JP4923546B2 - Method for producing fiber-reinforced resin molded body - Google Patents

Description

The present invention relates to a matrix resin for forming the shape precursor RTM (Resin Transfer Molding) manufacturing how the fiber-reinforced resin molded body obtained by impregnating the method. The molding precursor of the present invention facilitates the finishing of a fiber-reinforced resin molded body composed of it and a resin.

  Fiber reinforced resin (FRP), in particular carbon fiber reinforced resin (CFRP), is used in various fields as a composite material having light weight and high mechanical properties. As one method of molding an FRP molded body, a reinforcing fiber base material is placed in a molding cavity of a molding die, and after closing the mold, a matrix resin having fluidity is injected into the die and cured by heating or cooling. The RTM method is known. In this method, the inside of the mold is evacuated as necessary.

  The RTM method is one of the optimum methods of FRP molding method that effectively expresses lightweight and high mechanical properties that are characteristic of FRP, especially CFRP, and efficiently molds a molded body having a complicated shape. .

  However, removal of unnecessary parts such as strong burrs generated at the outer edge of the obtained molded body, which is known as one of post-processing after molding, requires water-digit processing, NC machining, and the like. This has led to an increase in processing man-hours and processes, which has been a factor in increasing costs. In particular, in CFRP, the reinforcing fibers present in the burrs generated at the outer edge of the molded body are hard, and as a result, they are frequently replaced due to the limit of water-digit processing capability and wear of tools for NC machining. This is one of the processes I want to do.

  In order to omit such deburring work that leads to an increase in cost, various proposals for shaping reinforcing fiber base materials have been made in an attempt to obtain a reinforcing fiber base shape (near net shape) as close as possible to the shape to be molded. ing.

  For example, before placing the fiber reinforced base material in the mold, it is proposed to shape the reinforcing fiber base material to a certain shape in advance by sandwiching the reinforcing fiber base material between the upper and lower forming dies. (Patent Document 1).

  In addition, it is proposed that a desired shape of the reinforcing fiber substrate can be maintained more reliably by applying a thermoplastic resin material to the laminated reinforcing fiber substrate and heat-forming with a shaping mold. (Patent Document 2).

Furthermore, a reference line is placed on the mold, markings along the weaving yarn are applied to the position of the reinforcing fiber base that matches the reference line, and the positioning is accurately performed when the reinforcing fiber base is placed on the mold. (Patent Document 3).
JP 2003-305719 A JP 2003-80607 A JP 2003-127157 A

  However, in the conventional method as described above, if water-digit processing or NC machining is to be omitted, a predetermined process is performed before molding using resin so that burrs including reinforcing fibers are not generated. Prepare a reinforcing fiber base (molding precursor) shaped smaller than the product shape, and prevent the reinforcing fiber base from protruding from the cavity when the reinforcing fiber base is placed in the molding cavity. Is required.

  For example, as shown in FIG. 1, a fiber reinforced resin molded body 101 used for a thin plate-shaped molded body (thickness: 0.5 to 3 mm) such as a motorcycle cowl is shaped to be smaller than the cowl shape. When the reinforced fiber base material 102 is molded by the RTM method, as shown in FIG. 2, the resin rich portion 103 where the fiber reinforced base material 102 does not exist is generated at the outer edge ends E1 and E2. In such a cowl, when an impact such as a collision is applied, the occurrence of local defects at the outer edge ends E1 and E2 where the resin-rich portion 103 exists due to stress concentration often becomes a problem.

  In order to have a predetermined strength up to the outer edge of the resin molded body 101 reinforced with the reinforcing fiber base 102, the reinforcing fiber base 102 has the edge of the outer edge ends E1 and E2 of the resin molded body 101. It is necessary to be surely spread. Therefore, in order to spread the reinforcing fiber base material 102 to the outer edge of the resin molded body, as shown in FIG. 3, the molding precursor 100 made of the reinforcing fiber base material 102 is shaped before being placed in the molding lower mold FM. We studied a method to precisely match the shape in advance using a mold. However, since the size of the woven fabric made of the reinforcing fiber used as the reinforcing fiber base material 102 is greatly changed, it is difficult to obtain the required dimensional accuracy (for example, about ± 2 mm). In addition, while the fabric is in the lower mold, it is possible to cut the end of the fabric with scissors or the like to make precise adjustments, but at the same time the work time becomes extremely long, and at the same time the quality difference depends on the skill level of the operator. The problem that appears.

The problem of the present invention is related to the outer edge ends E1 and E2 of the fiber reinforced resin molded body, which is a problem of the conventional RTM method, and is a cause of cost increase due to water-digit processing or NC machining for deburring after molding. is to provide a manufacturing how the fiber-reinforced resin moldings of the RTM method using Elaborate molded precursor to eliminate such as strength reduction factors due to the generation of reinforcing fibers 102a are not spread resin-rich portion 103.

Each aspect of the manufacturing how the fiber-reinforced resin molded article of the present invention for solving the above problem is shown in the following (1) to (2) term.
( 1 ) A step of placing the molding precursor in the molding cavity of the molding die, a step of closing the molding die in which the molding precursor is disposed, and heating and pressurizing in the molding cavity of the closed molding die. A step of injecting a resin, a step of solidifying the resin injected into the molding cavity, a step of opening the mold after the resin is solidified, and a molding from the opened mold A method for producing a fiber reinforced resin molded article by RTM comprising a step of taking out a fiber reinforced resin molded article,
(A) As the molding precursor, the molding precursor according to any one of ( i ) to ( iv ) is used,
(B) At least a part of the outer periphery of the molding cavity is provided with a film gate through which the injected resin flows,
(C) In the step of disposing the molding precursor in a molding cavity of the molding die, the molding precursor is a molding cavity of the molding die so that the second substrate is located at least at a part of the film gate. Placed in
(D) A method for producing a fiber-reinforced resin molded article by RTM in which the second base material is present in at least a part of the burr portion of the resin formed by the film gate.
(I) A molding precursor comprising a main body part and a burr forming part extending continuously outward from an edge of the main body part, wherein the main body part includes a first base material comprising a plurality of reinforcing fibers; And a second substrate made of a plurality of fibers laminated on the first substrate at the outer edge of the main body, and the burr forming portion extends outward from the edge of the main body. A molding precursor formed of the second base material, wherein gaps between the plurality of fibers form a flow path of molding resin.
(Ii) The molding precursor according to (i), wherein the first base material is disposed so as to cover at least a part of the second base material located at the outer edge portion.
(Iii) The molding according to any one of (i) and (ii), wherein the first base material is disposed so as to sandwich at least a part of the second base material located at the outer edge portion. precursor.
(Iv) A surface layer forming base material that forms a surface layer portion of the first base material extends outward from an edge of the main body portion and covers the second base material positioned in the burr forming portion. The molding precursor according to any one of (i) to (iii), which is arranged.
(2) on the outside of the film gate, runner communicating with the film gate is provided, the second base material of the shaped precursor to said (1) which is arranged in a state of reaching the position of the runner The manufacturing method of the fiber reinforced resin molding of description.

