JP6685616B2 - Carbon fiber composite material and manufacturing method thereof - Google Patents

Description

  TECHNICAL FIELD The present invention relates to a carbon fiber composite material having a surface on which either or both of a concave portion and a convex portion are formed, and a method for producing the same.

  In recent years, carbon fiber prepregs made by impregnating carbon fiber with resin and semi-drying carbon fiber prepreg have been used for members that require light weight and rigidity, such as casings and machine parts for office automation equipment such as laptop computers and printers, and insoles for artificial legs. Carbon fiber reinforced plastics, which are integrated by heating and pressing by laminating a plurality of sheets, have come to be used.

  Conventionally, in order to obtain a carbon fiber reinforced plastic in which convex portions or concave portions are formed on the surface by varying the thickness depending on the portion, as shown in FIG. 10, the number of laminated carbon fiber prepregs 91A to 91G is different for each portion having different thickness. It is necessary to make them different from each other and to stack them at correct positions to integrate them. Moreover, in that case, it is necessary to prepare a large number of carbon fiber prepregs 91A to 91G to be laminated that have different shapes according to the site to be laminated. It is not practical because it also complicates molding.

  Further, when a plurality of carbon fiber prepregs are laminated and pressure is applied by using a pressure die having irregularities on the mold surface in advance, when irregularities are formed on the surface of the carbon fiber reinforced plastic during heat molding, a plurality of carbons are formed. Since the fiber prepreg is shaped by pressing the convex portion of one mold surface to the concave portion of the other mold surface, as shown in FIG. 11, a carbon fiber reinforced plastic composed of a plurality of carbon fiber prepregs 92A, 92B, 92C, 92D. 90 is formed by forming a pair of a convex portion 95 on one side and a concave portion 96 on the opposite side, and there is a restriction on the shape. Further, since the general portion 91 having no unevenness and the concave portion and the convex portion can obtain only the fiber reinforced plastic having a constant thickness and the thickness is partially changed, the degree of freedom in design is low. , There are restrictions on usage.

JP 2012-106461 A JP 2004-209717 A JP, 07-243147, A

  The present invention has been made in view of the above points, and it is an object of the present invention to provide a carbon fiber composite material having a high degree of freedom in design and a method of manufacturing the same, which facilitates shaping of concave portions and convex portions on the surface. To do.

According to the invention of claim 1, a plurality of carbon fiber prepregs in which a thermosetting resin is impregnated into a carbon fiber woven fabric made of a weave composed of warp yarns and weft yarns and a porous material made of a foam having an open cell structure are heated. At least one sheet of porous prepreg impregnated with a curable resin is laminated, and the carbon fiber woven fabric and the thermosetting resin impregnated in the porous material are cured and integrated by heating and pressurization to form an integrated carbon fiber. A composite material, wherein the porous prepreg is arranged between the carbon fiber prepregs and the surface of the carbon fiber composite material is constituted by the carbon fiber prepregs, and the surface of at least one side of the carbon fiber composite material, Either one or both of the concave portion and the convex portion formed by the integral heating and pressurization are shaped, and the thickness of the porous prepreg is reduced or increased corresponding to the concave portion and the convex portion, Carbon fiber Wherein the shape is fixed with prepreg and the porous prepreg are integrated.

According to a second aspect of the present invention, in the first aspect , the surface on the opposite side of the concave portion and the convex portion is a flat surface having no unevenness.

According to a third aspect of the invention, in the first or second aspect , the plurality of carbon fiber prepregs and the porous prepreg have the same shape in plan view.

A fourth aspect of the present invention is characterized in that, in any one of the first to third aspects, a plurality of the porous prepregs are overlapped and arranged between the carbon fiber prepregs.

According to a fifth aspect of the present invention, in any one of the first to fourth aspects, the carbon fiber prepreg is present between a surface on one side of the carbon fiber composite material and the porous prepreg closest to the surface. The number of carbon fiber prepregs is equal to the number of carbon fiber prepregs existing between the surface on the other side and the porous prepreg closest to the surface.

