JP2022061350A - Manufacturing method for fiber-reinforced molded body - Google Patents

Abstract

To provide a manufacturing method for a fiber-reinforced molded body that can suppress a division of each part when manufacturing the fiber-reinforced molded body having a complex three-dimensional shape.SOLUTION: A manufacturing method for a fiber-reinforced molded body having a core material containing reinforcing fibers and a matrix resin with embedded the core material includes: a fixing step R1 to fix a fiber assembly 14 as the core material along a peripheral surface 201 of a medium mold 20; and a taking-out step R2 to take out the fiber-reinforced molded body by dismantling, deforming or reducing the medium mold 20, after the fiber assembly 14 is embedded in the matrix resin. The medium mold 20 can have a recess 203 on the peripheral surface 201 that accommodates a thickness of the fiber assembly 14. The peripheral surface 201 can have a protrusion 205 that engages a through hole 143 in the fiber assembly 14.SELECTED DRAWING: Figure 1

Description

The present invention relates to a method for producing a fiber-reinforced molded product. More specifically, the present invention relates to a method for producing a fiber-reinforced molded product having a core material containing reinforcing fibers and a matrix resin in which the core material is embedded.

Conventionally, as a method for producing a fiber-reinforced molded product, an RTM (Resin Transfer Molding) method, a VaRTM (Vacum Assisted Resin Transfer Molding) method, and the like are known (see Patent Document 1). In these, a woven fabric containing reinforcing fibers is placed in a molding cavity, an uncured resin is injected into the cavity, the woven fabric is impregnated with the uncured resin, and then the uncured resin is cured to form the fibers. It is a method for obtaining a reinforced molded product, and among the above, the VaRTM method is different from the RTM method in that it involves an operation of degassing the inside of the cavity in order to assist the impregnation of the uncured resin.

Japanese Unexamined Patent Publication No. 2015-186884

Although the RTM method and the VaRTM method as described above have the advantage of being suitable for mass production, there is a problem that it is difficult to manufacture a molded body having a three-dimensional three-dimensional shape, that is, a complicated three-dimensional shape. be. That is, since the woven fabric containing the reinforcing fibers originally has a flat two-dimensional shape, it is difficult to shape it into a complicated three-dimensional shape by molding. Therefore, Patent Document 1 discloses a method of using the core material 7 in the RTM method. Although this method is excellent in a fiber-reinforced molded body having a linear shape in the longitudinal direction of the core material 7, it is difficult to form the core material 7 in a branched shape, for example.

For this reason, a fiber-reinforced molded body having a complicated shape is often realized by integrating a plurality of separately manufactured parts. However, in order to integrate the parts manufactured separately, there is a problem that the structure tends to be complicated in order to obtain the strength of the joint portion. Further, in a fiber-reinforced molded body such as a skeleton structure formed by combining reinforcing structures having different shapes, the strength is lowered at the joint portion, which causes a problem that it is difficult to obtain a well-balanced reinforcing structure.

The present invention has been made in view of the above circumstances, and is a method for producing a fiber-reinforced molded product that can suppress the production of each part separately when producing a fiber-reinforced molded product having a complicated three-dimensional shape. The purpose is to provide.

That is, in order to solve the above problem, the present invention is shown below.
[1] The method for producing a fiber-reinforced molded product of the present invention is a method for producing a fiber-reinforced molded product having a core material containing reinforcing fibers and a matrix resin in which the core material is embedded.
A fixing step of fixing the fiber aggregate to be the core material along the peripheral surface of a medium size (core, etc.)
The gist is to include a step of burying the fixed fiber aggregate in the matrix resin, and then disassembling, deforming, or reducing the volume of the medium mold to take out the fiber-reinforced molded product.
[2] In the method for producing a fiber-reinforced molded body of the present invention, the fiber aggregate has a fiber bundle in which continuous fibers including the reinforcing fibers are bundled, and a base layer on which the fiber bundle is sewn.
The fiber bundles can have strips sewn onto the base layer so as to line up in multiple rows.
[3] In the method for producing a fiber-reinforced molded product of the present invention, the fixing step can include a step of winding the strip-shaped portion around the peripheral surface of the medium size.
[4] In the method for producing a fiber-reinforced molded product of the present invention, the medium-sized mold can have a recess on the peripheral surface for accommodating the thickness of the fiber aggregate.
[5] In the method for producing a fiber-reinforced molded body of the present invention, the medium-sized mold can have a convex portion on the peripheral surface that engages with a through hole provided in the fiber aggregate.
[6] In the method for manufacturing a fiber-reinforced molded product of the present invention, in the fixing step, a locking tool is driven from the outer surface side of the fiber aggregate along the peripheral surface of the medium mold toward the medium mold. It can be carried out.
[7] In the method for producing a fiber-reinforced molded product of the present invention, the medium mold is formed of a material that can be disassembled.
The material can be selected from a binder obtained by binding the granular material with a binder and a solidified product in which the granular material is aggregated.
[8] In the method for producing a fiber-reinforced molded product of the present invention, the medium-sized mold is formed of a material that can be heated and melted.
The material can be a thermoplastic composition.
[9] In the method for producing a fiber-reinforced molded product of the present invention, the fiber-reinforced molded product has a plurality of reinforcing holes for forming a reinforcing structure, including _two adjacent reinforcing holes H1 and _a reinforcing hole H2. Have,
The opening surface of the reinforcing hole H ₁ and the opening surface of the reinforcing hole H ₂ can belong to different planes.

