 33 (e), the end portion of the outer peripheral body 70 slightly protrudes outward from the side surface of the endmost laminated body 50 in the aggregate 55, but this deformation In the other outer peripheral body 70 in Example 8, instead of this, a body protruding outward by a predetermined length from the side surface of the endmost laminated body 50 in the aggregate 55 is used. The length of the other outer peripheral body 70 is not limited to this, and an appropriate length can be appropriately set. In short, an appropriate length according to the number of times of folding and the like, which will be described later, can be appropriately applied. be.

As shown in FIG. 40, an external force is applied to the end portion of the other outer peripheral body 70 so as to fold a predetermined length portion from the end of the other outer peripheral body 70, and an external force is applied so as to further fold the folded portion. By repeating the addition of the above (by undergoing a folding step of folding the end of the other outer peripheral body 70 a plurality of times), the end portion of the other outer peripheral body 70 is in a state of being folded into a plurality of layers. By curing the aggregate 55 in this state, a plate-shaped fiber reinforced resin structure 100-8 is formed, and the end portion of the fiber reinforced resin structure 100-8 is in a state of being folded into a plurality of layers. The end of the other outer peripheral body 70 becomes a hardened protruding portion 70G. Then, the foam 30 is removed from the fiber-reinforced resin structure 100-8 (see FIG. 43 (a)).

In the present modification 8, as shown in FIG. 43A, the thickness of the protruding portion 70G of the plate-shaped fiber reinforced resin structure 100-8 is the central portion of the plate-shaped fiber reinforced resin structure 100-8 or the like. It is half the thickness W1 of. Further, a bolt hole BL1 for inserting the bolt BL is formed in the protruding portion 70G. The fiber-reinforced resin structure 100-8 thus formed is, for example, a building material such as a panel material (for example, a floor panel, a wall panel, a roof panel, a frame material, a partition, a door panel, a wall material of a container house, etc. It can be used as an arcade, etc.).

That is, as shown in FIG. 43A, the plate-shaped fiber-reinforced resin structure 100-8 as the panel material is in a state where the respective protrusions 70G of the fiber-reinforced resin structure 100-8 are joined. By inserting the bolt BL into the bolt hole BL1 formed in each projecting portion 70G and fastening the bolt BL with the nut NT, the respective fiber reinforced resin structures 100-8 are connected as shown in FIG. 43 (b). It is supposed to be done. In other words, it can be said that the protruding portion 70G is a connecting portion for joining the fiber reinforced resin structure 100-8. In the present modification 8, since the thickness of the protruding portion 70G is halved, when the protruding portions 70G of the respective fiber reinforced resin structures 100-8 are joined, the thickness is the same as that of the fiber reinforced resin structure 100-8. The surface of the fiber reinforced resin structure 100-8 as a panel material which matches the thickness and is connected to each other becomes flush with each other and looks good.

The thickness of the protruding portion 70G is not limited to the above-mentioned thickness, and may be, for example, 1/3 of the thickness W1. This thickness adjusts the number of times the end portion of the other outer peripheral body 70 is folded. Needless to say, it can be set as appropriate. Further, in the present modification 8, the bolt hole BL1 is formed after the aggregate 55 is cured, but instead of this, the bolt hole BL1 may be formed before the curing.

<Modification 9>
FIG. 44 is a perspective view showing the fiber reinforced resin structure according to the modified example 9. As shown in FIG. 44 (a), the fiber reinforced resin structure 100-9 according to the modified example C is formed in an airfoil shape. The cross-sectional shape of the fiber reinforced resin structure 100-9 is as shown in FIG. 44 (b). That is, the fiber-reinforced resin structure 100-9 is located on one side thereof (the left end as seen in FIG. 44), one end side is formed at a sharp angle, and the other end is formed in an arc shape. A through hole H1 having a wing-shaped cross section, a plurality of through holes H2 having a circular cross section, and a substantially semicircular cross section located on the outermost side of the fiber-reinforced resin structure 100-9. It has a through hole H3 having a shape. Further, the plurality of through holes H2 gradually increase in diameter from one end toward the other end, and gradually decrease in diameter from the middle toward the other end. It is a through hole, and these through holes H1, H2, and H3 make the fiber reinforced resin structure 10-9 have an airfoil shape.

