JP5956187B2 - Method for molding fiber reinforced plastic molding with three-dimensional additive - Google Patents

Description

  The present invention is a fiber reinforced composite material using a thermoplastic resin or a thermosetting resin as a matrix resin, and has a three-dimensional reinforcing structure such as a rib or a screw hole in a shell structure such as a box shape, a flat plate, or a key shape. The present invention relates to a method for molding a fiber-reinforced plastic molded article with a three-dimensional additive having (hereinafter referred to as “three-dimensional additive”).

  Conventionally, molded with a three-dimensional additive-added fiber reinforced plastic with a three-dimensional additive, such as a three-dimensional reinforcing structure such as a rib or screw hole, in a shell structure such as a box shape, flat plate, or key shape. Various methods for forming a body have been proposed.

  Patent Document 1 discloses a composite molded body made of a synthetic resin comprising a first molded product molded from a fiber reinforced thermosetting resin sheet and a second molded product molded from a thermoplastic synthetic resin molded by injection molding. And the said 1st molded product and the said 2nd molded product are integrated by heat sealing | fusion, It is characterized by the above-mentioned. In this method, a fiber reinforced plastic with a shell structure molded with reinforced fibers and a thermosetting resin is set in an injection mold, and then the thermoplastic resin is attached to the shell structure by heat fusion by injection molding. is there.

  The molding described in Patent Document 1 is costly because it is a two-stage molding of FRP molding using a thermosetting resin and subsequent injection molding.

  In Patent Document 2, a random layer composed of a composite material in which carbon fibers that are oriented in a two-dimensional random manner and satisfy a specific opening state are present in a thermoplastic resin, and the carbon fibers are aligned in one direction. By forming a molded body having a unidirectional material layer made of a unidirectional material and a thermoplastic resin, a carbon fiber composite material having excellent rigidity is molded. Press-molding a random layer composed of carbon fibers with a fiber length of more than 5 mm and not more than 100 mm and a thermoplastic resin, and a unidirectional material layer composed of a unidirectional material in which carbon fibers are aligned in one direction and a thermoplastic resin. It is a carbon fiber composite molded body obtained as described above.

  The technique described in Patent Document 2 is suitable for molding as a relatively large molded product, but if a fine rib structure or screw hole is molded, the shape of the added three-dimensional structure becomes unstable, and the height High three-dimensional structure is difficult to mold.

  Patent Document 3 describes a method for forming a vehicle hood having a rib structure by combining a long fiber base material and a short fiber base material such as SMC. The molding method of Patent Document 3 is applied to a relatively large molded product.

JP 2002-347067 A JP 2011-241338 A Japanese Patent No. 4220805

  As a result of conducting many research experiments in order to solve the problems of the techniques described in Patent Documents 1, 2, and 3, the present inventors have found that the fiber length and content of the reinforcing fibers used are By adjusting the structure of the mold, etc., the fiber reinforced plastic molded body with screw holes and fine rib structure can be shortened by one press molding to the shell structure with continuous reinforcing fiber in one direction or fabric shape. It has been found that it can be molded in time.

  The present invention has been made based on such novel findings of the present inventors.

  An object of the present invention is to provide a method for molding a fiber-reinforced plastic molded article with a three-dimensional additive having a three-dimensional reinforcing structure such as a rib or a screw hole in a shell structure such as a box shape, a flat plate, or a key shape. .

  Another object of the present invention is to shorten the fiber reinforced plastic with a three-dimensional additive having a three-dimensional reinforcing structure such as a rib or a screw hole into a shell structure such as a box shape, a flat plate, or a key shape by a single press molding. It is an object of the present invention to provide a method for molding a fiber-reinforced plastic molded article with a three-dimensional additive that can be molded in time.