According to the method for manufacturing a fiber-reinforced molded body of the present invention, when manufacturing a fiber-reinforced molded body having a complicated three-dimensional shape, it is possible to suppress the production of each part separately.
More specifically, while enjoying the merit of being suitable for mass production caused by the RTM method and the VaRTM method, a more complicated fiber-reinforced molded body (for example, a skeleton structure having a reinforcing structure, etc.) as compared with the conventional method. Can be manufactured integrally without being manufactured separately. Therefore, the fiber-reinforced molded product can be efficiently manufactured by suppressing the generation of connection points. Further, since the generation of the connection portion can be suppressed, it is possible to obtain a fiber-reinforced molded product in which the complicated shape and the increase in the weight required for the connection are suppressed. Then, it is possible to realize a smoother shape and obtain a fiber-reinforced molded product having a uniform strength balance. Further, conventionally, it is possible to obtain an opening reinforcing structure that can be realized by obtaining a molded body without holes and then making holes at necessary locations without performing a hole making process with a low man-hour. Can be done.

The present invention will be further described in the following detailed description with reference to the plurality of references mentioned with reference to non-limiting examples of typical embodiments according to the invention, although similar reference numerals are in the drawings. Similar parts are shown through several figures.
It is explanatory drawing explaining an example of the manufacturing method of the fiber-reinforced molded article of this invention. It is explanatory drawing explaining an example of a fiber aggregate. It is explanatory drawing explaining the sewing mode of the sewing type fiber aggregate. It is explanatory drawing explaining the sewing mode of the sewing type fiber aggregate. It is explanatory drawing explaining the fixing process. It is explanatory drawing explaining an example of the fiber reinforced molded article. It is explanatory drawing explaining an example of the fiber reinforced molded article. It is explanatory drawing explaining an example of the fiber reinforced molded article. It is explanatory drawing explaining another example of a fiber reinforced molded article.

The matters shown here are for illustrative purposes and embodiments of the present invention, and are the most effective and effortless explanations for understanding the principles and conceptual features of the present invention. It is stated for the purpose of providing what seems to be. In this regard, it is not intended to show structural details of the invention beyond a certain degree necessary for a fundamental understanding of the invention, and some embodiments of the invention are provided by description in conjunction with the drawings. It is intended to clarify to those skilled in the art how it is actually realized.
In FIG. 2B, the sewing thread 175 is shown, but in the other drawings, the sewing thread 175 is not shown because it is complicated. Further, the figure (a) in FIG. 1 in the drawings is referred to as FIG. 1 (a) or FIG. 1a in the specification.

The method for producing a fiber-reinforced molded product of the present invention is a fiber-reinforced molded product having a core material (13) containing the reinforcing fibers (12) and a matrix resin (15) in which the core material (13) is embedded. It is the manufacturing method of 1) (see FIGS. 1 and 9).
This manufacturing method includes a fixing step (R1) and a taking-out step (R2).
Of these, the fixing step (R1) is a step of fixing the fiber aggregate (14) to be the core material (13) along the peripheral surface (201) of the medium size (20).
Further, in the extraction step (R2), after the fixed fiber aggregate (14) is embedded in the matrix resin (15), the medium size (20) is disassembled, deformed or reduced in volume, and the fiber reinforced molded body (1) is formed. Is the process of taking out.

[1] Fixing Step The fixing step R1 is a step of fixing the fiber aggregate 14 to be the core material 13 along the peripheral surface 201 of the medium-sized 20 (see FIGS. 1a, 1b, and 1c).
(1) Core material and fiber aggregate The core material 13 is a portion of the fiber reinforced molded body 1 that reinforces the matrix resin 15, and is formed from an aggregate of fibers. That is, the matrix resin 15 is fixed (cured, solidified, etc.) in a state of being impregnated into the core material 13 to form a fiber-reinforced molded body 1 having high strength as a whole. Therefore, as compared with the resin member made of only the matrix resin 15, the addition of the core material 13 in the resin makes the fiber-reinforced molded body 1 have enhanced mechanical strength.
In the present specification, the aggregate of fibers forming a part of the fiber reinforced molded body 1 is referred to as a core material 13, and the core material 13 before the fiber reinforced molded body 1 is completed is referred to as a fiber aggregate 14. As described above, the core material 13 and the fiber aggregate 14 are basically the same. Therefore, the fiber aggregate 14 will be described below, but the core material 13 is also the same.