In the fiber-reinforced resin structure 100-9, generally, the laminated bodies 50 having the shapes of the through holes H1, H2, and H3 are arranged as shown in FIG. 44 (b), and then the outer peripheral body 70 is surrounded by them. Is wound to form an aggregate 55 (not shown). It is formed by compressing and curing the entire aggregate 55 of the above, and then removing the foam 30. In the present modification 9, in order to maintain the shape of the through hole H2 having a circular cross-sectional shape, a foam having a hardness that does not deform the shape when cured is used. By doing so, it is possible to form a through hole having a desired shape. The point of "using a foam having a hardness that does not deform the shape when cured" described in the present modification 9 is not applied only to the present modification 9, and each of the above-mentioned implementations is performed. It goes without saying that it can be applied to any of the forms.

The fiber reinforced resin structure 100-9 of the present modification 9 can be used, for example, in the rear wing of a car or the like. The shape of the fiber reinforced resin structure 100-9 is not limited to that shown in FIG. 44, and can be formed into various shapes. That is, the fiber-reinforced resin structure 100-9 having a desired shape can be formed by appropriately combining the laminated bodies 50 having various shapes. Specifically, it is possible to form through holes having various shapes shown in FIG. E, which will be described next as Modifications 10-1 to 3.

<Modification 10-1>
As shown in FIG. 45 (a), the columnar laminated body 50 is arranged so as to swirl around a columnar core material made of resin or metal, and an outer peripheral body is arranged on the outer periphery of these laminated bodies 50. The 70 is wound to form an aggregate 55. When the entire aggregate 55 is compressed, as shown in FIG. 45 (b), the cross-sectional shape of the laminate 50 is deformed so as to fill the gap between the laminated bodies 50 adjacent to each other and the gap with the outer peripheral body 70. At the same time, the adjacent laminated body 50 and the outer peripheral body 70 are joined. When the aggregate 55 in this state is cured, a fiber reinforced resin structure 100-10 having a core material SZ is formed as shown in FIG. 45 (c).

<Modification 10-2>
As shown in FIG. 45 (d), after a plurality of (three in the figure) laminated bodies 50 are bundled so as to be in contact with each other, the laminated body 50 is bundled with the inner peripheral surface of the outer peripheral body 70. The outer peripheral body 70 is wound around the bundled laminated body 50 so as to be in contact with the outer peripheral surface to form an aggregate 55. When the entire assembly 55 is compressed so as to be squeezed, as shown in FIG. 45 (e), the cross-sectional shape of each of the laminated bodies 50 is such that the gaps between the laminated bodies 50 adjacent to each other and the outer peripheral body 70 are formed. Adjacent laminated bodies 50 and outer peripheral bodies 70 are joined while being deformed so as to fill the gap. When the foam 30 is removed after the aggregate 55 in this state is cured, as shown in FIG. 45 (f), a cylindrical fiber reinforced resin structure 100 having a plurality of through holes H formed inside thereof is formed. -11 is formed. In other words, the fiber reinforced resin structure 100-11 is formed as a cylindrical member having a partition partition wall (rib) KH that divides the inside of the cylinder into three parts inside the fiber reinforced resin structure 100-11. As described above, by having the partition wall KH, it is possible to improve the strength of the fiber reinforced resin structure 100-11.

<Modification 10-3>
As shown in FIG. 45 (g), the laminated body 50B having a diameter smaller than that of the laminated body 50 is arranged above and below the central laminated body 50A and the laminated body 50A as seen in the figure so as to be in contact with each other. More than these laminates 50A and B on both sides of the joint between the upper laminate 50B and the central laminate 50A and on both sides of the junction between the bottom laminate 50B and the central laminate 50A, respectively. The laminated body 50C having a smaller diameter is arranged so as to be in contact with the laminated bodies 50A and B. After that, the outer peripheral body 70 is wound around these to form an aggregate 55, and when the entire aggregate 55 is compressed, the cross-sectional shapes of the respective laminated bodies 50A to C become as shown in FIG. 45 (h). The adjacent laminated bodies 50A to C and the outer peripheral body 70 are joined while being deformed so as to fill the gaps between the laminated bodies 50A to C adjacent to each other and the outer peripheral body 70. When the foam 30 is removed after the aggregate 55 in this state is cured, as shown in FIG. 45 (i), the cross-sectional shape in which a plurality of through holes H having different sizes are formed is an elliptical shape. Cylindrical fiber reinforced resin structure 100-12 is formed. In other words, the fiber-reinforced resin structure 100-12 is formed as a cylindrical member having a partition wall KH for partitioning the inside thereof, and having the partition wall KH improves the strength as described above. Will be possible. In this way, by using the laminated bodies 50 having different diameters, it is possible to form a plurality of through-holes KH having different cross-sectional areas, and the size and shape of the cross-sectional areas of the through-holes KH are different from each other. It can be set as appropriate by adjusting the size and shape of 50. In the fiber-reinforced resin structure 100-11 shown in FIG. 45, in order to improve the shape retention of the laminated body 50 (foamed material 30), the laminated body 50 (s) may be singular or plural. Needless to say, the curing step may be carried out in a state where the shrink tape is fitted in the mold or the shrink tape is arranged around the laminated body 50. The same applies to the fiber-reinforced resin structure 100-5 shown in FIGS. 36 to 38, the fiber-reinforced resin structure 100-9 shown in FIG. 44, and the like, and the same applies to any of the above embodiments as necessary. It goes without saying that it is possible.