The above object is achieved by the method for molding a fiber-reinforced plastic molded article with a three-dimensional additive according to the present invention. In summary, the present invention is a sheet-like, flake-like or pellet-like heat in which short fibers having a fiber length of 0.01 mm or more and 2.0 mm or less are randomly oriented at a blending amount of 5 to 50 wt%. A short fiber reinforced resin which is a plastic resin or a thermosetting resin;
Unidirectional or woven continuous reinforcing fiber prepreg impregnated with thermoplastic resin or thermosetting resin;
A continuous fiber layer and a short fiber layer formed of the continuous reinforcing fiber prepreg and the short fiber reinforced resin by one-time press molding using a mold having an outer mold and an inner mold. A method of molding a fiber-reinforced plastic molded body having a shell made of a laminate of the above and a three-dimensional additive molded with the short fiber-reinforced resin,
When the outer mold and the inner mold are arranged in combination with each other, they are arranged opposite to each other to form the fiber-reinforced plastic molded body between the outer mold and the inner mold. And has a flange portion that forms a molding space for
The flange portion is formed to extend outward from the molding space to the outer periphery of the outer mold and the inner mold at 20 mm or more and 100 mm or less,
The clearance of the flange portions of the two molds arranged to face each other is 0.5 · t (mm) or more with respect to the plate thickness (tmm) of the shell of the fiber-reinforced plastic molding to be molded, and by adjusting the 75 · t (mm) or less, causing the pressure of the press, the pressure of the press, solid additives, wherein isosamples in flowing resin was protrude a resin into the clearance of the flange portion This is a method for forming a fiber-reinforced plastic molded article with a ring.

  According to one embodiment of the present invention, the clearance is gradually provided with a gradient of 0.1 ° or more and 20 ° or less in the resin flow direction between at least 15 to 30 mm from the molding space in the flange portion. By narrowing, a pressure of a press is generated in the molding space inside the mold to flow the short fiber reinforced resin.

  According to another embodiment of the present invention, when the resin of the continuous reinforced fiber prepreg and the resin of the short fiber reinforced resin are thermoplastic resins, the fiber reinforced plastic material is brought to a temperature higher than the melting point of the thermoplastic resin. After preheating, press molding is performed with the mold adjusted to a temperature lower than the melting point.

  According to another embodiment of the present invention, when the resin of the continuous reinforced fiber prepreg and the resin of the short fiber reinforced resin are thermosetting resins, the fiber reinforced plastic material is more than the curing temperature of the thermosetting resin. It press-molds with the said metal mold | die adjusted to high temperature.

  ADVANTAGE OF THE INVENTION According to this invention, the fiber reinforced plastic molding with a three-dimensional additive which has three-dimensional reinforcement structures, such as a rib and a screw hole, can be shape | molded with high precision in shell structures, such as a box shape, a flat plate, and a key type. . Further, according to the present invention, a fiber reinforced plastic with a three-dimensional additive having a three-dimensional reinforcing structure such as a rib or a screw hole in a shell structure such as a box shape, a flat plate, or a key shape can be shortened by one press molding. Can be molded in time.

FIG. 1 (a) is a cross-sectional view for explaining a molding method of a fiber-reinforced plastic molded article with a three-dimensional additive of the present invention, and FIG. 1 (b) is with a three-dimensional additive molded according to the present invention. It is a cross-sectional perspective view of a fiber reinforced plastic molding. It is a top view which shows one Example of the fiber reinforced plastic material used for the shaping | molding method of this invention. Fig.3 (a) is a perspective view which shows one Example of the fiber reinforced plastic molding with a three-dimensional additive shape | molded by this invention, FIG.3 (b) is a line A- of Fig.3 (a). It is sectional drawing taken in A. FIG. FIG. 4 (a) is a cross-sectional view showing an example of an inner mold, and FIG. 4 (b) is a cross-section showing an example of an outer mold. FIG. 4C is a cross-sectional view showing a state when the inner mold and the outer mold are arranged in a molding process state.

  Hereinafter, the molding method of the fiber-reinforced plastic molded body with a three-dimensional additive according to the present invention will be described in more detail with reference to the drawings.

Example 1
A method for molding a fiber-reinforced plastic molded body with a three-dimensional additive according to one embodiment of the present invention will be described with reference to FIGS. 1 (a), 1 (b) and FIGS. 2 (a), 2 (b).

  According to the present invention, as shown in FIGS. 1 (a) and 2 (a), (b), a continuous reinforcing fiber prepreg 11 in which a reinforcing fiber of continuous fibers is impregnated with a matrix resin, a predetermined fiber length, A fiber reinforced plastic material 10 having a short fiber reinforced resin 12 in which a predetermined amount of reinforced fibers of short fibers are blended is used. As shown in FIG. 1A, the fiber reinforced plastic material 10 is press-molded once with a mold 100 (for example, an inner mold 101 and an outer mold 102), and is shortened by the pressing pressure at that time. As shown in FIG. 1 (b), the fiber reinforced resin 12 is caused to flow, thereby forming a shell composed of a laminate of a continuous fiber reinforced plastic layer (continuous fiber layer) 11A and a short fiber reinforced plastic layer (short fiber layer) 12A. A fiber-reinforced plastic molded body 1 with a three-dimensional additive including 1A and a three-dimensional additive 2A composed of a short fiber-reinforced plastic layer 12A is molded.