According to the manufacturing how the fiber-reinforced resin moldings by R TM method of the present invention, since the high degree of alignment accuracy to mold the molded precursor is not required, it is easy to work in the molding process, the inter-operator There is no difference in product quality. Since the burr portion after molding is a thin resin burr including a second base material having a lower strength than the main body portion, precision and expensive machining such as water jet machining and NC machining is performed to remove the burr portion. There is no need, and the burr can be removed with a simple tool. The molded body molded in the molding cavity is a fiber-reinforced resin molded body of good quality in which a desired strength is ensured because the first and second substrates are reliably arranged up to the outer edge. The manufacturing cost of the fiber reinforced resin molded product is low. A fiber-reinforced resin molded product can be easily and stably produced.

  Embodiments of the present invention will be described below with reference to the drawings.

  In the present invention, the fiber reinforced resin molded product refers to a molded product made of a resin (matrix resin) reinforced with reinforced fibers.

  Examples of the reinforcing fibers include inorganic fibers such as carbon fibers, glass fibers, and metal fibers, or organic fibers such as aramid fibers, polyethylene fibers, and polyamide fibers.

  Examples of the matrix resin include thermosetting resins such as epoxy resins, unsaturated polyester resins, vinyl ester resins, phenol resins, and further, polyamide resins, polyolefin resins, dicyclopentadiene resins, polyurethane resins, polypropylene resins. A thermoplastic resin such as can also be used.

  As the matrix resin, a thermosetting resin having a low viscosity and easily impregnating reinforcing fibers, or a monomer for RIM (Reaction Injection Molding) that forms a thermoplastic resin is preferable. From the viewpoint that the occurrence of cracks can be reduced and the occurrence of cracks can be suppressed, an epoxy resin, or a modified epoxy resin, a nylon resin, a dicyclopentadiene resin or the like blended with a thermoplastic resin or a rubber component is preferable.

  The molding precursor of the present invention includes a main body portion and a burr forming portion. A main-body part is a part which forms the main structure of a molded object. The burr forming part is a part where a burr is formed at a joint part of the mold when the mold is closed.

  A base material including reinforcing fibers that are usually used is mainly applied to the main body portion as the first base material. A material having better machinability than the first base material is mainly applied as the second base material from the burr forming part to the outer edge part of the main body part adjacent thereto.

  By setting it as such a structure, a base material spreads to the edge part of a molded object, and a molded object with favorable cutting property of a burr | flash or an edge part can be obtained. Therefore, machining by water jet machining for removing burrs or NC machining can be avoided.

  When the molding precursor is applied to the RTM method, the first base material and the second base material may be prepared as a molding precursor shaped in advance using a shaping mold, or It is also possible to arrange the first base material and the second base material in the mold and form the molding precursor in the mold at the time of molding.

  The 1st base material used by this invention points out the base material of the state which aggregated many reinforcement fibers. Examples of the reinforcing fibers include inorganic fibers such as the above-described carbon fibers, glass fibers, and metal fibers, or organic fibers such as aramid fibers, polyethylene fibers, and polyamide fibers. Examples of the form of the substrate include woven fabric (plain weave, twill weave, satin weave), non-woven fabric (chopped fiber, mat), braid, knit material and the like.

  An insert material or component may be incorporated in the base material, and the insert material or component is appropriately selected depending on the application. Examples of insert materials or parts include metal plates such as steel and aluminum, metal columns, metal bolts, nuts, hinge metals such as hinges, aluminum honeycomb cores, polyurethane, polystyrene, polyimide, vinyl chloride, phenol, Examples thereof include foam materials, rubber materials, and wood materials made of polymer materials such as acrylic. Principally, insert parts for the purpose of joining, such as the effect of nails and the setting of screws, insert parts for the purpose of weight reduction with a hollow structure, insert parts for the purpose of damping vibration, etc. are preferably used.

  The second base material is preferably made of a material or a material structure having a deformability greater than that of the first base material and having a low strength and / or Young's modulus. For example, when carbon fiber is used as the material of the first base material, the second base material is formed of flame resistant yarn, glass fiber, metal fiber, aramid fiber, polyethylene fiber, polyamide fiber, or the like. The second base material is composed of a material or a material structure having a strength of the material or the material structure of the first base material and / or a strength of 1/4 to 3/4 of the Young's modulus and / or a Young's modulus. More preferably.

  Among the same materials, it is also possible to use a high strength grade as the material for the first substrate and a relatively low strength grade as the material for the second substrate. Moreover, even if it is the same physical property as a material, it may be based on the material structure that the strength as FRP is low because of its low basis weight.

The form of the second substrate is a form having continuous voids, and has a low basis weight from the viewpoint of, for example, nonwoven fabric, mats, or resin impregnation, for example, preferably 10 to 1500 g / m. ² , More preferably, a woven fabric, a knitted fabric, a braid, a unidirectional fiber bundle having a basis weight of 10 to 200 g / m ² can be used.