A sixth aspect of the present invention is the carbon fiber prepreg according to any one of the first to fourth aspects, wherein the carbon fiber prepreg exists between a surface on one side of the carbon fiber composite material and the porous prepreg closest to the surface. It is characterized in that the number of sheets and the number of carbon fiber prepregs existing between the surface on the other side and the porous prepreg closest to the surface are different.

The invention of claim 7 is a method for producing a carbon fiber composite material in which porous prepregs are arranged between carbon fiber prepregs, wherein the carbon fiber prepregs are carbon fiber woven fabrics composed of warp and weft yarns. The thermosetting resin is impregnated into the porous prepreg, and the porous prepreg is formed by impregnating a thermosetting resin into a porous material made of a foam having an open cell structure. Between the lower pressure mold and the upper pressure mold in which at least one or both of the concave portion and the convex portion are formed on the mold surface of at least one pressure mold of the pressure mold, the carbon fiber prepreg and the porous prepreg, the carbon Arranged in a laminated state in which the porous prepreg is located between the fiber prepregs, the carbon fiber prepreg and the porous prepreg in the laminated state, the lower pressure mold and the upper pressure mold Under pressure to the entire surface compressing the porous prepreg, the concave and convex portions of the mold surface is heated while the amount of compression in accordance with the concave and convex portions of the mold surface, the carbon fiber woven fabric and the porous material By curing the thermosetting resin impregnated in, to form a carbon fiber composite material by integrating the carbon fiber prepreg and the porous prepreg, on the surface of at least one side of the carbon fiber composite material. Is a concave portion and a convex portion of the mold surface, at least one of the concave portion and the convex portion is shaped , corresponding to the surface of the carbon fiber composite material shaped at least one of the concave portion and the convex portion, the porous prepreg The thickness of the porous prepreg is fixed by decreasing or increasing the thickness of the porous prepreg .

  According to the invention of claim 1, a carbon fiber composite in which one or both of a concave portion and a convex portion are formed on the surface by arranging a porous prepreg between a plurality of carbon fiber prepregs and applying heat and pressure. It becomes possible to obtain a material, and it is not necessary to stack various types of carbon fiber prepregs or porous prepregs having different shapes in order to shape the concave and convex portions, and it is easy to shape the unevenness and design The degree of freedom in designing is increased.

According to the invention of claim 1 , since the thickness of the porous prepreg is reduced or increased corresponding to the concave portion and the convex portion, various types having different shapes for shaping the concave portion and the convex portion are formed. Since it is not necessary to stack the carbon fiber prepreg and the porous prepreg, it becomes easy to shape the unevenness and the degree of freedom in design is increased.

According to the invention of claim 2 , since the surface on the opposite side of the concave portion and the convex portion is a flat surface without irregularities, the surface on the side opposite to the concave portion and the convex portion is affected by the influence of the shape of the concave portion and the convex portion on the flat surface. The design can be performed without affecting the design, and the degree of freedom in design design is increased. For example, if it is a component, the storage space can be effectively used without waste in the storage space.

According to the invention of claim 3 , since the plurality of carbon fiber prepregs and the porous prepreg have the same shape in a plan view, various types of carbon fiber prepregs and porous prepregs having different shapes for forming the concave portions and the convex portions are formed. Since it is not necessary to stack them, unevenness can be easily shaped, dimensional variation in the product can be suppressed, mass productivity can be improved, and work man-hours can be reduced.

According to the invention of claim 4 , since a plurality of porous prepregs are overlapped and arranged between the carbon fiber prepregs, it is possible to increase the depth of the concave portion and the height of the convex portion.

According to the fifth and sixth aspects of the present invention, carbon is formed depending on the case where the recess and the projection are formed on only one surface of the carbon fiber composite material, or when the recess and the projection are formed on both surfaces. By changing the number of carbon fiber prepregs arranged between both side surfaces of the fiber composite material and the porous prepreg, it is possible to obtain a carbon fiber composite material in which favorable recesses and protrusions are formed and which is free from warpage. Further, the warp amount can be controlled by appropriately changing the arrangement position of the porous prepreg.

According to the invention of claim 7 , by disposing a porous prepreg between a plurality of carbon fiber prepregs and heating and pressurizing the carbon fiber prepregs, one or both of the concave portions and the convex portions are shaped on the surface of the carbon fiber composite. It becomes possible to obtain a material, and it is not necessary to stack various types of carbon fiber prepregs or porous prepregs having different shapes in order to shape the concave and convex portions, and it is easy to shape the unevenness and design The degree of freedom in designing is increased.