The form of the fiber assembly 14 is not limited. For example, it can be a non-woven fabric, a woven fabric, a knitted fabric, a fiber bundle (tow), or a composite form thereof.
Among the above, the fiber bundle 17 is a form in which continuous fibers 171 are bundled, and the reinforcing fibers 12 are included as a part or all of the continuous fibers 171. The fiber bundle 17 may be formed only from the reinforcing fibers 12, or may contain fibers 172 other than the reinforcing fibers.
Further, among the above, the composite form is a form in which two or more of non-woven fabric, woven fabric, knitted fabric and fiber bundle are combined. Specifically, a form in which the fiber bundle is fixed to the base layer can be mentioned. The fixing means is not limited, and for example, one or more of means such as sewing, adhesion, and fusion can be adopted. That is, the fiber aggregate 14 has a fiber bundle 17 and a base layer 18 on which the fiber bundle 17 is sewn, and the fiber bundle 17 can be sewn onto the base layer 18 or the like. The fiber bundle 17 may be sewn on only one surface of the base layer 18, or may be sewn on both sides of the base layer 18.

In the sewn-type fiber aggregate 14, one or more of non-woven fabrics, woven fabrics, knitted fabrics, and the like can be adopted as the base layer. That is, for example, a form in which the fiber bundle 17 is sewn on the base layer 18 made of woven fabric and a form in which the fiber bundle 17 is sewn on the base layer 18 made of non-woven fabric can be mentioned (see FIG. 2).
As described above, the fiber aggregate 14 in the form in which the fiber bundle 17 is sewn on the base layer 18 (hereinafter, the fiber aggregate 14 in this form is also referred to as a “sewn type fiber aggregate”) (FIGS. 2 and 4). (See), the fiber bundle 17 is sewn by the sewing thread 175. Any fiber of sewing thread 175 may be used. That is, a fiber similar to the reinforcing fiber described later may be used, or a fiber other than the reinforcing fiber may be used.

Further, among the above, the base layer 18 in the sewn-type fiber aggregate 14 is preferably a woven fabric. In the case of a woven fabric, the fiber bundle 17 is easily sewn, the restraint on the sewing thread 175 at the time of sewing is high, the base layer 18 is excellent in flexibility, and further, the matrix resin (unsolidified) is impregnated. It has advantages such as being easy to make. When the base layer 18 is a woven fabric, any fiber may be used as the fiber constituting the woven fabric. That is, a fiber similar to the reinforcing fiber described later may be used, or a fiber other than the reinforcing fiber may be used.

Further, in the sewn-type fiber aggregate 14, the shape of the base layer 18 usually determines the overall outline of the fiber aggregate 14. For example, when the base layer 18 has the band-shaped portion 141, the fiber assembly 14 can also have the strip-shaped portion 141 (see FIGS. 1, 2, and 5).
In the sewing type fiber aggregate 14, as described above, the fiber bundle 17 can have a region (sewn region) sewn to the base layer 18, but in addition, the fiber bundle 17 is attached to the base layer 18. It is possible to have a region (non-sewn region) which is not sewn and is arranged so as to be separated from the base layer 18.

As described above, when sewing is selected as a means for fixing the fiber bundle 17 to the base layer 18, the degree of restraint of the fiber bundle 17 can be freely controlled by the tension of the sewing thread 175. Therefore, while firmly fixing the fiber bundle 17 to the base layer 18, the mobility of the fiber bundle 17 (movability to the base layer 18 and / or the mobility between the fiber bundles 17) is controlled by weaving the fiber bundle. More can be secured compared to woven fabrics and the like. As a result, for example, the flexibility of the fiber assembly 14 in the sewn region can be kept high.

Further, in the sewing region, the fiber bundle 17 may be sewn in any manner, and may be arranged in a plane so as to be arranged in a plurality of rows with respect to the base layer 18. More specifically, a plurality of fiber bundles 17 can be aligned and sewn (see FIG. 3a) so as to fill a predetermined surface. Further, the fiber bundle 17 can be folded and sewn so as to fill a predetermined surface. More specifically, one fiber bundle 17 can be folded and arranged in a bellows shape (see FIG. 3b). Further, it can be folded and arranged (see FIG. 3c) by winding it in a spiral shape (circular spiral, polygonal spiral, etc.). As these sewing modes, only one type may be used, and two or more types may be used in combination. Further, as a matter of course, sewing modes other than these can be used.

Further, the fiber bundle 17 may be sewn by laying it in one layer with respect to the base layer 18 (see FIG. 4a), or by laying it in multiple layers so as to have two or more layers. (See FIGS. 4b and 4c). Further, the front and back surfaces of the base layer 18 may be spread and sewn. Further, when two or more layers are laid and sewn, or when the front and back surfaces are laid and sewn, the arrangement direction of the fiber bundles 17 constituting one layer and the arrangement of the fiber bundles 17 constituting the other adjacent layers are arranged. The directions may be arranged in parallel, but they may be arranged so as to be crossed (see FIGS. 4b and 4c) so that the arrangement directions are different. In this case, the crossing angle can be 90 degrees or less (0 degrees <θ ≦ 90 degrees).

Further, as described above, the core material 13 contains the reinforcing fibers 12 (see FIG. 2b). That is, the fiber aggregate 14 also contains the reinforcing fibers 12. The fiber assembly 14 may contain the reinforcing fibers 12 in any portion. That is, for example, the sewing thread 175 may contain the reinforcing fiber 12, or the base layer 18 may contain the reinforcing fiber 12, but it is particularly preferable that the fiber bundle 17 contains the reinforcing fiber 12.