The second base material is preferably a combination of the aforementioned materials and forms, for example, reinforcing fibers such as carbon fiber, flame resistant yarn, glass fiber, metal fiber, aramid fiber, polyethylene fiber, polyamide fiber, Non-woven fabrics, mats, and fiber constituent materials processed into woven fabrics, knitted fabrics, braided fabrics, unidirectional fiber bundles, and the like having a low basis weight. As another embodiment, a foam (foam material) or a rubbery material made of a polymer material such as polyurethane, polystyrene, polyimide, vinyl chloride, phenol, or acrylic can be used. In the foam, a hard core having an apparent density of 0.05 to 1.0 g / cm ³ is desirable for the formation of the second base material located at the outer edge of the main body.

  The molding die used in the RTM method is, for example, a molding die that combines an upper die and a lower die, and the upper die is attached to a die lifting device (press device). A molding precursor is disposed on the lower mold. In some cases, the molding precursor is prepared in advance by a shaping mold different from the molding mold for the purpose of shaping the reinforcing fiber base into a product shape so that the molding precursor is easily accommodated in the molding mold.

  Examples of the material of the mold include FRP, cast steel, structural carbon steel, aluminum alloy, zinc alloy, nickel electroforming, and copper electroforming. For mass production, structural carbon steel is suitable in terms of rigidity, heat resistance, and workability.

  FIG. 4 is an explanatory view of an example of a molding system used when the fiber-reinforced resin molded body of one embodiment of the present invention is manufactured by the RTM method. In FIG. 4, a molding die 2 is a molding die and includes an upper die 2a and a lower die 2b. The upper mold 2 a is attached to the mold lifting device 1. The mold lifting device 1 has a hydraulic unit 9 including a hydraulic pump 10 and a hydraulic cylinder 11, and the vertical operation and pressurization operation of the upper mold 2 a are controlled by the hydraulic unit 9.

  A resin injection path 13 connected to the resin injection port 8a and a resin discharge path 14 connected to the resin discharge port 8b are connected to the mold 2. The resin injection path 13 is connected to the resin injection port 8a via the resin injection valve 22a, and the resin discharge path 14 is connected to the resin discharge port 8b via the resin discharge valve 22b. The opening / closing operation and operation timing of the resin injection valve 22a and the resin discharge valve 22b are performed based on commands from the control device 22c.

A resin injection device 3 is connected to the resin injection path 13. The resin injection device 3 has a main agent tank 5 in which the main agent is accommodated and a curing agent tank 6 in which the curing agent is accommodated. Each tank has a heating mechanism and a vacuum defoaming function by the vacuum pump 24. . When the resin is injected into the mold 2, the resin is supplied from each tank toward the resin injection path 13 by the pressurizing device 23. It is preferable to secure quantitativeness by using a syringe pump as the pressurizing device 23 and simultaneously extruding the syringe. The main agent and the curing agent are mixed in the mixing unit 4 to become a molding resin and reach the resin injection path 13. The resin discharge path 14 is provided with a resin trap 15 in order to prevent the resin from flowing into the vacuum pump 7a.



The number and position of the resin injection ports 8a vary depending on the shape and size of the mold 2 and the number of molded articles formed simultaneously in one mold, but it is preferable that the number of the resin injection ports 8a is as small as possible. This is to prevent the injection operation from becoming complicated due to an increase in the number of locations where the injection flow path 13 from the resin injection device 3 is connected to the resin injection port 8a. It is preferable that the material of the resin injection flow path 13 be taken into consideration of ensuring a sufficient flow rate and compatibility with the resin (temperature, solvent resistance, pressure resistance). The tube has a diameter of 5 to 30 mm, preferably has a pressure resistance of 1.0 MPa or more to withstand the injection pressure of the resin, and has a heat resistance of 100 ° C. or more to withstand the temperature when the resin is cured. A tube made of fluororesin such as “Teflon (registered trademark)” having a thickness of about 2 mm is preferable. However, in addition to “Teflon (registered trademark)”, relatively inexpensive plastic tubes such as polyethylene and nylon, and metal tubes such as steel and aluminum are also applicable. The number and positions of the resin outlets 8b vary depending on the shape and dimensions of the molding die, the number of molded bodies that are simultaneously molded in one mold, and the like, but it is preferable that the number of resin outlets 8b is as small as possible. The resin discharge port 8b is preferably installed at a higher position in the direction in which the gas is more likely to float than the resin injection port 8a so that the gas remaining in the mold can easily escape. As for the material of the resin discharge passage 14, it is preferable to take into consideration the securing of a sufficient flow rate and compatibility with the resin (temperature, solvent resistance, pressure resistance) in the same manner as the resin injection passage 13. The discharge path 14 may be a metal tube such as steel or aluminum, or a plastic tube such as polyethylene, nylon, or “Teflon (registered trademark)”, but “Teflon (registered) having a diameter of 5 to 10 mm and a thickness of 1 to 2 mm. (Trademark) "tube is more preferable from the viewpoint of workability.

  The resin injection valve 22a and the resin discharge valve 22b installed in the middle of the resin injection path 13 and the resin discharge path 14 at the time of resin injection can be opened and closed by the operator directly sandwiching the flow path with a vise grip or the like. What can change an aperture is preferable. For example, as shown in FIG. 5, a vise grip 21 can be provided in the middle of the resin injection passage 13 and the discharge passage 14 connected to the upper die 16 side of the molding die composed of the upper die 16 and the lower die 17. .

  FIG. 15 shows details of the resin injection port 8a of the mold 2 in FIG. In FIG. 15, the sealing material 20 is disposed around the entire cavity 26 of the mold 2, and the cavity 26 is substantially sealed by closing the upper mold 2 a and the lower mold 2 b. The resin injected from the resin injection path 13 is stored in the runner 19. The length of the runner 19 is the same as the width of the cavity 26, and the runner 19 and the cavity 26 are connected by a thin film gate 18.

  When the runner 19 is filled with resin, the resin is injected into the cavity 26 through the film gate 18. By making the resin injection port 8 a such a structure, the resin injected from one point is injected all at once over the width of the cavity 26. As a result, the resin is efficiently impregnated into the reinforcing fiber base housed in the cavity 26.