It is a top view of the carbon fiber composite material which concerns on 1st Embodiment of this invention. 2 is a sectional view taken along line 2-2 of FIG. 1. FIG. 3 is an enlarged cross-sectional view of part A in FIG. 2. It is a schematic sectional drawing which shows the apparatus at the time of molding the carbon fiber composite material of 1st Embodiment. It is a top view of the carbon fiber composite material which concerns on 2nd Embodiment of this invention. FIG. 6 is a sectional view taken along line 6-6 of FIG. 5. It is a B section expanded sectional view of FIG. It is a schematic sectional drawing which shows the apparatus at the time of molding the carbon fiber composite material of 2nd Embodiment. It is an expanded sectional view showing a part of carbon fiber compound material concerning a 3rd embodiment. It is an expanded sectional view which shows the convex part formed in the carbon fiber reinforced plastic by the conventional lamination. It is an expanded sectional view which shows the convex part formed in the carbon fiber reinforced plastic by the conventional pressurization.

  Hereinafter, embodiments of the present invention will be described. The carbon fiber composite material 10 of the first embodiment shown in FIG. 1 is used as an outer plate of a lid in a case of a notebook computer, and as shown in FIGS. 2 and 3, a frame is provided on the outer surface. A character constituted by the concave portion 103 is formed in a portion surrounded by the concave portion 101 having a shape. A metal foil may be attached to the recesses 101 and 103, or a colored resin for decoration may be laminated.

The carbon fiber composite material 10 is composed of a laminated body in which one porous prepreg 21 is arranged between two carbon fiber prepregs 11 and 13 and integrated by heating and pressing.
The carbon fiber prepregs 11 and 13 are made of carbon fiber woven fabric impregnated with a thermosetting resin. The carbon fiber woven fabric is excellent in light weight and high rigidity, and in particular, it is preferable that the woven fabric is not unidirectional in fiber, for example, plain weave, twill weave, satin weave and three-way weave composed of warp and weft. A triaxial weave composed of the above-mentioned threads is suitable. Further, the carbon fiber woven fabric preferably has a fiber weight of 50 to 600 g / m ² from the viewpoint of impregnation with a thermosetting resin and rigidity.

  The thermosetting resin with which the carbon fiber woven fabric is impregnated is not particularly limited, but in order to increase the rigidity of the carbon fiber composite material 10, the thermosetting resin itself must have a certain degree of rigidity. It can be selected from the group consisting of phenolic resins and mixtures of epoxy resins and phenolic resins. When the carbon fiber composite material 10 is required to have flame retardancy, the thermosetting resin is preferably flame retardant. Phenolic resin is suitable as a thermosetting resin to be impregnated in the carbon fiber woven fabric, because it can reduce additives that impart flame retardancy due to its composition and has good flame retardancy.

  The thermosetting resin is preferably impregnated into the carbon fiber woven fabric so that the resin weight ratio in the carbon fiber prepreg is 50 to 80%, particularly 55 to 70%. By setting the resin ratio as described above, it is possible to further improve the lightness and the rigidity.

The porous prepreg 21 is a porous material impregnated with a thermosetting resin.
The porous material is not particularly limited and may be a foam. As the foam, a foam having an open cell structure is suitable, and for example, it can be selected from urethane resin foam, melamine resin foam, polyolefin (polyamide) foam and the like. Since the foam is open-celled, it can be impregnated with a thermosetting resin and can be molded at a high compression rate. By selecting the above-mentioned material as the porous material, it is possible to perform compression molding to a thickness in which carbon fiber woven fabrics are laminated. In particular, a melamine resin foam or a polyamide resin foam is preferable as the porous material. Further, when the carbon fiber composite material 10 is required to have flame retardancy, the porous material is preferably flame retardant, and the melamine resin foam has good flame retardancy. It is a suitable material. The original thickness of the porous material before compression is appropriately set and is, for example, 1 to 25 mm. When the porous material is a foam, the foam preferably has a density before compression of 5 to 80 kg / m ³ in terms of ease of compression, impregnation, lightness, and rigidity.