The reinforcing fiber 12 is a fiber having excellent mechanical strength as compared with a normal fiber, and for example, a fiber having a tensile strength of 7 cN / dtex or more (usually 50 cN / dtex) according to JIS L1015 is preferable.
The reinforcing fiber 12 may be a fiber made of an inorganic material, a fiber made of an organic material, or a fiber in which these are used in combination. Examples of the inorganic material fiber include carbon fiber (PAN-based carbon fiber, pitch-based carbon fiber), glass fiber, metal fiber and the like. Only one of these may be used, or two or more thereof may be used in combination. As organic material fibers, aromatic polyamide resin fibers (para-type aramid: product name "Kevlar", product name "Twaron", product name "Technora", etc., meta-type aramid: product name "Nomex", product name " Cornex ", etc.), Polybenzazole resin fiber (polyparaphenylene benzobisoxazole fiber, trade name" Zylon ", etc.), aromatic polyester resin fiber (trade name" Vectran ", etc.), high-strength polyethylene resin fiber (trade name) "Dyneema") and the like. Only one of these may be used, or two or more thereof may be used in combination.

Further, the fiber form of the reinforcing fiber 12 is not limited, and may be a span yarn, a filament yarn, or a combined form thereof, but among these, the filament yarn may be used. preferable. Further, the reinforcing fiber 12 may be a monofilament, a multifilament, or a combination thereof.

The fiber aggregate 14 may consist of all of the constituent fibers 12 or may partially include the reinforcing fibers 12. The composition ratio of the reinforcing fibers 12 is not limited, but the content ratio of the reinforcing fibers 12 can be 50% by mass or more (may be 100% by mass) with respect to 100% by mass of all the constituent fibers forming the fiber aggregate 14. It can be 75% by mass or more, and can be 90% by mass or more. That is, when the fiber aggregate 14 contains other fibers other than the reinforcing fibers, the other fibers can be less than 50% by mass (1% by mass or more) when the total constituent fibers are 100% by mass, 25. It can be less than 10% by weight and less than 10% by weight.

The constituent materials of the fibers other than the reinforcing fibers 12 are not limited, and fibers other than the above-mentioned reinforcing fibers can be used. Specifically, various resin fibers, vegetable fibers, and the like can be used, and among them, as the resin constituting the resin fiber, a polyamide (aliphatic polyamide, etc.) and a polyester (a constituent unit derived from an aromatic dicarboxylic acid) are included. Polyester etc.) can be used. Further, as the plant fiber, cotton fiber, hemp fiber and the like can be used.
Further, the fiber form of the other fiber is not limited, and may be a span yarn, a filament yarn, or a combined form thereof.

Further, the fiber bundle 17 may be bundled in any way. A plurality of continuous fibers may be simply aligned, or a plurality of continuous fibers may be bound using a thread (thread for bundling), and an adhesive, an adhesive, and heat may be used. The continuous fibers may be bound and bundled with each other via another agent such as a fusing agent, and may be further bundled by another method.

The number of continuous fibers constituting one fiber bundle 17 is not limited, and may be, for example, 3000 or more. When the number of continuous fibers constituting the fiber bundle 17 is 3000 or more, it is possible to exhibit excellent strength as the fiber aggregate 14 and the core material 13 while being flexible. The number is not limited, but can be, for example, 3000 or more and 100,000 or less, further 5000 or more and 70,000 or less, further 7,000 or more and 50,000 or less, and further 10,000. The number can be 30,000 or more and 30,000 or less.

Further, in consideration of workability when handling the fiber bundle 17, a fiber bundle (thick bundle) having a large number of continuous fibers constituting one fiber bundle 17 can be used. In this case, the number of continuous fibers constituting one fiber bundle 17 can be, for example, 30,000 or more, further 40,000 or more, and further 60,000 or more. On the other hand, the number of continuous fibers constituting one fiber bundle 17 can be, for example, 1500,000 or less, and further, 1,000,000 or less.

(2) Medium-sized The medium-sized 20 is a member for fixing the fiber aggregate 14 along the peripheral surface 201, and is a member that is removed after the matrix resin 15 is solidified (FIGS. 1, 5 and 5). See FIG. 6).
Further, the medium size 20 is a member that gives a three-dimensional shape to the fiber aggregate 14 as a result. Normally, the fiber aggregate 14 has a planar shape, and by fixing it along the peripheral surface 201 of the medium-sized 20, it has a three-dimensional shape. Further, the medium mold 20 may be a mold independent of the outer mold 21 (for example, upper mold, lower mold, main mold, etc.) like the core, or may be projected as a part of the outer mold 21. It may be a mold.