  Although not shown, the resin discharge port 8b has the same structure as the resin injection port 8a.

  The pressurization of the resin is performed by the pressurizer 23. By using a quantitative pump such as a syringe pump for the pressurizer 23, not only the pressurization of the resin but also the meterability of the resin can be obtained. The resin injection pressure Pi is preferably in the range of 0.1 to 1.0 MPa.

  Finally, the resin is completely impregnated into the base material (molding precursor) 59 in the mold 2 and reaches the resin discharge path 14. Then, the resin discharge path 14 is closed, and after a while, the resin injection path 13. Is closed and resin injection is completed. The mold 2 is heated by, for example, a mold temperature controller 25, whereby the resin is cured.

  In the conventional method, after the reinforcing fiber base (corresponding to the first base in the present invention) matched to the shape of the mold 2 is placed in the mold, the mold is closed. At this time, a part of the reinforcing fiber base is sandwiched between the molds. Next, in a state where the resin injection valve 22a is closed, the inside of the mold is evacuated by the vacuum pump 7a through the resin discharge path 14 leading to the opened resin discharge valve 22b. The resin pressure Pm in the mold is reduced, and then the resin injection valve 22a is opened, and the resin is supplied from the resin injection path 13 into the mold. Until the resin is completely filled in the mold, the resin is injected under pressure to form a molded body.

  However, since the molded body molded in this way is molded in a state in which a part of the reinforcing fiber base material is sandwiched between molds, a burr including reinforcing fibers is formed. In order to make this molded body into a product, it is necessary to remove burrs including reinforcing fibers. For this reason, in the case of a thin plate-like molded body (thickness: about 0.5 to 3 mm) such as a motorcycle cowl, and a molded body that requires high accuracy, a predetermined amount is obtained by water jet machining or NC machining. A process of finishing to a shape has been required.

  Further, as a method of avoiding such machining, the molding precursor is made smaller than the product shape and does not protrude from the predetermined product shape. That is, in molding, a part of the reinforcing fiber base is interposed between the molds. It is necessary not to be pinched, but as described above, there is a problem that an outer edge end portion that is not filled with a reinforcing fiber base material is generated, and due to the nature of the outer edge end portion, when receiving an impact due to an external force such as a collision The defect at the outer edge was a problem.

  In order to eliminate the problems of the prior art, in the molding precursor of the present invention, a base material containing reinforcing fibers that are usually used is mainly used as the first base material in the main body, and burr formation is performed. A base material made of a material having better machinability than the first base material is mainly used as the second base material at the outer edge portion of the main body part adjacent to the part.

  The molding precursor of this invention consists of a fiber structure containing a main-body part and a burr | flash formation part. The main body part is the part that forms the main structure of the fiber reinforced resin molding, and the burr forming part is where the burrs that are formed in the mold joints other than the cavity part of the molding die are located when the molding die is closed Point to the part to be. In the post-processing step of the molded body, the burrs are removed, and a fiber-reinforced resin molded body composed of the main body is obtained.

  Next, an example of a method in which the first base material and the second base material are arranged in the mold and the molding precursor is prepared in the mold will be described.

  First, a first base material that is slightly smaller than the product shape (cavity portion of the mold) to be molded by the RTM method is prepared. The size of the first substrate at this time is preferably about 3 to 80 mm smaller than the product shape. If it is larger than this size, high positioning accuracy is required for the placement on the shaping mold, and the time and labor spent for shaping the molding precursor become large. If it is smaller than this size, the portion occupied by the first substrate in the molded body becomes small, and there is a possibility that sufficient strength cannot be obtained in the molded body. The size of the first substrate is more preferably 5 to 20 mm smaller than the molded shape. Thus, since there is room in the size setting range, the dimensional accuracy of the first base material can be set wider than the conventional allowable range, and the base material can be easily arranged.

  Next, in order to compensate for the gap between the first base material and the mold shape, the second base material is arranged so as to protrude outward from the product shape. In the second base material, a part of the second base material overlaps with a part of the first base material in order to prevent a gap in which the first or second base material is not present in the mold. Arrange as follows. At this time, it is preferable from the viewpoint of the strength of the molded body that at least a part of the second substrate is arranged so as to have a sandwich structure sandwiched between the reinforcing fiber substrates.

  The protruding length of the second substrate from the product shape to the outside is preferably more than 1 mm and less than 50 mm from the end of the cavity. If it protrudes by 50 mm or more, the amount of the second base material sandwiched between the molds is too large, and it is difficult to clamp the mold, or it takes time to bring the inside of the mold to a reduced pressure state of 0.01 MPa or less. When the protrusion length is 1 mm or less, high accuracy is required for positioning when the molding precursor is placed in the mold, and the work takes time. A more preferable protruding length is more than 1 mm and not more than 15 mm.

The basis weight of the second base material is preferably 10 to 1500 g / m ^{2 although} it depends on the thickness of the molded shape. If the basis weight of the second base material exceeds 1500 g / m ² , the amount of the second base material sandwiched between the molds is too large, making it difficult to clamp the mold, or reducing the pressure in the mold to 0.01 MPa or less. It takes time to do. If the basis weight of the second base material is less than 10 g / m ² , the voids in the mold cannot be filled, and a resin-rich part may be formed in the molded body.

  A part of the first base material may protrude from the molded shape to the outside while covering the second base material. By projecting the surface layer forming base material of the first base material located on the surface side of the molding precursor to the burr forming portion while covering the second base material, the second base material is exposed to the surface of the compact. A molded product with good appearance can be obtained. In this case, the surface layer forming base material of the first base material is composed of 1 to 3 ply fiber sheets.

The basis weight of the surface layer forming substrate is preferably 100 to 1000 g / m ² . If the basis weight of the surface layer-forming substrate is less than 100 g / m ² , the second substrate may not be covered and may be exposed to the surface. When the basis weight of the surface layer forming substrate exceeds 1000 g / m ² , when the molded body is molded, a strong burr is formed, and deburring processing becomes difficult. A more preferable surface area of the surface layer forming base material for improving the surface appearance of the molded body and easily performing the deburring process is 150 to 350 g / m ² .