  The thermosetting resin with which the porous material is impregnated is not particularly limited, but in order to increase the rigidity of the carbon fiber composite material 10, the thermosetting resin itself needs to have a certain degree of rigidity. It can be selected from the group consisting of phenolic resins and mixtures of epoxy resins and phenolic resins. When the carbon fiber composite material 10 is required to have flame retardancy, the thermosetting resin is preferably flame retardant. Phenolic resin has good flame retardancy and is therefore suitable as a thermosetting resin for impregnating the porous material. Further, it is preferable that the thermosetting resin impregnated in the porous prepreg and the thermosetting resin impregnated in the carbon fiber prepreg are the same, and the increase in the adhesiveness significantly reduces the occurrence of delamination.

  The carbon fiber composite material 10 has the frame-shaped concave portion 101 and the concave portion 103 of a character formed on the outer surface, and at the positions of the concave portions 101 and 103, a general portion 111 without a concave portion and a convex portion is formed. On the other hand, the amount of compression of the porous prepreg 21 is increased and the thickness of the porous prepreg 21 is reduced, which reduces the thickness of the carbon fiber composite material 10. The surface on the opposite side of the recesses 101 and 103 is formed of a flat surface without unevenness.

  The carbon fiber prepregs 11 and 13 and the porous prepreg 21 have the same plan view shape. The number of laminated carbon fiber prepregs and porous prepregs is appropriately set according to the application of the carbon fiber composite material and the required strength. By the way, the pattern portion consisting of the frame shape and the concave portion of the character in FIG. 1 has a size of 30 mm long and 100 mm wide, and the depth of the concave portion is 0.5 mm.

  An example of a molding method for the carbon fiber composite material 10 of the first embodiment will be described. As shown in FIG. 4, the carbon fiber prepreg 11 and the porous prepreg 21 before being cured are provided between the lower pressure mold 31 and the upper pressure mold 32 having the recess forming projections 33 and 34 formed on the mold surface. The carbon fiber prepreg 13 is laminated in this order, and the lower pressure die 31 and the upper pressure die 32 are brought close to each other to press the carbon fiber prepreg 11, the porous prepreg 21, and the carbon fiber prepreg 13 in a laminated state. Heat with. The lower pressure die 31 and the upper pressure die 33 are heated to a temperature at which the thermosetting resin can be cured by a heating means such as an electric heater.

  At the time of pressing and heating the carbon fiber prepregs 11 and 13 and the porous prepreg 21 by the lower pressure mold 31 and the upper pressure mold 32, the recess 101 is formed at a portion pressed by the protrusions 33 and 34 of the upper pressure mold 32. , 103 are formed, and the thermosetting resin impregnated in the carbon fiber prepregs 11 and 13 and the porous prepreg 21 is cured in that state, so that the carbon fiber prepregs 11 and 13 and the porous prepreg 21 are integrated. The carbon fiber composite material 10 is obtained as the carbon fiber composite material 10 is solidified and its shape is fixed.

  The carbon fiber composite material 50 of the second embodiment shown in FIG. 5 is used as an insole for a prosthesis, and as shown in FIGS. 6 and 7, the vicinity of the base of the toes, the arch part, and the heel. Concave portions 501 and 503 and convex portions 502, 504 and 506 are formed at portions corresponding to the portions.

  The carbon fiber composite material 50 includes, in order from the bottommost layer on the back side, carbon fiber prepregs 51, 52, 53, 54, a porous prepreg 61, a carbon fiber prepreg 55, a porous prepreg 62, and carbon fiber prepregs 56, 57, 58. It is composed of a laminated body of 10 layers that are laminated and integrated by heating and pressing. The carbon fiber prepregs 51 to 58 and the porous prepregs 61 and 62 in the second embodiment have the same configurations as the carbon fiber prepregs 11 and 13 and the porous prepreg 21 in the first embodiment.