Further, in the present invention, the medium-sized 20 has a complicated three-dimensional shape, so that the effect of the present invention can be obtained more remarkably. Since the medium-sized 20 may be formed in any way and various three-dimensional modeling methods can be used, for example, utilization of 3D printing is included in one of the methods. The molding obtained by 3D printing may be used as it is as the medium mold 20, or after the obtained molding is reworked, the molding is performed again to form a female mold, and then the female mold becomes the medium mold 20. It is also possible to add a material to obtain a medium-sized 20 as a male type.
The configuration of the medium size 20 and the like will be described in detail in the description of the extraction step R2.

Any method may be used when fixing the fiber assembly 14 to the medium size 20, but for example, the medium size 20 has a recess 203 (for example, a recess 203 containing a part or all of the thickness of the fiber assembly 14). (See FIG. 1a) can be provided on the peripheral surface 201. By having the recess 203, the fiber aggregate 14 can be fitted and fixed in the recess 203. Further, the recess 203 can exert a function of suppressing the movement of the fiber aggregate 14 due to the impregnation pressure of the resin when the fiber aggregate 14 is impregnated with the uncured resin or the like.

Further, the medium size 20 can have a convex portion 205 (see FIG. 1a) that engages with the through hole 143 (see FIG. 1b) provided in the fiber assembly 14 on the peripheral surface 201. By having the convex portion 205, the through hole 143 provided in the fiber aggregate 14 can be fitted into the convex portion 205 and fixed. Further, the convex portion 205 exerts a function of suppressing the movement of the fiber aggregate 14 due to the impregnation pressure of the resin when the fiber aggregate 14 is impregnated with the uncured resin (uncured resin, molten resin, etc.). can.

Further, it can be fixed by driving the locking tool 207 (see FIG. 5b) toward the medium size 20 from the outer surface side of the fiber aggregate 14 along the peripheral surface 201 of the medium size 20. Specifically, (1) a locking tool having a U-shape, a U-shape, an L-shape, or the like, and (2) a locking having a wide locking portion such as a thumbtack, a nail, a screw, or the like. Various locking tools 207 such as tools can be driven into the medium size 20 to fix the fiber aggregate 14 to the peripheral surface 201. As the above (1), for example, a device called a stapler, a stapler, a paper binding device, or the like can be used. These locking tools 207 can also exert a function of suppressing the movement of the fiber aggregate 14 due to the impregnation pressure of the resin when the fiber aggregate 14 is impregnated with the unsolidified resin.

Further, in the fixing step R1, the fiber aggregate 14 is fixed along the peripheral surface 201 of the medium size 20. By aligning the fibers, the fiber aggregate 14 and the peripheral surface 201 are in close contact with each other, and when the fiber aggregate 14 is impregnated with the unsolidified resin, the fiber aggregate 14 is moved by the impregnation pressure of the resin. Can be suppressed.
Further, when the fiber aggregate 14 has the strip-shaped portion 141, it is preferable that the strip-shaped portion 141 is wound around the peripheral surface 201 of the medium-sized 20 in the fixing step R1. By winding using the band-shaped portion 141, it is possible to design a shape with a high degree of freedom. That is, when the fiber aggregate 14 having a planar shape is wound around the medium size 20, the fiber aggregate 14 can be made three-dimensional only in a tubular shape. On the other hand, when the strip-shaped fiber aggregate 14 is wound around the medium-sized 20, a spiral shape, a branched shape, or the like can be formed in addition to the tubular shape, so that the skeleton structure can be easily formed. For example, when the medium size 20 has a cubic shape, the medium size 20 has six squares as its peripheral surface 201. When the planar fiber aggregate 14 is used, the fiber aggregate 14 cannot be wound so as to pass through all of these six surfaces, but in the strip-shaped fiber aggregate 14, the six surfaces are hung by a ribbon. It is possible to form a skeletal shape that passes through all of the above.

[2] Extraction step The extraction step R2 is a step of embedding the fixed fiber aggregate 14 in the matrix resin 15 and then disassembling, deforming or reducing the volume of the medium-sized 20 to take out the fiber-reinforced molded body 1. 1d, FIG. 1e, FIG. 1f, FIG. 1g).
(1) Matrix resin 15
The matrix resin 15 is a resin in which the core material 13 is embedded. More specifically, it is a resin that is impregnated and fixed (cured when it is a curable resin and solidified when it is a thermoplastic resin) so as to spread inside the core material 13. As the impregnation method and the fixing method of the matrix resin 15, various conventionally known methods can be used.

The type of the matrix resin 15 is not limited, and various resins can be used. That is, a curable resin may be used, a thermoplastic resin may be used, or these may be used in combination. Examples of the curable resin include epoxy resin, polyester resin (curable polyester resin), urethane resin and the like. On the other hand, examples of the thermoplastic resin include a polyolefin resin, an acrylic resin, a polyester resin (thermoplastic polyester resin), and a polyamide resin.

For burying in the matrix resin 15, for example, after the fixing step R1, an outer mold arranging step of covering the peripheral surface 201 of the medium mold 20 to which the fiber aggregate 14 is fixed with the outer mold 21, and the outer mold 21 and the medium mold 20 The gap is filled with the unsolidified resin and the fiber aggregate 14 is impregnated with the resin, and the fiber aggregate 14 is solidified to obtain the matrix resin 15. can.
Of the above, the outer mold 21 used in the outer mold arrangement process may be any type, and a metal mold, a resin mold, etc. can be used, and a bag-shaped material (resin bag, etc.) is outside. It can be used as a mold 21.