  More specifically, the continuous reinforcing fiber prepreg 11 is a unidirectional or woven continuous reinforcing fiber prepreg in which a reinforcing fiber to be unidirectional or woven is impregnated with a thermoplastic resin or a thermosetting resin.

  As the reinforcing fiber, carbon fiber is most preferable, but various other fibers can be used. For example, as the reinforcing fiber, in addition to carbon fiber, glass fiber, basalt fiber; metal fiber such as boron fiber, titanium fiber, steel fiber; and further, aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, poly Organic fibers such as arylate and polyester can be used alone or in a mixture of plural kinds.

  Further, as the resin, a thermosetting resin or a thermoplastic resin can be used, and as the thermosetting resin, a room temperature curable type or a thermosetting type epoxy resin, a vinyl ester resin, an unsaturated polyester resin, or Phenol resin and the like are preferably used, and as the thermoplastic resin, polycarbonate resin, polyetherimide resin, polyether ether ketone resin, polyether ketone ketone resin, polyphenylene sulfide resin, acrylic resin, polyurethane resin, polypropylene resin, ABS resin, nylon, vinylon and the like can be suitably used.

  The continuous reinforcing fiber prepreg 11 is a UD-shaped prepreg formed by impregnating a reinforcing fiber sheet formed by aligning reinforcing fibers in one direction with a resin, or a plain weave or twill weave formed by weaving reinforcing fibers. A cross prepreg formed by impregnating a woven fabric such as a satin weave with a resin. The resin impregnation amount is 30 to 70 wt%, preferably 40 to 60 wt%.

  On the other hand, according to the present invention, the short fiber reinforced resin 12 includes a reinforced fiber and a resin, and the reinforced fiber has a fiber length of 0.01 to 2.0 mm (0.01 mm or more and 2.0 mm or less). The resin is a thermoplastic resin or a thermosetting resin. In the short fiber reinforced resin 12, the reinforced fiber is contained in a blending amount of 5 to 50 wt%. The short fiber reinforced resin 12 is in the form of a sheet (FIG. 2 (b)), flakes or pellets (FIG. 2 (a)) in which reinforcing fibers are randomly oriented.

  In the present invention, as described above, the reinforcing fiber blended in the short fiber reinforced resin 12 is a short fiber having a fiber length of 0.01 to 2.0 mm, but if the fiber is 3 mm or more, If a three-dimensional additive having a fine rib structure or a high three-dimensional structure is formed, the fluidity of the resin deteriorates, making it difficult to form a fine structure, and forming a sufficiently high three-dimensional structure is difficult. If the fiber length is less than 0.01, sufficient strength as the short fiber reinforced resin 12 cannot be obtained.

  Further, the reinforcing fiber is contained in a blending amount of 5 to 50 wt% (5 wt% or more and 50 wt% or less), but if the content exceeds 50 wt%, the fluidity of the resin is deteriorated and the fineness is reduced. It is difficult to form a structure, and it is difficult to form a three-dimensional structure with a sufficient height. If the content is less than 5 wt%, the structure may be distorted by heat shrinkage after solidification, and the resin needs to contain 5 wt% or more. Preferably, the fiber length is 0.3 to 1.0 mm, and the amount of fiber is 5 to 30 wt%.

  The reinforcing fiber and resin used for the short fiber reinforced resin 12 may be the same as those of the continuous reinforcing fiber prepreg 11. That is, as the reinforcing fiber, carbon fiber is most preferable, but various other fibers can be used. For example, as the reinforcing fiber, in addition to carbon fiber, glass fiber, basalt fiber; metal fiber such as boron fiber, titanium fiber, steel fiber; and further, aramid, PBO (polyparaphenylene benzbisoxazole), polyamide, poly Organic fibers such as arylate and polyester can be used alone or in a mixture of plural kinds.