  In the carbon fiber composite material 50, the number of carbon fiber prepregs existing between the surface on which the concave portions 501, 503 and the convex portions 502, 504, 506 are formed and the porous prepreg 62 closest to the surface is Whereas the number of the carbon fiber prepregs is 3, the number of the carbon fiber prepregs existing between the surface on the opposite side having no recesses and protrusions and the porous prepreg 61 closest to the surface is 4 and Further, the porous prepreg 62 is arranged near the convex portion side. This arrangement facilitates shaping of the concave and convex portions.

  At the positions of the recesses 501 and 503, the amount of compression of the porous prepregs 61 and 62 is increased and the thickness of the porous prepregs is reduced as compared with the general portion 511 having no recesses and protrusions, whereby the carbon fiber is reduced. The thickness of the composite material 50 is reduced. On the other hand, at the positions of the convex portions 502, 504, 506, the amount of compression of the porous prepregs 61, 62 is reduced and the thickness of the porous prepreg is increased as compared with the general portion 511 having no concave portion or convex portion. As a result, the thickness of the carbon fiber composite material 50 is increased. Further, the surfaces of the concave portions 501, 503 and the convex portions 502, 504, 506 on the opposite side are formed by flat surfaces without irregularities.

  The plurality of carbon fiber prepregs 51 to 58 and the porous prepregs 61 and 62 have the same plan view shape. Further, the number of laminated carbon fiber prepregs and porous prepregs is appropriately set according to the application of the carbon fiber composite material and the required strength.

  An example of a method of forming the carbon fiber composite material 50 will be described. As shown in FIG. 8, before curing, between the lower pressure die 71 and the upper pressure die 72 in which the depression forming projections 73 and 75 and the protrusion forming depressions 74, 76 and 78 are formed on the die surface. The carbon fiber prepregs 51, 52, 53, 54, the porous prepreg 61, the carbon fiber prepreg 55, the porous prepreg 62, and the carbon fiber prepregs 56, 57, 58 are laminated in this order, and the lower pressure mold 71 and the upper side are laminated. The pressing mold 72 is brought close to pressurize and heat the carbon fiber prepreg and the porous prepreg in the laminated state. The lower pressure mold 71 and the upper pressure mold 72 are heated to a temperature at which the thermosetting resin can be cured by heating means such as an electric heater.

  When the carbon fiber prepreg and the porous prepreg are pressed and heated by the lower pressure mold 71 and the upper pressure mold 72, the recesses 501 and 503 are formed at the portions pressed by the protrusions 73 and 75 of the upper pressure mold 72. On the other hand, the convex portions 502, 504, 506 are formed at the portions contacting the depressions 74, 76, 78, and in that state, the carbon fiber prepregs 51-56 and the porous prepregs 61, 62 are impregnated. By curing the thermosetting resin, the carbon fiber prepregs 51 to 58 and the porous prepregs 61 and 62 are integrated and the shape is fixed, and the carbon fiber composite material 50 is obtained.

  FIG. 9 shows an enlarged part of the carbon fiber composite material 80 of the third embodiment having another laminated structure. In the carbon fiber composite material 80, two porous prepregs 81A and 81B are stacked, and four carbon fiber prepregs 82A, 82B, 82C, 82D, 83A, 83B, 83C and 83D are stacked on both sides thereof. It is composed of a laminated body of 10 layers integrated by heating and pressing, and convex portions 85 and 87 are formed on both side surfaces of the carbon fiber composite material 80. The carbon fiber prepregs 82A to 82D, 83A to 83D and the porous prepregs 81A and 81B in the third embodiment have the same configurations as the carbon fiber prepregs 11 and 13 and the porous prepreg 21 in the first embodiment.

  The carbon fiber composite material 80 includes the number of the carbon fiber prepregs 82A to 82D existing between the surface on one side where the convex portion 85 is formed and the porous prepreg 81A closest to the surface, and the number of the carbon fiber prepregs 82A to 82D on the opposite side. The number of the carbon fiber prepregs 83A to 83D existing between the surface on which the convex portion 87 is formed and the porous prepreg 81B closest to the surface is all four, and the carbon fiber prepregs 83A to 83D are equally arranged on both sides. . With this arrangement, it is easy to shape the convex portions 85 and 87 on both side surfaces.