(2) Taking out the fiber-reinforced molded body The fiber-reinforced molded body 1 is taken out by disassembling, deforming or reducing the volume of the medium-sized 20. That is, the medium size 20 is formed of a material that can be disassembled, deformed, or reduced in volume.
Among the above, examples of the material (material) that can be disassembled include a binder obtained by binding granules (including powder) with a binder, and a solidified product in which granules (including powder) are aggregated. Be done. Specifically, examples of the former include sand molds and compressed wood. The latter includes gypsum. As described above, the concave portion 203, the convex portion 205, and the like can be formed on the medium mold 20 by a method such as engraving and / or cutting. It is also possible to drive the locking tool 207. Further, the dismantling of these medium sized 20 can be performed by a method such as pressurization, application of impact, cutting, and grinding. As these dismantling methods, only one kind may be used, or two or more kinds may be used in combination.

Among the above, examples of the material that can be melted by heating (thing), the material that can be deformed by heating (thing), and the material that can be reduced in volume by heating (thing) include a thermoplastic composition. Further, examples thereof include a binder in which granules are bound by a thermoplastic composition, a binder in which powder is bound by a thermoplastic composition, and the like.
Examples of the above-mentioned thermoplastic composition include liquids that become solid in a temperature range below the melting point, such as a thermoplastic resin, wax, wax, and a low melting point metal (tin, tin alloy, etc.). When the thermoplastic composition is used as the material of the medium-sized 20 and the thermosetting resin is used as the matrix resin 15, the thermoplastic composition is determined from the curing start temperature ( _TA ) of the thermosetting resin. It is preferable to use a combination in which the melting point ( _TB ) of the above is 25 ° C. or higher. This temperature is further preferably TB-TA (° C.) ≥30, further preferably _{TB - TA} (° C.) _≥40 , and particularly preferably _TB - _TA (° C.) ≥50.

The melting point ( _TB ) is preferably 50 ° C. or higher. In this case, the concave portion 203, the convex portion 205, etc. can be easily formed on the medium mold 20 by a method such as engraving and / or cutting (mold molding can also be performed). It is also suitable from the viewpoint of driving the locking tool 207. The melting point ( _TB ) is more preferably 60 ° C. or higher, and even more preferably 70 ° C. or higher. However, the melting point ( _TB ) is usually 200 ° C. or lower.
In the taking-out step, the medium-sized 20 made of the thermoplastic composition may be disassembled if it can be disassembled in the same manner as described above, but it is more preferable to reduce or deform the medium-sized 20 by heating. That is, it is softened by heating and then deformed by pressure to be removed from the fiber reinforced molded body 1, or melted by heating to be removed from the fiber reinforced molded body 1, melted by heating, or heated. If it can be eliminated by burning, the volume may be reduced by burning.

When a thermoplastic resin is used as the material of the medium size 20, for example, polyolefin can be used. Polyolefin has an advantage that it can be easily used as a low melting point material. Also, polyamide can be used. Polyamide has an advantage that it is easy to use from the viewpoint of low melt viscosity.

[3] Other steps In this method, other steps can be provided in addition to the above steps. That is, as described above, the outer mold disposing step can be provided after the fixing step R1 and before the taking-out step R2. Further, a fiber aggregate forming step for obtaining the fiber aggregate 14 can be provided before the fixing step R1. Further, for example, the extraction step R2 can include a filling step of filling the gap between the medium mold 20 and the outer mold 21 with the unsolidified resin, a solidification step of solidifying the unsolidified resin to obtain the matrix resin 15, and the like. These steps may include only one type, or may include two or more types.

[4] Fiber Reinforced Mold The fiber reinforced molded body 1 obtained by this method has a core material 13 and a matrix resin 15 in which the core material 13 is embedded (see FIGS. 6 to 9). In the fiber reinforced molded product 1, the matrix resin 15 is a resin in which the core material 13 is embedded. More specifically, it is a resin that is impregnated and fixed (cured when it is a curable resin and solidified when it is a thermoplastic resin) so as to spread inside the core material 13. As the impregnation method and the fixing method of the matrix resin 15, various conventionally known methods can be used.

The type of the matrix resin 15 is not limited, and various resins can be used. That is, a curable resin may be used, a thermoplastic resin may be used, or these may be used in combination. Examples of the curable resin include epoxy resin, polyester resin (curable polyester resin), urethane resin and the like. On the other hand, examples of the thermoplastic resin include a polyolefin resin, an acrylic resin, a polyester resin (thermoplastic polyester resin), and a polyamide resin.

The dimensions such as the shape, size, and thickness of the fiber-reinforced molded body ₁ manufactured by this method are not particularly limited, but for example, a reinforcing structure including _two adjacent reinforcing holes H1 and reinforcing holes H2 is formed. It is suitable for manufacturing a fiber-reinforced molded product 1 having a plurality of reinforcing holes H and having a shape in which the opening surface of the reinforcing hole H ₁ and the opening surface of the reinforcing hole H ₂ belong to different planes. (See FIGS. 6 to 8).