By appropriately combining and carrying out the steps described above, it is possible to manufacture various fiber-reinforced resin structures having a complicated shape.

<Use of fiber reinforced plastic structure>
Although various fiber-reinforced resin structures have been described above, the fiber-reinforced resin structures described above can be applied to various structures. Next, the uses of the fiber-reinforced resin structure described in the present specification are sequentially listed. It should be noted that the uses of the fiber reinforced resin structures listed below are merely examples, and it goes without saying that fiber reinforced resin structures can be appropriately used in addition to those listed below.

<Pipe material>
For example, the fiber-reinforced resin structure 100-1 such as the columnar, square, and hexagonal columns shown in FIGS. 14 to 16 can be used as a pipe material. The fiber-reinforced resin structure as the pipe material is not limited to the fiber-reinforced resin structure 100-1 having the above-mentioned cross-sectional shape, and for example, the cross-sectional shape may be triangular or trapezoidal, and FIG. 23. , 26-28, and 45 may have through holes having a plurality of cross-sectional shapes having different shapes and sizes from each other, and may have a partition partition partition for partitioning these through holes. Further, it may be a curved fiber reinforced resin structure shown in FIGS. 17, 18 and 34, or a bent fiber reinforced resin structure shown in FIGS. 19, 39 and 40, and may be described above depending on the intended use and specifications. It is possible to use the above-described embodiment and other fiber-reinforced structures having an appropriate shape. The fiber-reinforced resin structure as this type of pipe material may be provided with a flange portion or a handle portion.

<Panel material>
For example, the fiber-reinforced resin structure shown in FIGS. 20 to 22, 29, 30, 32, 33, and 43 can be used as a panel material, and any of the fiber-reinforced resin structures can be linearly or bent. It is also possible to connect them so that they have a shape, a circular shape, or the like. In this case, for example, the fiber-reinforced resin structure shown in FIG. 42 may be used to connect the fiber-reinforced resin structures formed in a plate shape, or as shown in FIG. 43, either of them may be connected. By providing the protruding portion (connecting portion) 70G shown in FIG. 43 on the fiber reinforced resin structure of the above, the fiber reinforced resin structure may be connected.

<Bicycle-related>
The fiber-reinforced resin structure of the above-described embodiment can be used for, for example, a handlebar, a frame, or the like of a bicycle.

<Motorcycle related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, for motorcycle handles, frames, swing arms, cowlings, wings, manifolds, wheels, various pipes through which gas or liquid passes, and the like.

<Automotive related>
The fiber-reinforced resin structure of the above-described embodiment is, for example, an automobile reinforcement (pillar, side sill, seat structure, etc.), wing, bonnet, floor panel (bulk head, etc.), roof panel (outer panel, door beam, etc.). Etc.), bucket seats, tower bars, intake manifolds, under panels, wheels, various pipes through which gas and liquid pass, etc.

<Bus related>
The fiber-reinforced resin structure of the above-described embodiment is, for example, a bath reinforcement (pillar, side sill, seat structure, etc.), wing, bonnet, floor panel (bulk head, etc.), roof panel (outer panel, door beam, etc.). Etc.), bucket seats, tower bars, intake manifolds, under panels, wheels, various pipes through which gas and liquid pass, luggage racks, handrails (various pipes as handrails), etc.

<Truck related>
The fiber-reinforced resin structure of the above-described embodiment is, for example, a truck reinforcement (pillar, side sill, seat structure, etc.), wing, bonnet, floor panel (bulk head, etc.), roof panel (outer panel, door beam, etc.). Etc.), bucket seats, tower bars, intake manifolds, under panels, wheels, various pipes through which gas and liquid pass, aerodynamic panels, loading platform panels, maintenance panels (seat structures, pillars, rudder frames, etc.), luggage containers, cold storage It can be used for car containers, camping car shells, intake manifolds for tow trailers, high-altitude work baskets, side guards (wheels), etc.

<Container related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, for an outer panel, a floor panel, a frame, or the like in a luggage container, a container house, a dome house, or the like.

<Train-related>
The fiber-reinforced resin structure of the above-described embodiment can be used for, for example, a door panel of a train body, an interior parting (seat structure), a luggage rack, a handrail (various pipes as a handrail), a platform door, or the like.