  The application location of the 2nd base material said to this invention is not restricted to the outer edge edge part of a shaping | molding precursor. For example, a sharply thinned part, a part where the wall thickness suddenly increases, a sheet-like base material such as a woven fabric cannot be formed smoothly, and rounded corners and cuts that are difficult to fill with reinforcing fiber base materials The second base material can be applied in a similar manner to a place where a uniform fiber volume content Vf cannot be obtained with only the reinforcing fiber base material, such as reinforcement of a three-dimensional curved surface that is more than necessary.

Next, an example in which the present invention is applied to the production of a motorcycle cowl will be described with reference to FIGS. FIG. 7 shows a perspective view of a cowl 51 made of the manufactured FRP molded body. The cowl 51 has a second non-woven fabric made of a material having a lower strength than the reinforcing fibers of the first base material around the first base material 52 made of a laminated sheet of the fabric shown in FIG. The FRP part 54 and the FRP part 55 are integrally formed by placing the base material 53, injecting and impregnating a matrix resin therein, and integrally molding the FRP part 54 and the FRP part 55.
Since burrs generated during FRP molding do not include a reinforcing fiber substrate, they can be easily removed by hand, and the molded body is an FRP structure in which reinforcing fibers are arranged in every corner of the outer shape. Therefore, excellent strength and rigidity can be expressed throughout, and the possibility of “chips” can be eliminated.

Next, more specific examples and comparative examples of the present invention will be shown.

  The base materials used in Examples and Comparative Examples are as follows.

Base material B1:
Carbon fiber fabric-Toray Industries, Inc. CO6343B
Woven structure: plain weave, fabric basis weight: 198 g / m ² , reinforcing fiber: T300B-3K, elastic modulus: 230 GPa, strength: 3530 MPa, fineness: 198 tex, number of filaments: 3000 Base material B2:
Carbon fiber fabric-BT70-30 manufactured by Toray Industries, Inc.
Woven structure: plain weave, fabric basis weight: 317 g / m ² , reinforcing fiber: T700SC-12K, elastic modulus: 230 GPa, strength: 4900 MPa, fineness: 800 tex, number of filaments: 12,000 base material B3:
Flame resistant yarn non-woven fabric-"Lastan (registered trademark)" TOP8300 manufactured by Asahi Kasei Corporation
Fabric form: Felt-like non-woven fabric, basis weight: 300 g / m ²
Base material B4:
Glass fiber surface mat-MF30P100BS6 manufactured by Nittobo Co., Ltd.
Fabric form: continuous fiber nonwoven fabric, basis weight: 30 g / m ²
Base material B5:
Carbon short fiber mat-"Torayca (registered trademark)" T700SC manufactured by Toray Industries, Inc.
Elastic modulus: 230 GPa, strength: 4900 MPa, fineness: 1650 tex, short fiber length: maximum 2 inches, basis weight: 80 g / m ²
Base material B6:
Continuous strand mat-manufactured by Nippon Sheet Glass Co., Ltd. Fabric form: glass continuous fiber nonwoven fabric, basis weight: 450 g / m ²
Base material B7:
Flameproof yarn nonwoven fabric-carbon felt 50CF manufactured by TRUSCO NAKAYAMA
Fabric form: Felt-like non-woven fabric, basis weight: 680 g / m ²
Base material B8:
Glass fiber nonwoven fabric-Super wool mat YWN-8 manufactured by Yazawa Sangyo Co., Ltd.
Fabric form: Felt-like non-woven fabric, basis weight: 720 g / m ²
Resin MR1:
Epoxy resin-TR-C35 manufactured by Toray Industries, Inc.
Main agent: Epoxy resin-“Epicoat” 828 manufactured by Yuka Shell Epoxy Co., Ltd.
Curing agent: Imidazole derivative-Toray Co., Ltd. blend TR-C35H
Mixing ratio: main agent / curing agent = 10/1
Example 1
Using the molding apparatus described with reference to FIG. 4 and the molding method described with reference to FIG. 6, the motorcycle cowl having a total length of about 600 mm described with reference to FIGS. 7 and 8 will be described next. The procedure was as follows. The produced cowl had excellent strength and rigidity throughout, and had no defect.

  As the 1st base material 52, the four base materials B1 cut from the shaping | molding shape by about 5 mm width on one side were prepared. Of these, the three base materials B1 were stacked and placed on the shaping mold lower mold 58 shown in FIG. As the second base material 53, the base material B3 is protruded outward by 5 mm from the ridgeline of the mold so as to eliminate the gap between the first base material 52 and the mold shape. Arranged. Next, the remaining one piece of the base material B1 was stacked thereon.

  In order to follow the shape of the shaping mold lower mold 58, a thermoplastic adhesive (epoxy-modified thermoplastic resin, melting point 71 ° C.) is applied to the first base material 52 in advance.

  The shaping mold upper mold (not shown) was brought into close contact with the shaping mold lower mold 58, and the shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes in a state where the substrate was made to follow the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. A molding precursor 59 obtained by integrating the first base material 52 made of the four base materials B1 and the second base material 53 made of the base material B3 thus obtained is shown in FIGS.

  The obtained molding precursor 59 was placed in the lower mold 17 as shown in FIG. The molding precursor 59 was disposed so that the end portion of the second base material 53 of the molding precursor 59 protruded 3 mm or more from the ridge line of the molding cavity. Thereafter, both the upper mold 16 and the lower mold 17 were held at a temperature of 100 ° C. by a temperature controller (not shown). Next, as shown in FIG. 14, the upper mold 16 was lowered and brought into close contact with the lower mold 17. At this time, a part of the second substrate 53 was sandwiched between the upper mold 16 and the lower mold 17. Since the base material B3 has a large deformability and can be thinly crushed by being sandwiched between molds, the mold can be sealed without any problem.

  Next, the resin injection path 13 was connected to the resin injection port 8a in the molding apparatus shown in FIG. 4, and the resin discharge path 14 was connected to the resin discharge port 8b. A tube made of “Teflon (registered trademark)” having a diameter of 12 mm and a thickness of 2 mm was used for both the resin injection path 13 and the resin discharge path 14. In order to prevent the resin from flowing into the resin pumping path 14 to the vacuum pump 7a, a resin trap 15 is provided in the middle.