  At the positions of the convex portions 85 and 87, the amount of compression of the porous prepregs 81A and 81B is reduced and the thickness of the porous prepregs 81A and 81B is increased as compared with the general portion 811 having no concave portion or convex portion, This increases the thickness of the carbon fiber composite material 80. The surface on the opposite side of the positions of the convex portions 85 and 87 is formed by a flat surface without irregularities.

  The plurality of carbon fiber prepregs 82A to 82D, 83A to 83D and the porous prepregs 81A and 81B have the same plan view shape. Further, the number of laminated carbon fiber prepregs and porous prepregs is appropriately set according to the application of the carbon fiber composite material and the required strength.

-Example 1
An example of molding the carbon fiber composite material 10 of FIG. 1 will be shown. As a thermosetting resin, phenol resin (manufactured by Asahi Organic Materials Co., Ltd., product name; PAPS-4 and Asahi Organic Materials Co., Ltd., product name; hexamethylenetetramine mixed at 100: 12) was added to methanol at a concentration of 30 wt%. Dissolved so that A plain weave carbon fiber fabric (manufactured by Toho Tex Co., Ltd., product name: W-3101, fiber weight 200 g / m ² ) was dipped in this phenol resin solution, taken out, and then naturally dried at room temperature of 25 ° C. for 2 hours, Further, it was dried in an atmosphere of 60 ° C. for 1 hour to form two carbon fiber prepregs. As the carbon fiber woven fabric, one cut into a plane size of 200 × 300 mm (weight: 12 g / sheet) was used.

Further, as a foam having an open cell structure, a melamine resin foam (manufactured by BASF, product name: Basotect V3012, density 9 kg / m ³ ) cut into a thickness of 10 mm and a plane size of 200 × 300 mm (weight 5.4 g) was used as carbon. It was dipped in a phenol resin solution in the same manner as the fiber woven fabric, taken out, naturally dried at room temperature of 25 ° C. for 2 hours, and further dried in an atmosphere of 60 ° C. for 1 hour to form one porous prepreg.

  Next, the carbon fiber prepreg and the porous prepreg are laminated and heated in an upper and lower molding die having a cavity to obtain a carbon fiber composite. That is, on the cavity of the lower mold made of SUS whose surface is previously coated with a release agent, the lamination order shown in FIG. 4, that is, the carbon fiber prepreg, the porous prepreg, and the carbon fiber prepreg are laminated and arranged. , Pressing the laminated body on the lower mold with a surface pressure of 5 MPa at 180 ° C. for 3 minutes by an upper mold having a projection for forming a concave portion on the mold surface to perform compression and heating, The phenol resin was reactively cured in the compressed state. The heating at that time was performed by a casting heater attached to the upper and lower molds. As for the thickness after compression, the cavity was designed according to the general part forming the flat plate according to the product shape. Then, the upper and lower molds were cooled at room temperature and then opened to obtain a carbon fiber composite material 10 of FIG. 1 in which the carbon fiber prepreg and the porous prepreg were laminated and integrated.

-Example 2
An example of molding the carbon fiber composite material 50 of FIG. 5 is shown. In the same manner as in Example 1, eight carbon fiber prepregs were formed and two porous prepregs were formed.
Next, a carbon fiber prepreg and a porous prepreg were sequentially laminated and arranged on the lower mold made of SUS having the surface coated with a release agent in the laminating order shown in FIG. The upper laminated body is pressed by applying an surface pressure of 5 MPa for 3 minutes at 180 ° C. by an upper mold having a projection for forming a concave portion and a depression for forming a convex portion on the mold surface, and compression and heating are performed. Then, the phenol resin was reacted and cured in the compressed state. The heating at that time was performed by a casting heater attached to the upper and lower molds. As for the thickness after compression, the cavity was designed according to the general part forming the flat plate according to the product shape. Then, the upper and lower molds were cooled at room temperature and then opened to obtain a carbon fiber composite material in which the carbon fiber prepreg and the porous prepreg were laminated and integrated. After that, trimming is performed to cut an excess portion around the carbon fiber composite material to obtain a carbon fiber composite material 50 in FIG.

  As described above, according to the present invention, it is not necessary to stack various types of carbon fiber prepregs or porous prepregs having different shapes in order to shape the recesses and the protrusions, and it is easy to shape the unevenness and design. The degree of freedom in designing is increased.

