JP6750949B2 - Method for manufacturing fiber-reinforced resin structure and fiber-reinforced resin structure - Google Patents

Description

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

2. Description of the Related Art In recent years, three-dimensional structural members made of fiber reinforced resin such as carbon fiber reinforced resin (CFRP) are being used as structural members constituting structures such as automobile bodies. The structural member made of the fiber-reinforced resin can reduce the weight of the structural member as compared with the metallic structural member. The structure made of fiber reinforced resin is, for example, a fiber reinforced resin laminate obtained by laminating a fiber reinforced resin sheet in which reinforced fibers are impregnated with a thermosetting matrix resin, is heated and pressed using an autoclave device, and the matrix resin It is manufactured by curing.

Here, the structural member may be provided with a hole into which the connector or the like is inserted. For example, Patent Document 1 discloses a resin arm made of a fiber-reinforced resin having an attachment portion for a joint device provided at an axial end portion. The shaft portion of such a resin arm is manufactured, for example, by cutting a long material obtained by a continuous drawing method using a molten resin material containing long fibers as reinforcing fibers, to an appropriate length. The tubular portion as the mounting portion of the resin arm is manufactured, for example, by filling a molten resin material containing short fibers as reinforcing fibers into a molding cavity formed by a molding die and cooling and solidifying. It

JP, 10-272707, A

However, although the resin arm described in Patent Document 1 is manufactured using a fiber-reinforced resin, the tubular portion is formed of a molten resin material containing short fibers, and like the suspension arm. However, it cannot be said that the rigidity and the strength are sufficient for a part that requires high rigidity and strength.

Therefore, the present invention has been made in view of the above problems, and an object of the present invention is to improve the rigidity and strength of the holes provided in the structure made of fiber reinforced resin, which is new and improved. The present invention provides a method for manufacturing the fiber-reinforced resin structure and the fiber-reinforced resin structure.

In order to solve the above problems, according to an aspect of the present invention, a fiber-reinforced resin structure is obtained by curing a fiber-reinforced resin laminate in which a plurality of fiber-reinforced resin sheets in which reinforcing fibers are impregnated with a matrix resin are laminated. A method of manufacturing a fiber-reinforced resin structure to be manufactured, comprising: a laminating step of manufacturing a fiber-reinforced resin laminate by laminating a plurality of fiber-reinforced resin sheets; and a fiber-reinforced resin structure obtained by curing the fiber-reinforced resin laminate. In the laminating step, the continuous fiber oriented in one direction was impregnated with the matrix resin, and the step of forming a hole in the fiber-reinforced resin structure by forming a hole in the fiber-reinforced resin structure. Provided is a method for producing a fiber-reinforced resin structure, in which a continuous fiber-reinforced sheet is arranged along the periphery of a portion corresponding to a hole.

The continuous fiber reinforced sheet may be laminated between the fiber reinforced resin sheets.

When arranging a plurality of continuous fiber reinforced sheets, all or a part of the plurality of continuous fiber reinforced sheets may be arranged at different positions.

The method may further include the step of disposing a cylindrical member in the hole.

Further, in order to solve the above problems, according to another aspect of the present invention, it is formed by curing a fiber-reinforced resin laminate in which a plurality of fiber-reinforced resin sheets impregnated with a matrix resin in a reinforcing fiber are laminated. A fiber reinforced resin structure, wherein a hole is formed in the fiber reinforced resin laminate by a perforating process, and the matrix resin is arranged along the periphery of the hole and the unidirectionally oriented continuous fibers. An impregnated continuous fiber reinforced sheet is provided, and a fiber reinforced resin structure is provided.

The fiber reinforced resin structure may be a vehicle suspension arm.

As described above, according to the present invention, it is possible to improve the rigidity and strength of the hole provided in the structure made of fiber reinforced resin.

It is a schematic diagram which shows the suspension apparatus provided with the lower arm as an example of a fiber reinforced resin structure. It is an explanatory view showing a suspension device. It is a perspective view showing a fiber reinforced resin structure (lower arm) concerning an embodiment of the invention. It is explanatory drawing which shows the manufacturing method of the fiber reinforced resin structure concerning the embodiment. It is explanatory drawing which shows the manufacturing method of the fiber reinforced resin structure concerning the embodiment. It is explanatory drawing which shows the manufacturing method of the fiber reinforced resin structure concerning the embodiment. It is explanatory drawing which shows the lamination process of the manufacturing method of the fiber reinforced resin structure concerning the embodiment. It is sectional drawing of the hole part of the fiber reinforced resin structure concerning the embodiment.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the present specification and the drawings, components having substantially the same functional configuration are designated by the same reference numerals, and duplicate description will be omitted. Further, in the present specification and the drawings, a plurality of constituent elements having substantially the same functional configuration may be distinguished by attaching different alphabets after the same reference numeral. However, when it is not necessary to specifically distinguish each of the plurality of constituent elements having substantially the same functional configuration, only the same reference numeral is given.