<Aviation-related>
The fiber reinforced resin structure of the above embodiment passes, for example, an aircraft seat structure, an intake manifold, a propeller, a blade, a wing, a helicopter rotor, a turbine part, a parting, a door panel, a bulkhead, a gas or a liquid. It can be used for various pipes and the like.

<Space related>
The fiber-reinforced resin structure of the above-described embodiment is used, for example, for a seat structure of a spacecraft (rocket or the like), an intake manifold, wings, blades, turbine parts, a bulkhead, various pipes through which gas or liquid passes, or the like. Can be done.

<Ship-related>
The fiber-reinforced resin structure of the above-described embodiment is, for example, a ship seat structure, a hull, a deck (floor panel), a rudder, a keel, a mast, a boom, a propeller, a blade, a bulkhead, an oar, a paddle, and the like. It can be used for intake manifolds, various pipes through which gas and liquid pass, and the like.

<Architecture-related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, for floor panels, wall panels, roof panels, frame materials, partitions, container houses, door panels, arcades, and the like of buildings.

<Civil engineering / infrastructure / other related>
The fiber-reinforced resin structure of the above-described embodiment is, for example, a pipe such as a water pipe, a gate bar, a fence, a safety fence, a water tank, a lid, a parabolic antenna, a blade, a support, an elevator basket, a case, a home door, an insulating work table, and the like. It can be used for insulated ladders, tanks, shelters, gratings (appropriate shapes such as honeycombs can be applied), play equipment, artificial fishing reefs, breeding reef underwater fences, gates, benches, various parts of musical instruments, etc.

<Industrial equipment related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, for various parts of industrial robots, rollers, work tables, turbine parts, and the like.

<Medical device related>
The fiber-reinforced resin structure of the above-described embodiment passes, for example, a medical device head, an X-ray fluoroscopic stretcher, an X-ray fluoroscopic operating table, wheelchair parts, crutches, medical robot parts, an infectious disease isolation shelter, gas or liquid. It can be used for various pipes and the like.

<Sports related>
It can be used for baseball bats, tennis rackets (frames, etc.), table tennis rackets, ice hockey sticks, packs, golf drivers, shaft parts such as irons, fishing rods, etc.

100-1 to 100-12 Fiber reinforced resin structure 10 Fiber body 15 Reinforcing member 20 Resin (cured resin)
25 Resin (uncured resin)
30 Foam 50 Laminated 55 Aggregate 60 Curved part 70 Outer circumference A Pillar shaft B Cylindrical shaft C Hole shaft H Communication hole

Claims (8)

A columnar first foam, a fiber covering at least a part of the side surface of the first foam, and a columnar second foam close to the first foam via the fiber. An aggregate having the above, in which the fiber body is impregnated with an uncured thermosetting resin, is prepared, and the aggregate is curved so that the column axis of the foam is curved. , Including a step of thermosetting the thermosetting resin contained in the aggregate.
Manufacture of a fiber-reinforced resin structure characterized in that the 25% compressive load measured according to JIS K6400-2: 2012 of the first foam and the second foam is 1 to 2000 kPa. Method (with a foam that can be secondarily foamed as the first foam; with a coating body having a bleed hole from which the uncured thermosetting resin and gas can be exuded and covering the aggregate; Except for the method using. In the step, before the thermosetting resin contained in the aggregate is thermally cured, an external force is applied to the aggregate to deform the cross-sectional shapes of the first foam and the second foam. The manufacturing method according to claim 1, further comprising a deformation process. The production method according to claim 1 or 2, wherein in the aggregate, the fibrous body is wound around the side surface portion of the first foam for one or more turns. The aggregate includes the first foam, the fibrous body that winds around the side surface portion of the first foam one or more times, the second foam, and the side surface of the second foam. The fiber body having a portion wound around one or more turns, and the fiber body winding the side surface portion of the first foam one turn or more, and the side surface portion of the first foam body. The manufacturing method according to claim 3, wherein the fiber body that is wound one or more turns is in contact with the fiber body. The production method according to any one of claims 1 to 4, wherein the first foam and the second foam are olefin resin foams. The production method according to any one of claims 1 to 5, wherein the first foam and the second foam have a density of 1 to 800 kg / m ^3. The manufacturing method according to claim 2, wherein the deformation process is carried out in a reduced pressure atmosphere. After the thermosetting step, the aggregate is cooled to shrink the first foam and the second foam.
Claims 1 to include a removal step of removing the first foam and the second foam contained in the aggregate after the step of shrinking the first foam and the second foam. The manufacturing method according to any one of 7.

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