Various modifications can be conceived by referring to the present specification and the drawings. In accordance with the teachings herein, the present invention includes the following.
The plurality of carbon fiber prepregs and the porous prepreg are not limited to the case where the shape in plan view is the same, depending on the shape of the product to be molded, depending on the stacking position, the planar shape of the above two kinds of prepregs, Can be cut and designed. In particular, the plan view shape of the porous prepreg can be cut and designed according to the stacking position.

10, 50, 80 Carbon fiber composite material 11, 13, 51-58, 82A-82D, 83A-83D Carbon fiber prepreg 21, 61, 62, 81A, 81B Porous prepreg 101, 103, 501, 503 Recess 502, 504 , 506, 85, 87 Convex part 111, 511, 811 General part

Claims (7)

A plurality of carbon fiber prepregs in which a thermosetting resin is impregnated in a carbon fiber woven fabric composed of a warp and a weft, and a porous material made of a foam having an open cell structure and impregnated with the thermosetting resin. A carbon fiber composite material in which at least one sheet of high-quality prepreg is laminated and the thermosetting resin impregnated in the carbon fiber woven fabric and the porous material is cured and integrated by heating and pressing,
The porous prepreg is arranged between the carbon fiber prepregs and the surface of the carbon fiber composite material is composed of the carbon fiber prepregs,
On at least one surface of the carbon fiber composite material, one or both of the concave portion and the convex portion formed by the integrated heating and pressing are shaped,
Corresponding to the concave portion and the convex portion, the thickness of the porous prepreg is reduced or increased, the carbon fiber prepreg and the porous prepreg are integrated and the shape is fixed. Material. The carbon fiber composite material according to claim 1, wherein a surface opposite to the concave portion and the convex portion is a flat surface having no irregularities. The carbon fiber composite material according to claim 1 or 2, wherein the plurality of carbon fiber prepregs and the porous prepreg have the same shape in plan view. The carbon fiber composite material according to any one of claims 1 to 3, wherein a plurality of the porous prepregs are overlapped and arranged between the carbon fiber prepregs. The number of carbon fiber prepregs existing between the surface of one side of the carbon fiber composite material and the porous prepreg closest to the surface, and the surface of the other side and the porous prepreg closest to the surface The carbon fiber composite material according to any one of claims 1 to 4, wherein the number of the carbon fiber prepregs existing between them is equal. The number of carbon fiber prepregs existing between the surface of one side of the carbon fiber composite material and the porous prepreg closest to the surface, and the surface of the other side and the porous prepreg closest to the surface The carbon fiber composite material according to any one of claims 1 to 4, wherein the number of carbon fiber prepregs existing between them is different. A method for producing a carbon fiber composite material in which a porous prepreg is arranged between carbon fiber prepregs,
  The carbon fiber prepreg is formed by impregnating a thermosetting resin into a carbon fiber woven fabric made of a weave composed of warp yarns and weft yarns,
  The porous prepreg is formed by impregnating a thermosetting resin into a porous material made of a foam having an open cell structure,
  Between the lower pressure mold and the upper pressure mold in which at least one or both of a concave portion and a convex portion are formed on the mold surface of at least one of the lower pressure mold and the upper pressure mold, the carbon fiber prepreg and the above The porous prepreg is arranged in a laminated state in which the porous prepreg is located between the carbon fiber prepregs,
  The carbon fiber prepreg and the porous prepreg in the laminated state are pressed by the lower pressure die and the upper pressure die to compress the entire surface of the porous prepreg, and the concave and convex portions of the die surface have the die surface. The amount of compression according to the concave and convex parts of
  By curing the carbon fiber woven fabric and the thermosetting resin impregnated in the porous material, the carbon fiber prepreg and the porous prepreg are integrated to form a carbon fiber composite material, and the carbon fiber The surface of at least one side of the composite material, the concave surface and the convex portion of the mold surface, at least one of the concave portion and the convex portion is shaped, the surface of the carbon fiber composite material shaped at least one of the concave portion and the convex portion The method for producing a fiber-reinforced composite material according to, wherein the thickness of the porous prepreg is reduced or increased to fix the thickness of the porous prepreg.

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