<1. Fiber-reinforced resin structure>
(1-1. Outline of lower arm)
First, a lower arm (suspension arm) 20 as an example of a fiber-reinforced resin structure manufactured by the method for manufacturing a fiber-reinforced resin structure according to the present embodiment will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic diagram for explaining a configuration example of a front wheel suspension device 100 of a vehicle including a lower arm 20, and FIG. 2 is an exploded perspective view of the lower arm 20 and a suspension cross member 108.

In the suspension device 100, the left and right of the engine room 102 are partitioned by a front wheel apron 103 which is a component of the vehicle body frame. The front wheel apron 103 is joined to a pair of left and right side frames 105 extending in the front-rear direction of the vehicle body. A strut tower 106 is formed at the rear of the front wheel apron 103. A strut-type suspension 107 is housed in the strut tower 106. The upper portion of the suspension 107 is supported by a strut support portion 106a formed on the upper portion of the strut tower 106 via a strut upper mount 107a.

A suspension cross member 108 is arranged below the engine room 102. Upper surfaces of the suspension cross member 108 at both ends in the vehicle width direction are fixed to the side frame 105 via fasteners such as bolts and nuts. A rear portion of the engine (not shown) is mounted on the upper surface of the suspension cross member 108 via an engine mount. In addition, arm support portions 109 are provided on the lower surfaces of both ends of the suspension cross member 108 in the vehicle width direction so as to project. Each of the left and right arm support portions 109 is provided with a pair of brackets 109a and 109b facing each other in the front-rear direction and the left-right direction at predetermined intervals, and a bolt insertion hole 109c is formed in each of the brackets 109a and 109b. A cylindrical first base portion 21 provided at one base end of the lower arm 20 is disposed between the brackets 109a and 109b.

The lower arm 20 is continuous from the first base portion 21 which is one base end to the tip portion 23, and is continuous from the second base portion 22 which is branched from the central portion and extends rearward to be the other base end, It has a T-shaped or L-shaped planar shape. A bush (not shown) is press-fitted into the first base portion 21 of the lower arm 20. A shaft portion of a bolt 112 inserted from the outside into a bolt insertion hole 109c formed in the brackets 109a and 109b penetrates the bush, and the shaft portion of the bolt 112 is fastened by a nut 113.

Further, a bush (not shown) is press-fitted into the second base portion 22. The second base portion 22 is pivotally supported by the side frame 105 via a bush. Further, a bush (not shown) is press-fitted into the tip portion 23 serving as the swing end. The tip portion 23 is connected to a ball joint (not shown) via a bush, and a wheel hub (not shown) that fixes the front wheel 111 is rotatably supported. As a result, the lower arm 20 supports the lower portion of the suspension 107 and is swingably supported by the suspension cross member 108 and the side frame 105 via the hub housing (not shown).

(1-2. Configuration example of lower arm)
Next, a configuration example of the lower arm 20 as the fiber reinforced resin structure according to the present embodiment will be described in detail. FIG. 3 is a perspective view showing an example of the lower arm 20. The lower arm 20 has a substantially T-shaped or L-shaped planar shape, and has a first base portion 21 connected to the suspension cross member 108, a second base portion 22 connected to the side frame 105, and a ball joint. Are connected to each other and have a tip end portion 23 serving as a swing end. The lower arm 20 is arranged in the main body 18, the holes 19a, 19b and 19c provided in the first base 21, the second base 22 and the tip 23, and the holes 19a, 19b and 19c. It has cylindrical members 27, 28 and 29. The first base portion 21, the second base portion 22, and the tip end portion 23 are provided on the tip end side of the arm portions 25a, 25b, 25c, respectively.

The main body 18 is molded using, for example, a fiber reinforced resin sheet containing continuous fibers. The fiber-reinforced resin sheet containing continuous fibers is formed by impregnating continuous fibers with a matrix resin. Further, the main body portion 18 is composed of a first half body 18a and a second half body 18b joined to each other. The first half body 18a and the second half body 18b are joined at a joining surface along a plane passing through the first base portion 21, the second base portion 22, and the tip portion 23. Each of the first half body 18a and the second half body 18b is molded using a fiber reinforced resin sheet containing continuous fibers. The method of joining the first half body 18a and the second half body 18b is not particularly limited, and various methods including joining with an adhesive, vibration fusion pressure bonding, and heat fusion pressure bonding should be adopted. You can

Examples of the continuous fibers used include carbon fibers, but other fibers may be used, and a plurality of fibers may be used in combination. However, since the carbon fiber has excellent mechanical properties, the reinforcing fiber preferably contains the carbon fiber.