  In order to keep the inside of the mold sealed, the sealing material 20 was disposed on the outer periphery of the mold. Ideally, by closing the molding upper die 16, the inside of the die is not in communication with the outside in portions other than the resin injection path 13 and the resin discharge path 14. However, substantially complete sealing is difficult. For example, the pressure of a vacuum pressure gauge (not shown) is closed with the resin injection valve 22a disposed in the resin injection path 13 closed and the resin discharge valve 22b opened. In this case, if the pressure in the mold is maintained at 0.01 MPa for 10 seconds after the vacuum pump 7a is stopped, it is determined that there is no problem in molding, and the state of sealing of the mold is confirmed.

  The air in the mold is sucked by the vacuum pump 7a through the resin discharge port 8b, and it is confirmed by the vacuum pressure gauge 32 that the pressure in the mold has become 0.01 MPa or less. Injection into the mold was started. A syringe pump was used as the pressurizing device 23. The resin was prevented from flowing back to the tanks 5 and 6 when the resin was injected.

  Resin MR1 (liquid epoxy resin) was used as the resin. In the resin injection device 3, the main agent in the main agent tank 5 and the hardener in the hardener tank 6 are heated to 40 ° C. with stirring, and lowered to a predetermined viscosity in advance. Defoaming was performed.

  At the initial stage of resin injection, since the air in the resin mixing unit 4 and the air in the hose enter the resin, the resin was discarded from a branch path (not shown) without flowing into the mold. The pressure device 23 was set to 200 g / stroke.

  After discarding the first resin, the resin injection pressure gauge 31 installed in the resin injection passage 13 is used to confirm the injection resin pressure (in this embodiment, the pressure was 0.6 MPa), and the resin injection valve 22a is opened. Resin was poured into the mold. At the start of resin injection, the resin discharge path 14 was opened. When the in-mold pressure (resin pressure in the mold) at this time is Pm and the resin injection pressure is Pi, the resin can be easily injected into the mold if the relationship of Pm <Pi is satisfied.

  After the resin is filled in the mold, the resin discharge passage 14 is closed and the resin injection is continued for 1 minute. As a precaution, the resin injection pressure Pi and the resin pressure Pm in the mold are made the same, and the gas remains in the resin. If so, try to crush that gas. After another minute, the resin injection path 13 was closed, and the resin injection was terminated. In this state, it was left for 40 minutes, and the resin was cured during this period.

Thereafter, the molded body was taken out from the mold. A thin burr made of the base material B3 and an epoxy resin was formed around the molded body. Since this burr is a low-strength FRP made of the second base material and resin, the burr was removed with a simple deburring tool and sanding tool. The burr was easily removed in about 1 minute. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
(Example 2)
A molded body was produced using the same method as in Example 1 except that the second base material in Example 1 was changed to base material B4. A thin burr made of the base material B4 and an epoxy resin was formed around the obtained molded body.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute and 30 seconds, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
(Example 3)
A molded body was produced using the same method as in Example 1, except that the first base material of Example 1 was changed to base material B2, and the second base material was changed to base material B5. A thin burr made of the base material B5 and an epoxy resin was formed around the obtained molded body.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 2 minutes, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
Example 4
A molded body was produced using the same method as in Example 1 except that the second base material in Example 1 was changed to base material B6. A thin burr made of the base material B6 and the epoxy resin was formed around the obtained molded body.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
(Example 5)
A molded body was manufactured using the same method as in Example 1, except that the upper mold of Example 1 was changed to the upper mold 61 having a thick end 61a shown in FIGS. did. Even when the upper mold 61 and the lower mold 17 are brought into close contact with each other, the second base material positioned in the cavity thick portion 61a is molded in a shape along the mold shape without being crushed. It was possible to realize thick hemming.
(Example 6)
As shown in FIG. 11, as the first base material 52, four base materials B <b> 1 that were cut from the molded shape to a width of about 5 mm on one side were prepared. Of these, three base materials B1 were stacked and placed on the shaping mold lower mold 62. As the 2nd base material 53, what cut | judged base material B3 from the shaping | molding shape large by 5 mm width as a whole was used. On the 1st base material 52, the 2nd base material was piled up so that it might protrude outside 5mm every from the ridgeline of a type | mold. Next, the remaining one piece of the base material B1 was stacked thereon.

  In order to follow the shape of the shaping mold lower mold 62, a thermoplastic adhesive (epoxy-modified thermoplastic resin, melting point 71 ° C.) is applied to the first base material 52 in advance.

  The shaping mold upper mold 63 was brought into close contact with the shaping mold lower mold 62, and the shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes in a state in which the substrate was made to follow the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. FIG. 12 shows a molding precursor 57 obtained by integrating the first base material 52 composed of the four base materials B1 and the second base material composed of the single base material B3.

  A molded body was produced using the same method as in Example 1 except that the obtained molding precursor 57 was used. A thin burr made of the base material B3 and an epoxy resin was formed around the obtained molded body.

  This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.

By producing the molding precursor by this method, it is possible to significantly reduce the time required for producing the molding precursor because there is no need to arrange the second base material in the vicinity of the outer edge of the cavity.
(Example 7)
As shown in FIG. 23, as the first base material 52, four base materials B2 cut from the molded shape so as to be smaller by about 5 mm on one side are prepared, and the four base materials B2 are stacked and shaped. The mold was placed on the mold 62. As the second base 53, the first base B3 is so formed that the gap between the first base 52 and the cavity is eliminated, and the first base 52 is protruded to the outside by 5 mm as a whole from the ridge line of the mold. Overlaid on the material 52.

  In order to follow the shape of the shaping mold lower mold 62, a thermoplastic adhesive (epoxy-modified thermoplastic resin, melting point 71 ° C.) is applied to the first base 52 in advance.