  In addition, as described above, a thermosetting resin or a thermoplastic resin can be used as the resin. As the thermosetting resin, a room temperature curing type or a thermosetting type epoxy resin, a vinyl ester resin, a non-volatile resin, or the like. Saturated polyester resin, phenol resin, or the like is preferably used, and as the thermoplastic resin, polycarbonate resin, polyether imide resin, polyether ether ketone resin, polyether ketone ketone resin, polyphenylene sulfide resin, acrylic resin, polyurethane Resin, polypropylene resin, ABS resin, nylon, vinylon, etc. can be suitably used.

  As described above, the inventors of the present invention have performed the fiber reinforced plastic material 10 including the short fiber reinforced resin 12 and the continuous reinforced fiber prepreg 11 by one press molding, in particular, by the press pressure during the press molding. The short fiber reinforced resin 12 is made to flow, the shell 1A which is a laminate of the continuous fiber reinforced plastic layer (continuous fiber layer) 11A and the short fiber reinforced resin layer (short fiber layer) 12A, and the short fiber reinforced resin layer (short fiber) It has been found that the fiber-reinforced plastic molded body 1 composed of the three-dimensional additive 2A based on the layer 12A can be suitably molded.

  In an example of the fiber reinforced plastic molded body 1 shown in FIG. 1B, the shell 1A which is the side wall and the bottom wall of the outer periphery of the box-shaped molded body 1 is a continuous fiber reinforced plastic layer (continuous fiber layer). 11A and a short fiber reinforced plastic layer (short fiber layer) 12A, and a three-dimensional additive formed by a short fiber reinforced plastic layer (short fiber layer) 12A having component mounting bases and ribs formed on the bottom wall. 2A.

  In the molding method of the present invention, it is important to apply pressure to the inside of the mold 100 during press molding.

  That is, by reducing the clearance CL on the upper surface of the molding space 100 (see FIG. 4C) formed by the inner mold 101 and the outer mold 102 during pressing, that is, the mold Immediately before the mold 100 is pushed out, it is necessary to have a structure in which the peripheral portion of the molding space V on the upper surface of the mold is sealed and pressure is applied to the inside. By adopting such a structure, the short fiber reinforced resin 12 flows under the pressure, and the short fiber reinforced resin 12 has a rib structure or a screw hole structure in the mold, and a high height (more than 5 times the width). ()) It goes into the three-dimensional structure part.

  If the fibers in the short fiber reinforced resin 12 are long or the amount of fibers is too large, the resin is not filled up to the details in the mold and it is difficult to obtain an accurate three-dimensional structure. In order to prevent the member from being distorted by shrinkage due to cooling after solidification, a resin containing a certain amount of fiber (5 to 50 wt%) is preferable.

  Next, the mold 100 configured according to the present invention will be further described. 4A to 4C, as will be described in detail later, the mold 100 (inner mold 101, outer mold) used in specific examples 1 and 2 for demonstrating the function and effect of the present invention. 102).

  (A) and (b) of FIG. 4A are a central longitudinal sectional view and a central transverse sectional view of the upper mold (inner mold) 101, respectively. 4B are (i) and (b), respectively, a central longitudinal sectional view and a central transverse sectional view of the lower mold (outer mold) 102. FIG.

  Generally speaking, the outer mold 102 includes a recess 102A, and the inner mold 101 includes a protrusion 101A that fits into the recess 102A of the outer mold 102. At the time of molding, the convex portion 101A of the inner mold 101 is combined with the concave portion 102A of the outer mold 102, and when arranged in the molding processing state, they are arranged to face each other and between the outer mold 102 and the inner mold 101. A molding space (V) (see FIG. 4C) for forming the fiber-reinforced plastic molded body 1 is formed on the substrate. At the time of actual molding, the fiber reinforced plastic material 10 configured according to the present invention is disposed in the molding space V and is press-molded by the inner mold 101 and the outer mold 102.

  4A to 4C, the mold 100 according to the present invention is formed on the outer peripheral edge portion of the convex portion 101A of the inner mold 101 and the concave portion 102A of the outer mold 102. Are formed with flange portions 101a and 102a, respectively. As shown in FIG. 4C, the flange portions 101a and 102a are formed by the convex portions 101A and the concave portions 102A when the inner die 101 and the outer die 102 are combined with each other and arranged in a molding state. The molding spaces V are arranged to face each other so as to be a closed space.