A thermoplastic resin or a thermosetting resin is used as the matrix resin of the fiber reinforced resin. Examples of the thermoplastic resin include polyethylene resin, polypropylene resin, polyvinyl chloride resin, ABS resin, polystyrene resin, AS resin, polyamide resin, polyacetal resin, polycarbonate resin, thermoplastic polyester resin, PPS (polyphenylene sulfide) resin, and fluorine. Examples include resins, polyetherimide resins, polyetherketone resins, and polyimide resins.

As the matrix resin, one kind of these thermoplastic resins or a mixture of two or more kinds can be used. Alternatively, the matrix resin may be a copolymer of these thermoplastic resins. When the matrix resin is a mixture of these thermoplastic resins, a compatibilizer may be used together. Furthermore, the matrix resin may contain a brominated flame retardant as a flame retardant, a silicon flame retardant, red phosphorus, or the like.

In this case, examples of the thermoplastic resin used include polyolefin resins such as polyethylene and polypropylene, polyamide resins such as nylon 6 and nylon 66, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyether ketone, Examples of the resin include polyether sulfone and aromatic polyamide. Among them, the thermoplastic matrix resin is preferably at least one selected from the group consisting of polyamide, polyphenylene sulfide, polypropylene, polyether ether ketone and phenoxy resin.

Examples of the thermosetting resin that can be used as the matrix resin include epoxy resin, unsaturated polyester resin, vinyl ester resin, phenol resin, polyurethane resin, and silicone resin. As the matrix resin, one kind of these thermosetting resins or a mixture of two or more kinds can be used. When these thermosetting resins are used as the matrix resin, an appropriate curing agent or reaction accelerator may be added to the thermosetting resin.

A bush is press-fitted into the cylindrical members 27, 28, 29. Therefore, for example, metal cylindrical members are used as the cylindrical members 27, 28, and 29. Examples of metals that can be used include, but are not limited to, stainless steel, cast iron, titanium, titanium alloys, and the like. The cylindrical members 28 and 29 arranged on the second base portion 22 and the distal end portion 23 may be arranged after the first half body 18a and the second half body 18b are joined and the holes 19b and 19c are formed. Good. Alternatively, the cylindrical members 28 and 29 arranged on the second base portion 22 and the distal end portion 23 form the hole portions 19b and 19c in the first half body 18a and the second half body 18b, respectively. It may be placed after joining the body 18a and the second half 18b.

Further, the cylindrical member 27 arranged on the first base portion 21 forms the half body of the first base portion 21 on each of the first half body 18a and the second half body 18b, and the first half body 18a is formed. And the second half 18b may be joined to form the hole 19a, and then the second half 18b may be arranged. Alternatively, when the first half 21a and the second half 18b are each formed with a half of the first base portion 21 and the first half 18a and the second half 18b are joined, The member 27 may be sandwiched and attached.

In the lower arm 20 configured as above, the cylindrical member 27 arranged on the cylindrical first base portion 21 has a central axis that substantially coincides with the front-rear direction of the vehicle, and the tip portion 23 swings in the vertical direction. To enable. Further, the cylindrical member 28 arranged on the second base portion 22 has a central axis extending substantially in the vertical direction, and allows the tip end portion 23 to swing in the horizontal direction. Since loads and vibrations on the vehicle body are transmitted to the lower arm 20, a large load can be generated on each of the first base portion 21, the second base portion 22, and the tip portion 23. Therefore, the first base portion 21, the second base portion 22, and the tip portion 23 are required to have high rigidity and strength. Therefore, in the lower arm 20 according to the present embodiment, continuous fibers are arranged along the peripheries of the holes 19b and 19c, and the strength of the holes 19b and 19c is increased.

<2. Manufacturing method of fiber-reinforced resin structure>
Next, an example of a method for manufacturing the fiber-reinforced resin structure according to this embodiment will be described. Here, bagging is performed after stacking a fiber reinforced resin sheet in which reinforced fibers are impregnated with a thermosetting matrix resin on a mold, and further, using an autoclave device while depressurizing the inside of the bag (cover sheet). An example of a method of manufacturing the lower arm 20 in which the entire bag is heated while being pressurized to cure the laminated body of the fiber reinforced resin will be described. The method for producing the fiber-reinforced resin structure described below is merely an example and does not limit the present invention.