  The shaping mold upper mold 63 was brought into close contact with the shaping mold lower mold 62, and the shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes in a state in which the substrate was made to follow the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. FIG. 24 shows a molding precursor 57 obtained by integrating the first base material 52 composed of the four base materials B2 and the second base material 53 composed of the single base material B3. .

  A molded body was produced using the same method as in Example 1 except that the obtained molding precursor 57 was used. A thin burr made of the base material B3 and an epoxy resin was formed around the obtained molded body.

  This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.

By producing the molding precursor by this method, the time required for producing the molding precursor can be greatly shortened because there is no need to sandwich the second base material between the first base material.
(Example 8)
A molded body was produced using the same method as in Example 1 except that the second base material in Example 1 was changed to base material B7. A thin burr made of the base material B7 and an epoxy resin was formed around the obtained molded body.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
Example 9
A molded body was produced using the same method as in Example 1 except that the second base material in Example 1 was changed to base material B8. A thin burr made of the base material B8 and an epoxy resin was formed around the obtained molded body.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute and 30 seconds, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
(Example 10)
As shown in FIG. 18, as the first base material 52, four base materials B <b> 2 that are cut from the molded shape by a width of about 5 mm on one side are prepared, and the four base materials B <b> 2 are stacked and shaped. The mold was placed on the mold 62. As the second base material 53, the base material B3 is formed so as to eliminate the gap between the first base material 52 and the mold shape and to protrude outward from the ridge line of the mold by 5 mm as a whole. The first substrate 52 was placed on top of one another.

  In order to follow the shape of the shaping mold lower mold 62, a thermoplastic adhesive (epoxy-modified thermoplastic resin, melting point 71 ° C.) is applied to the first base material 52 in advance.

  The shaping mold upper mold 63 was brought into close contact with the shaping mold lower mold 62, and the shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes in a state in which the substrate was made to follow the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. FIG. 19 shows a molding precursor 56 obtained by integrating the first base material 52 made of the four base materials B2 and the first base material 53 made of the base material B3.

  A molded body was manufactured using the same method as in Example 1 except that the obtained molding precursor 56 was used. A thin burr made of the base material B3 and an epoxy resin was formed around the obtained molded body.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 1 minute, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
(Example 11)
As shown in FIG. 20, as the first base material 52, one base material B1 cut from the molded shape to a width of 5 mm on one side and five pieces cut from the molded shape to a width of about 5 mm on one side are cut. Base material B1 was prepared. One base material B <b> 1 cut to a large size was placed in the shaping mold lower mold 62. Next, four base materials B1 which were stacked on top of each other and cut into small pieces were arranged in the shaping mold lower mold 62. As the second base material 53, the base material B7 is first so as to eliminate the gap between the first base material 52 and the mold shape and to protrude outward by 5 mm from the ridge line of the mold as a whole. And placed on the base material 52. Further, the remaining one base material B1 was stacked thereon.

  In order to follow the shape of the shaping mold lower mold 62, a thermoplastic adhesive (epoxy-modified thermoplastic resin, melting point 71 ° C.) is applied to the first base material 52 in advance.

  The shaping mold upper mold 64 was brought into close contact with the shaping mold lower mold 62, and the shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes in a state in which the substrate was made to follow the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. FIG. 21 shows a molding precursor 58 obtained by integrating the first base material 52 made of the five base materials B1 and the second base material 53 made of the base material B7.

  A molded body was produced using the same method as in Example 5 except that the obtained molding precursor 58 was used. As shown in FIG. 22, the obtained molded body 70 has a main body portion 71 and a burr forming portion 72 extending from this edge. The molded body 70 includes a first base material 52 and a second base material 53 impregnated with a resin, and includes a single base material B1, a base material B7, and an epoxy resin that are cut in a large size around the first base material 52 and the second base material 53. A thin burr was formed.

This burr was removed with a simple deburring tool and sanding tool. The deburring process was completed in about 2 minutes, and deburring was easily performed. The compact could be finished with a simple deburring tool without the need for large-scale equipment such as water jet machining and NC machining.
(Comparative Example 1)
A reinforcing fiber base material on which four base materials B1 were laminated was prepared. After this base material was cut into a molded shape, it was placed over the shaping mold lower mold.

  In order to follow the shape of the shaping mold lower mold, a thermoplastic pressure-sensitive adhesive material (epoxy-modified thermoplastic resin, melting point 71 ° C.) is previously applied to the reinforcing fiber base.

  The shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes with the shaping mold upper mold in close contact with the shaping mold lower mold and the base material conforming to the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. Here, a molding precursor made of a reinforcing fiber base material in which four base materials B1 were integrated was obtained.

  The obtained molding precursor was placed in a mold, and a molded body was produced using the same method as in Example 1. A thin burr made of a reinforcing fiber base and a resin was formed around the obtained molded body.

Since this burr is a high-strength FRP made of a reinforcing fiber base and a resin, it has been difficult to deburr only with a simple deburring tool and a sanding tool. It was necessary to finish the molded body by NC machining.
(Comparative Example 2)
A reinforcing fiber base material on which four base materials B1 were laminated was prepared. This fiber reinforced base material was cut from the molded shape so as to be smaller by about 5 mm on one side, and then placed on the shaping mold lower mold.

  In order to follow the shape of the shaped lower mold, a thermoplastic adhesive material (epoxy-modified thermoplastic resin, melting point 71 ° C.) is previously applied to the reinforcing fiber base.

  The shaping mold was heated to a temperature of 90 ° C. and held for about 10 minutes with the shaping mold upper mold in close contact with the shaping mold lower mold and the base material conforming to the mold shape. Thereafter, the shaping mold was rapidly cooled, and the substrate was taken out of the shaping mold. Here, a molding precursor made of a reinforcing fiber base material in which four base materials B1 were integrated was obtained.

  The obtained molding precursor was placed in a mold, and a molded body was produced using the same method as in Example 1. It was confirmed that the resin rich part 103 which does not contain the reinforcing fiber base as shown in FIG. 2 is present at the end of the obtained molded body. The molded body did not have the desired strength.