  The flange portions 101a and 102a extend from the inner end, that is, from the upper surface of the molding space V to the outside with a width W101a and W102a of 20 to 100 mm (20 mm or more and 100 mm or less).

  Further, the flange portions 101a and 102a formed on the outer peripheral edge portion of the fiber-reinforced plastic molded body 1 to be molded do not adhere to each other during the actual molding process, and as shown in FIG. The flange portions 101a and 102a are provided with a predetermined clearance (gap) CL. According to the present invention, the clearance CL formed by the flange portions 101a and 102a of both molds is the gap of the molding space V corresponding to the shell portion 1A in the fiber-reinforced plastic molded body 1 to be molded, that is, the shell. 1A thickness (t) (mm) (see FIG. 3 (b)) 0.5 or more and 0.75 or less (0.5 · t (mm) ≦ CL ≦ 0.75 · t (mm)) It is necessary to adjust.

  By adjusting the clearance CL of the flange portion as described above, a press pressure is generated in the molding space V during the molding process, and the short fiber reinforced resin 12 is moved from the molding space V to the outer peripheral edge portion by the pressure during the pressing. And can be made to flow.

  That is, according to the present invention, as described above, the mold 100 (the inner mold 101, the outer mold 102) is provided with the flange portions 101a, 102a having a width (W101a, W102a) of 20 to 100 mm, and the outer mold The clearance CL between the mold (lower mold) 102 and the inner mold (upper mold) 101 is the thickness (t) of the shell structure portion 1A of the molded product formed from the continuous reinforcing fiber prepreg 11 and the short fiber reinforced resin 12. On the other hand, it is adjusted in the range of (0.5 to 0.75) · t (mm).

  In the present invention, the flange portions 101a and 102a of the mold 100 have a width (W101a, W102a) of 20 to 100 mm, and the short-fiber-containing resin is cooled and solidified in the flange portion to press into the mold. To form solid additives such as ribs and bosses. When the flange portions 101a and 102a are less than 20 mm, it is necessary to rapidly harden the resin in the flange portions 101a and 102a, and it is necessary to lower the mold temperature. For this reason, the resin in the mold is also cured in the pressed state without sufficient flow, and the shell part plate thickness (t) and the like are molded with a predetermined dimension or more. Moreover, there is a possibility that a good rib structure or the like cannot be obtained. In addition, when the flange portions 101a and 102a exceed 100 mm, it is necessary to increase the mold temperature in order to cause the resin to flow and solidify the flange portions 101a and 102a exceeding 100 mm. As a result, the resin moves along the flange portions 101a and 102a with sufficient fluidity. Therefore, in order to maintain the press pressure in the mold, the resin escapes too much and it becomes difficult to maintain the press pressure. For this reason, pressure easily escapes during pressing, and a good rib structure or the like cannot be formed.

  In addition, when the clearance CL is smaller than 0.5 · t (mm), the thickness of the continuous reinforcing fiber prepreg 11 which is the long fiber base material and the resin protruding from the short fiber reinforcing resin 12 fill the clearance CL. Therefore, it cannot be pushed down to a predetermined thickness and cannot be finished according to the dimensions. Further, when a clearance CL larger than 0.75 · t (mm) is provided, the clearance CL is not sufficiently filled with the protruding resin from the short fiber reinforced resin 12, and the internal pressure escapes and the smooth surface is not finished.

  In the flange portions 101a and 102a, from the inner end (molding space V) outward, that is, in the flow direction of the short fiber reinforced resin 12, at least the width W101a (W102a) is 0.1 to 30 mm. It is preferable to apply an inner gradient (θ) of 1 to 20 ° (0.1 ° or more and 20 ° or less) so that the clearance CL gradually becomes narrower toward the outside. In FIG. 4C, the gradient (θ) is illustrated as being provided on the flange portion 102a of the outer mold 102, but of course, it may be provided on the flange portion 101a side of the inner mold 101. Or you may provide in both the collar parts 101a and 102a.

  As described above, in the present invention, the resin used for the short fiber reinforced resin 12 and the continuous fiber reinforced prepreg 11 may be a thermoplastic resin or a thermosetting resin. When a thermoplastic resin is used, after preheating the fiber reinforced plastic material 10 comprising the short fiber reinforced resin 12 and the continuous fiber reinforced prepreg 11 to a temperature higher than the melting point of the thermoplastic resin, the temperature is lower than the melting point of the resin. It can shape | mold by press-molding with the adjusted metal mold | die 100. FIG.