The method for manufacturing the fiber-reinforced resin structure according to this embodiment includes the following steps.
・Prepreg cutting process ・Laminating process ・Bagging process ・Molding process ・Joining process ・Punching process

Hereinafter, the method for manufacturing the fiber-reinforced resin structure shown in FIG. 3 will be described in the order of steps with appropriate reference to FIGS. 4 to 7. 4 to 6 are explanatory views showing the flow of the method for manufacturing the lower arm 20 according to the present embodiment.

(2-1. Prepreg cutting process)
As shown in FIG. 4, in the prepreg cutting step, the fiber-reinforced resin sheet 5 having a predetermined width is cut into a size or a length suitable for the fiber-reinforced resin structure to be manufactured, and the prepreg 12 is produced. .. The shape of the prepreg 12 can be made substantially the same as the expanded shape of the main body portion 18, and in this case, the dimensions of the prepreg 12 may be larger than the outer shape of the main body portion 18.

The fiber-reinforced resin sheet 5 containing continuous fibers is manufactured by, for example, a known film impregnation method or a melt impregnation method, by impregnating the reinforcing fibers with the matrix resin while continuously feeding the reinforcing fibers. The fiber reinforced resin sheet 5 is appropriately cut to produce a prepreg 12 having a desired plane shape. The thickness of one fiber-reinforced resin sheet 5 or prepreg 12 can be set to a value within the range of 0.03 to 1.0 mm, for example.

(2-2. Laminating process)
As shown in FIG. 5, in the laminating step, a plurality of prepregs 12 are laminated to produce a fiber-reinforced resin laminate 14. The prepreg 12 is laminated on the molding surface of the molding die 40, for example. The number of prepregs 12 to be laminated is not particularly limited and may be selected according to the application of the fiber reinforced resin structure to be manufactured, but for example, 3 to 6 prepregs 12 can be laminated. .. At this time, the fiber-reinforced resin laminate 14 may be produced by aligning the orientation directions of the continuous fibers of the prepregs 12 in one direction and laminating them. This can increase the strength of the manufactured lower arm 20 in a specific direction along the orientation direction of the continuous fibers. Alternatively, the fiber-reinforced resin laminate 14 may be manufactured by laminating the continuous fibers of some or all of the prepregs 12 with different orientation directions. As a result, the strength of the manufactured lower arm 20 can be made anisotropic.

In addition, when laminating|stacking several prepregs 12 and shaping|molding the fiber reinforced resin laminated body 14, the kind, content rate, etc. of the reinforced fiber contained in each fiber reinforced resin sheet may differ. Further, in the plurality of laminated fiber-reinforced resin sheets, different materials having compatibility may be used as the matrix resin, or different additives may be mixed with the same matrix resin. Good. Also in this case, a matrix resin having a similar melting point may be used so that the fiber-reinforced resin laminate 14 can be efficiently melted and cured.

Here, in the method for manufacturing the lower arm 20 according to the present embodiment, when the prepreg 12 is laminated in the laminating step, continuous fibers that are oriented in one direction along the periphery of the portions corresponding to the holes 19b and 19c are formed. Arrange continuous fiber reinforced sheet containing. As a result, the holes 19b and 19c of the manufactured lower arm 20 are reinforced by the continuous fibers, and the rigidity and strength can be improved.

FIG. 7: is explanatory drawing which shows a mode that the prepreg 12 and the continuous fiber reinforcement sheets 13a and 13b are laminated|stacked in the lamination process, and the 2nd base 22 is formed. The prepreg 12 constituting the main body portion 18 is arranged, for example, such that the continuous fibers are oriented along the extending direction of the arm portion 25b whose tip is the second base portion 22. When the main body portion 18 is formed by stacking the prepregs 12 arranged in this manner, the continuous fiber is cut at the hole portion 19b by performing the perforating process. Therefore, the continuity of the fibers is lost in the holes 19b, and the rigidity and strength around the holes 19b are significantly reduced. In particular, of the periphery of the hole 19b, the fiber length on the tip side of the arm 25b becomes short, so that the hole 19b is easily broken.