  The present invention relates to an FRP structure in which the arrangement of reinforcing fibers is desired to every corner, in particular, an FRP sheet that is required to maintain the strength of the end, a manufacturing method thereof, and a molding precursor used for the manufacturing. . The molding precursor of the present invention is not limited to a method for producing FRP by an RTM method using an epoxy resin, but can be applied to a method for producing FRP by impregnating another molding precursor with a fluid resin. The molding precursor of the present invention, the method for producing a fiber-reinforced resin molded body, and the fiber-reinforced resin molded body are used for automobile parts (outer plates and structural members), aircraft members (primary, secondary structural materials, interior materials, reinforcing members). ), Ship members, windmill blades, building panel materials, and other general industrial members.

It is a perspective view of the conventional molded object. It is AA sectional drawing of the molded object of FIG. It is a longitudinal cross-sectional view of another conventional molded body. It is a systematic diagram of the shaping | molding system by the RTM method used for manufacture of the molded object of this invention. It is a perspective view of the metal mold | die part of FIG. It is a longitudinal cross-sectional view of the shaping type | mold used for preparation of an example of the shaping | molding precursor of this invention. It is a perspective view of an example of the molded object of this invention. It is BB sectional drawing of the molded object of FIG. It is a longitudinal cross-sectional view of the shaping | molding die used for manufacture of an example of the molded object of this invention. FIG. 10 is a longitudinal sectional view showing a state in which the mold of FIG. 9 is closed. It is a longitudinal cross-sectional view of the shaping type | mold used for preparation of another example of the shaping | molding precursor of this invention. It is a longitudinal cross-sectional view of the state where the shaping mold of FIG. 11 is closed. It is a longitudinal cross-sectional view of the shaping | molding die used for manufacture of another example of the molded object of this invention. It is a longitudinal cross-sectional view of the state where the mold of FIG. 13 is closed. It is a longitudinal cross-sectional view of the resin casting part of the shaping | molding die in the shaping | molding system of FIG. It is a perspective view of an example of the molding precursor of the present invention. It is CC sectional drawing of the shaping | molding precursor of FIG. It is a longitudinal cross-sectional view of the shaping type | mold used for preparation of another example of the shaping | molding precursor of this invention. It is a longitudinal cross-sectional view of the state where the shaping mold of FIG. 18 is closed. It is a longitudinal cross-sectional view of the shaping type | mold used for preparation of another example of the shaping | molding precursor of this invention. It is a longitudinal cross-sectional view of the state where the shaping mold of FIG. 20 is closed. It is a cross-sectional photograph of the edge part of the other example of the molded object of this invention. It is a longitudinal cross-sectional view of the shaping type | mold used for preparation of another example of the shaping | molding precursor of this invention. It is a longitudinal cross-sectional view of the state where the shaping mold of FIG. 23 is closed.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Mold raising / lowering apparatus 2 Mold 3 Resin injection apparatus 4 Mixing unit 5 Main agent tank 6 Hardener tank 7a Vacuum pump 7b Pressure pump 8a Resin injection port 8b Resin discharge port 9 Hydraulic unit 10 Hydraulic pump 11 Hydraulic cylinder 12 Check valve DESCRIPTION OF SYMBOLS 13 Resin injection path 14 Resin discharge path 15 Resin trap 16 Mold upper mold 17 Mold lower mold 18 Film gate 19 Runner 20 Sealing material 21 Vise grip 22a Resin injection valve 22b Resin discharge valve 22c Controller 23 Pressurizer 24 Vacuum pump 25 Mold temperature controller 26 Cavity 31 Injection resin pressure gauge 32 In-mold pressure gauge 51 Motorcycle cowl 52 First base material 53 Second base material 54 FRP section mainly including the first base material 55 Mainly the second FRP part including base material 56 Molding precursor 57 Molding precursor 58 Molding precursor 59 Molding precursor 61 Mold upper mold 62 Molding mold lower mold 63 Molding mold upper mold 64 Molding mold upper mold 71 Main body 72 Burr forming section 101 Fiber reinforced resin molded body 102 Reinforced fiber base material 103 Resin Rich part

Claims (2)

A step in which the molding precursor is disposed in a molding cavity of the molding die, a step in which the molding die in which the molding precursor is disposed is closed, and a resin that is heated and pressurized in the molding cavity of the closed molding die. A step of injecting, a step of solidifying the resin injected into the molding cavity, a step of opening the mold after the resin is solidified, and a fiber reinforced resin molded from the opened mold A method for producing a fiber-reinforced resin molded article by RTM comprising a step of removing a molded article,
(A) As the molding precursor, the molding precursor described in any of the following (i) to (iv) is used,
(B) At least a part of the outer periphery of the molding cavity is provided with a film gate through which the injected resin flows,
(C) In the step of disposing the molding precursor in a molding cavity of the molding die, the molding precursor is a molding cavity of the molding die so that the second substrate is located at least at a part of the film gate. Placed in
(D) A method for producing a fiber-reinforced resin molded article by RTM in which the second base material is present in at least a part of the burr portion of the resin formed by the film gate.
(I) A molding precursor comprising a main body part and a burr forming part continuously extending outward from an edge of the main body part, wherein the main body part includes a first base material comprising a plurality of reinforcing fibers; And a second substrate made of a plurality of fibers laminated on the first substrate at the outer edge of the main body, and the burr forming portion extends outward from the edge of the main body. A molding precursor formed of the second base material, wherein gaps between the plurality of fibers form a flow path of molding resin.
(Ii) The molding precursor according to (i), wherein the first base material is disposed so as to cover at least a part of the second base material located at the outer edge portion.
(Iii) The molding according to any one of (i) and (ii), wherein the first base material is disposed so as to sandwich at least a part of the second base material located at the outer edge portion. precursor.
(Iv) A surface layer forming base material that forms a surface layer portion of the first base material extends outward from an edge of the main body portion and covers the second base material positioned in the burr forming portion. The molding precursor according to any one of (i) to (iii), which is arranged. Outside of the film gate, runner is provided which communicates with the said film gate, said shaped precursor second substrate is a fiber-reinforced according to claim 1, which is arranged in a state of reaching the position of the runner Manufacturing method of resin molding.