  Further, when a thermosetting resin is used for the short fiber reinforced resin 12 and the continuous fiber reinforced prepreg 11, the mold 100 is preheated to a temperature higher than the temperature at which the resin is cured, and then the short fiber reinforced resin 12 and The fiber reinforced plastic material 10 composed of the continuous fiber reinforced prepreg 11 is press-molded by the mold 100, and the mold 100 is opened after the curing is completed.

  With reference to FIGS. 2 and 3, the reinforcing method of the present invention will be described more specifically.

(Specific example 1)
FIG. 3 shows the overall configuration of a fiber-reinforced plastic molded body with a three-dimensional additive (hereinafter simply referred to as “molded body”) 1 molded in this specific example.

  The molded body 1 of this specific example has a height (H) of 15 mm inside a box-shaped shell 1A having outer dimensions of a width (W0) of 60 mm, a length (L0) of 100 mm, and a height (H0) of 20 mm. The structure has a cross-shaped rib structure 2A. The thickness t of the shell 1A was 1 mm, and the thickness t2A of the rib 2A was 1.5 mm.

  As described above, in this specific example, the mold 100 having the structure shown in FIGS. 4A to 4C is used.

  The outer mold 102 used in this example has an inner dimension of a flange 102a having a width (W102) of 60 mm, a length (L102) of 100 mm, a depth (H102) of 20 mm, and a width (W102a) of 25 mm. It is a steel mold attached. The protruding corner (R102a) was subjected to R processing of 3 mm, and the entering corner (R102b) was left square.

  The inner mold 101 used in this example has outer dimensions of 58 mm in width (W101), 98 mm in length (L101), 19.5 mm in height (H101), and 25 mm in width (W101a). This is a steel mold with a rudder 101a. Further, the inner mold 101 was grooved with a cross-shaped shape of a groove 101b having a width (W101b) for forming a rib structure of 1.5 mm and a depth (H101b) of 15 mm. The protruding corner (R101a) of the inner mold 101 was subjected to R processing of 2 mm, and the entering corner (R101b) was left square.

  Further, as shown in FIG. 4C, the flange 102a of the outer mold 102 has an angle (θ) of at least 0.1 ° so as to be lowered inward (that is, the molding space V side). In this example, the angle (θ) is about 0.3 °, and the height (h) is about 0.1 mm higher at the outer end than the inner surface. ing. Further, the clearance CL between the flange portions 101a and 102a was set to 0.5 mm.

The materials used in this specific example are as follows.
・ Continuous reinforcing fiber prepreg (11)
Carbon fiber plain weave cloth prepreg: Porcher composites (PIPREG C / PC (trade name) (polycarbonate resin fabric prepreg / carbon fiber basis weight: 196 g / m ² , resin content: 45 wt%)
・ Short fiber reinforced resin (12)
Made by Mitsubishi Rayon (PC-C-30: trade name) (carbon fiber short fiber reinforced polycarbonate resin pellet / carbon fiber length: average 0.3 mm, carbon fiber content: 30 wt%)
2, the carbon fiber plain weave cross prepreg (continuous reinforcing fiber prepreg) 11 is cut into a width (W11) of 170 mm and a length (L11) of 210 mm, and the resin pellet (short fiber reinforced resin) 12 is 25 g. The carbon fiber plain weave cloth prepreg 11 was placed so as to be as uniform as possible in the center of the carbon fiber plain weave cloth prepreg 11, and the two sides were fixed with a clip with a spring, and left in a heating oven and heated to 300 ° C. Thereafter, the fiber reinforced plastic material 10 obtained in this way was set in a mold 100 and pressed. The mold temperature was 50-70 ° C.

  In this specific example, the thickness (t) of the molded box shell portion 1A is 1 mm, and the mold clearance CL of the flange portions 101a and 102a is 0.5 mm, and the molten pellet resin rises at the moment of pressing. Then, in order to fill the clearance CL of the flange portions 101a and 102a, the entire mold interior is pressurized.