Specifically, for example, it is difficult to uniformly form the structural portion constituting the reinforcing hole H ₁ and the reinforcing hole H ₂ by using an openable upper / lower mold. In this respect, since the medium-sized mold 20 is used in this method, the shaped shape can be obtained separately from the upper and lower molds. Therefore, it is possible to obtain particularly excellent formability in the above-mentioned shape. Therefore, when manufacturing the fiber-reinforced molded product 1 having a complicated three-dimensional shape as described above, it is possible to prevent each part from being manufactured separately. As a result, the fiber-reinforced molded body 1 can be integrally manufactured, so that the fiber-reinforced molded body 1 can be efficiently manufactured by suppressing the generation of connection points. Further, since the generation of the connection portion can be suppressed, it is possible to obtain a fiber-reinforced molded product in which the complicated shape and the increase in the weight required for the connection are suppressed. Then, a fiber-reinforced molded product 1 having a smoother shape and a uniform strength balance can be obtained. Further, conventionally, it is possible to obtain an opening reinforcing structure that can be realized by obtaining a molded body without holes and then making holes at necessary locations without performing a hole making process with a low man-hour. Can be done.

The reinforcing hole is a hole that forms a reinforcing structure such as a truss structure, a rigid frame structure, or an arch structure in a three-dimensional model. That is, a reinforced structure can be formed in the three-dimensional model by providing holes in the three-dimensional model which is thin as a whole after the fact. A complicated force load is generated on a three-dimensional model without holes, but by providing reinforcing holes, it is possible to clarify the location where the force is applied, so that higher structural strength can be obtained.
Conventionally, such a reinforcing hole requires a post-hole making step as described above, but in this method, the fiber aggregate 14 is not cut and is reinforced by using the fiber aggregate 14. Reinforcing holes can be provided in advance without degrading the characteristics. That is, a better reinforcing hole can be obtained without requiring a hole making step. In particular, it is possible to collectively obtain two or more reinforcing holes whose opening surfaces belong to different planes.

Similarly, in the present method, a fiber-reinforced molded body 1 having an endless and three-dimensionally continuous band-shaped portion, a fiber-reinforced molded body 1 having at least one of a ring-shaped portion, an annular portion and an opening, and a curve. It is also excellent in manufacturing a fiber-reinforced molded body 1 having a strip-shaped portion having a twisted surface, a fiber-reinforced molded body 1 having a strip-shaped branched portion branched in three sterically different directions (see FIG. 5), and the like. In particular, in the case of using a fiber-reinforced molded body 1 having a strip-shaped branch portion having a first branch portion 141a and a second branch portion 141b, each branch portion is a different peripheral surface 201 (first surface) of the medium-sized 20. It is excellent in manufacturing when it is fixed to 201a and the second surface 201b).

Further, the use of the fiber reinforced molded body 1 obtained by this method is not particularly limited, but for example, exterior materials, interior materials, structural materials (body shell, vehicle body, aircraft fuselage) such as automobiles, railroad vehicles, ships and airplanes. And can be used as a shock absorber or the like. Among these, automobile supplies include automobile exterior materials, automobile interior materials, automobile structural materials, automobile shock absorbers, engine room interior parts, and the like.
Specifically, bumpers, spoilers, cowlings, front grilles, garnishes, bonnets, trunk lids, cowl louvers, fender panels, rocker moldings, door panels, roof panels, instrument panels, center clusters, door trims, quarter trims, roof flying, Pillar garnish, deck trim, tonoboard, package tray, dashboard, console box, kicking plate, switch base, seat backboard, seat frame, armrest, sun visor, intake manifold, engine head cover, engine undercover, oil filter housing, for automobiles Examples include housings for electronic parts (ECUs, TV monitors, etc.), energy absorbers such as air filter boxes and rush boxes, and body shell components such as front-end modules.

Further, for example, interior materials such as buildings and furniture, exterior materials, structural materials and the like can be mentioned. That is, it can be a door surface material, a door structural material, a surface material of various furniture (desk, chair, shelf, chest of drawers, etc.), a structural material, a unit bath, a septic tank, and the like. In addition, it can also be used as a packaging body, an accommodating body (tray or the like), a protective member, a partition member, or the like. Further, it can be a molded body such as a housing and a structure of a home electric appliance (thin TV, refrigerator, washing machine, vacuum cleaner, mobile phone, portable game machine, notebook computer, etc.).

Hereinafter, the present invention will be specifically described with reference to Examples.
(1) Materials used Base layer 18: Plant fiber cloth (woven cloth woven from spun cotton fibers)
Fiber bundle 17: Fiber bundle (12K multifilament) with 12,000 carbon fibers aligned
Sewing thread 175: Resin fiber (multifilament using polyester single fiber)

(2) Preparation of Fiber Aggregation 14 The fiber bundle 17 is sewn with a sewing thread 175 at a pitch of 1.7 mm only at the necessary part of the base layer 18, and the unnecessary part of the base layer 18 is cut off to form a band as a whole (meandering shape). The fiber aggregate 14 was obtained.

(3) Preparation of Fiber Reinforced Molded Body 1 The fiber aggregate 14 obtained up to (2) above is three-dimensionalized by being wound around a medium-sized 20 (see FIG. 6) made of wax (melting point 101 ° C.). The shape was given.
After that, the medium-sized 20 having the fiber aggregate 14 fixed therein is put into a resin bag, and while degassing the inside of the resin bag, an uncured epoxy resin (manufactured by Nagase ChemteX Corporation, product number "XNR6830") to be a matrix resin is applied. I put it in. Next, by heating the medium mold 20, the uncured epoxy resin is impregnated into the fiber aggregate 14 while the wax is thermally expanded, and then the uncured epoxy resin is cured to form the fiber reinforced molded body 1 (FIGS. 6 to 8). See).

The obtained fiber-reinforced molded product 1 could be integrally manufactured without dividing each part while having a complicated skeleton shape. Therefore, the fiber-reinforced molded product 1 could be efficiently manufactured by suppressing the generation of connection points. Further, since the generation of the connection portion can be suppressed, the fiber-reinforced molded product 1 in which the complicated shape and the increase in weight required for the connection are suppressed can be obtained. Then, a fiber-reinforced molded product 1 having a smoother shape and a uniform strength balance could be obtained. Further, conventionally, it is possible to obtain an opening reinforcing structure that can be realized by obtaining a molded body without holes and then making holes at necessary locations without performing a hole making process with a low man-hour. Was done.

The above examples are for illustration purposes only and are not to be construed as limiting the invention. Although the present invention has been described with reference to examples of typical embodiments, the wording used in the description and illustration of the invention is understood to be descriptive and exemplary rather than limited wording. As detailed here, modifications may be made within the scope of the appended claims without departing from the scope or spirit of the invention in its form. Although specific structures, materials and examples have been referred to herein in detail of the invention, it is not intended to limit the invention to the disclosures set forth herein, but rather the invention is claimed in the attachment. It shall cover all functionally equivalent structures, methods and uses within the scope of.

1; Fiber reinforced molded body,
12; Reinforcing fiber, 13; Core material, 14; Fiber aggregate,
141; strip, 141a; first branch, 141b; second branch, 143; through hole,
15; Matrix resin,
17; fiber bundle, 171; continuous fiber, 172; fiber other than reinforcing fiber,
175; sewing thread,
18; base layer,
20; Medium size,
201; peripheral surface, 201a; first surface, 201b; second surface,
203; concave, 205; convex, 207; locking tool,
21; Outer mold, 215; Degassing, 216; Filling with unsolidified resin,
H, H ₁ , H ₂ ; Reinforcing holes,
R1; fixing process,
R2; Extraction process.

Claims (9)

A method for manufacturing a fiber-reinforced molded product having a core material containing reinforcing fibers and a matrix resin in which the core material is embedded.
A fixing step of fixing the fiber aggregate to be the core material along the peripheral surface of the medium size,
The fiber-reinforced molded product is characterized by comprising a step of embedding the fixed fiber aggregate in the matrix resin, then disassembling, deforming or reducing the volume of the medium-sized mold to take out the fiber-reinforced molded product. Manufacturing method. The fiber aggregate has a fiber bundle in which continuous fibers including the reinforcing fibers are bundled, and a base layer on which the fiber bundle is sewn.
The method for producing a fiber-reinforced molded product according to claim 1, wherein the fiber bundle has a strip-shaped portion sewn on the base layer so as to be lined up in a plurality of rows. The method for manufacturing a fiber-reinforced molded product according to claim 2, wherein the fixing step includes a step of winding the strip-shaped portion around the peripheral surface of the medium size. The method for producing a fiber-reinforced molded product according to any one of claims 1 to 3, wherein the medium size has a recess on the peripheral surface for accommodating the thickness of the fiber aggregate. The method for producing a fiber-reinforced molded product according to any one of claims 1 to 4, wherein the medium mold has a convex portion on the peripheral surface that engages with a through hole provided in the fiber aggregate. The fiber according to any one of claims 1 to 5, wherein the fixing step is performed by driving a locking tool from the outer surface side of the fiber aggregate along the peripheral surface of the medium size toward the medium size. A method for manufacturing a reinforced molded product. The medium size is made of dismantleable material and is
The production of the fiber-reinforced molded product according to any one of claims 1 to 6, wherein the material is selected from a binder obtained by binding granules with a binder and a solidified product in which granules are aggregated. Method. The medium size is made of a material that can be heated and melted.
The method for producing a fiber-reinforced molded product according to any one of claims 1 to 6, wherein the material is a thermoplastic composition. The fiber-reinforced molded body has a plurality of reinforcing holes for forming a reinforcing structure, including two adjacent reinforcing holes H ₁ and a reinforcing hole H ₂ .
The method for producing a fiber-reinforced molded product according to any one of claims 1 to 8, wherein the opening surface of the reinforcing hole H ₁ and the opening surface of the reinforcing hole H ₂ belong to different planes.

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