  As a result, a molded body 1 as shown in FIGS. 3A and 3B could be obtained. That is, the box-shaped shell portion 1A has an outer layer 11A and an inner layer 12A, the outer layer 11A is a carbon fiber reinforced plastic layer of a plain weave cloth of carbon fibers of long fibers, and the inner layer 12A is carbon of short fibers as reinforcing fibers. A short fiber reinforced plastic layer containing fibers. Also, the inner rib portion 2A was molded only from the same resin material as the inner layer 12A of the box-shaped shell portion 1A.

  The thickness (t) of the shell 1A is 1.0 ± 0.05 mm, the height (H) of the central cross-shaped rib is 15 mm, and the thickness (t2A) is 1.5 mm. A good molded product was obtained.

Example 2
In this specific example, a unidirectional thermoplastic resin prepreg was used as the continuous reinforcing fiber prepreg 11. This prepreg 11 was TPFL-UD (trade name) manufactured by Snappe Technologies (unidirectional prepreg of nylon 12 resin / carbon fiber basis weight 288 g / m ² , resin content: 68 wt%). A laminate of two unidirectional thermoplastic prepregs, vertically and horizontally, was cut into the same shape as in Example 1, and the same amount of the same thermoplastic resin pellet 12 as in Example 1 was placed thereon, and pressed in the same manner as in Example 1. .

  As a result, a good molded product having good surface properties and no corner chipping of the rib portion was obtained.

DESCRIPTION OF SYMBOLS 1 Fiber reinforced plastic molding with an additive 1A Shell 2A Three-dimensional additive 10 Fiber reinforced plastic material 11 Continuous reinforcing fiber prepreg 11A Continuous fiber reinforced plastic layer (continuous fiber layer)
12 Short fiber reinforced resin 12A Short fiber reinforced plastic layer (short fiber layer)
100 mold 101 upper mold (inner mold)
101a collar 102 lower mold (outer mold)
102a heel part

Claims (4)

A sheet-like, flake-like or pellet-like thermoplastic resin or thermosetting resin in which short fibers having a fiber length of 0.01 mm or more and 2.0 mm or less are randomly oriented at a blending amount of 5 to 50 wt%; Short fiber reinforced resin,
Unidirectional or woven continuous reinforcing fiber prepreg impregnated with thermoplastic resin or thermosetting resin;
A continuous fiber layer and a short fiber layer formed of the continuous reinforcing fiber prepreg and the short fiber reinforced resin by one-time press molding using a mold having an outer mold and an inner mold. A method of molding a fiber-reinforced plastic molded body having a shell made of a laminate of the above and a three-dimensional additive molded with the short fiber-reinforced resin,
When the outer mold and the inner mold are arranged in combination with each other, they are arranged opposite to each other to form the fiber-reinforced plastic molded body between the outer mold and the inner mold. And has a flange portion that forms a molding space for
The flange portion is formed to extend outward from the molding space to the outer periphery of the outer mold and the inner mold at 20 mm or more and 100 mm or less,
The clearance of the flange portions of the two molds arranged to face each other is 0.5 · t (mm) or more with respect to the plate thickness (tmm) of the shell of the fiber-reinforced plastic molding to be molded, and With a three-dimensional additive characterized in that the pressure of the press is generated by adjusting to 75 · t (mm) or less, and the resin flows by the pressure of the press so that the resin protrudes into the clearance of the flange portion. A method for forming a fiber-reinforced plastic molded body. In the flange portion, at least 15 to 30 mm from the molding space, the clearance is gradually narrowed with a gradient of 0.1 ° or more and 20 ° or less in the resin flow direction, thereby reducing the pressure of the press. 2. The method for molding a fiber-reinforced plastic molded body with a three-dimensional additive according to claim 1 , wherein the short-fiber-reinforced resin is caused to flow in the molding space inside the mold.   When the resin of the continuous reinforced fiber prepreg and the resin of the short fiber reinforced resin are thermoplastic resins, the fiber reinforced plastic material is preheated to a temperature higher than the melting point of the thermoplastic resin, and is lower than the melting point. The method for molding a fiber-reinforced plastic molded body with a three-dimensional additive according to claim 1 or 2, wherein press molding is performed with the mold adjusted to a temperature.   When the resin of the continuous reinforced fiber prepreg and the resin of the short fiber reinforced resin are thermosetting resins, the fiber reinforced plastic material is pressed with the mold adjusted to a temperature higher than the curing temperature of the thermosetting resin. The method for molding a fiber-reinforced plastic molded body with a three-dimensional additive according to claim 1 or 2, wherein the molding is performed.

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