On the other hand, in the method for manufacturing the lower arm 20 according to the present embodiment, the continuous fiber reinforcing sheets 13a and 13b made of a fiber reinforced resin sheet (UD (Uni-Directional) material) containing continuous fibers oriented in one direction, It is arranged along the periphery of a portion corresponding to the hole portion 19b (hereinafter, also referred to as "portion to be opened"). As a result, the continuity of the fibers around the hole 19b is maintained even after the perforation process is performed, and the rigidity and strength around the hole 19b can be prevented from lowering. The continuous fiber-reinforced sheets 13a and 13b can be formed by cutting the above-mentioned fiber-reinforced resin sheet 5 (see FIG. 4) into a predetermined length and width. That is, the thickness of the continuous fiber reinforcing sheets 13 a and 13 b may be the same as the thickness of the prepreg 12.

In the example shown in FIG. 7, the continuous fiber reinforced sheets 13a and 13b made of UD material are arranged along the periphery of the distal end side of the arm portion 25b in the planned hole-forming portion 19b′, and both ends thereof are arranged in the arm portion 25b. Are arranged along the extending direction of the. As a result, the continuous fibers are continuously arranged along the periphery of the hole portion 19b on the distal end side, and the periphery of the hole portion 19b on the distal end side of the arm portion 25b is reinforced. As a result, the rigidity and strength of the hole 19b can be improved. Further, both ends of the continuous fiber reinforced sheets 13a and 13b are arranged along the extending direction of the arm portion 25b, so that the continuous fiber reinforced sheet is heated and pressed and cured in the molding step. The continuous fibers contained in 13a and 13b easily enter between the continuous fibers contained in the prepreg 12 of the arm portion 25b, and are easily integrated.

At this time, the continuous fiber reinforcing sheets 13a and 13b may be arranged on the plurality of laminated prepregs 12. However, in order to improve the integrity of the prepreg 12 and the continuous fiber reinforcing sheets 13a and 13b, a plurality of sheets may be used. It is preferably laminated between the prepregs 12. Moreover, the number of the continuous fiber reinforcing sheets 13a and 13b arranged is not particularly limited. However, if only one continuous fiber reinforcing sheet 13a, 13b is provided, the rigidity and strength of the hole 19b may not be sufficiently improved. Further, if the continuous fiber reinforcing sheets 13a and 13b are too much, the thickness around the hole 19b may be excessively large, and the step between the portion where the continuous fiber reinforcing sheets 13a and 13b are not arranged and the boundary is large. Become. Therefore, the number of the continuous fiber reinforcing sheets 13a and 13b arranged can be set to, for example, 2 to 5.

Further, as shown in FIG. 7, when a plurality of continuous fiber reinforcing sheets 13a, 13b are arranged, the continuous fiber reinforcing sheets 13a, 13b may be arranged with their end portions being displaced. By displacing the positions of the end portions in this way, it is possible to make a level difference at the boundary with the portion where the continuous fiber reinforcing sheets 13a and 13b are not arranged. FIG. 7 shows an example in which the end portions of the two continuous fiber reinforcing sheets 13a and 13b are displaced, but when stacking three or more continuous fiber reinforcing sheets 13a and 13b, all the end portions are They may be offset, or some ends may be offset.

In addition, here, although the example in which the continuous fiber reinforcing sheets 13a and 13b are arranged along the periphery of the planned hole-forming site 19b′ of the second base portion 22 has been described, the distal-end part 23 similarly has the planned hole-forming site. A continuous fiber reinforced sheet may be arranged along the perimeter of. The continuous fiber reinforcing sheet may be arranged on either one of the second base portion 22 and the tip portion 23, or may be arranged on both.

(2-3. Bagging process)
As shown in FIG. 5, in the bagging step, a bag (covering sheet) 31 made of rubber, for example, is placed on the fiber-reinforced resin laminate 14 arranged on the molding die 40, and the bag 31 and the molding die 40 are separated from each other. Is clamped. The mold 40 may be, for example, a mold or a mold made of fiber reinforced resin. The bag 31 is not limited to a rubber bag as long as it is a deformable bag. However, both the molding die 40 and the bag 31 are made of a material that can withstand heat treatment using an autoclave device in a subsequent step. By this bagging, at least the molding space 33 formed by the molding die 40 and the bag 31 is made airtight.

(2-4. Molding process)
As shown in FIG. 5, in the molding step, the bagged fiber reinforced resin laminate 14 is put into the autoclave device. The autoclave device is a device that performs heat treatment while maintaining a high pressure inside the kettle. After the fiber-reinforced resin laminate 14 is put into the autoclave device, the air in the molding space 33 is sucked by the pump 35 or the like, and the molding space 33 is evacuated. As a result, the fiber-reinforced resin laminate 14 is heated and cured under pressure while the air inside the prepreg 12 and the continuous fiber-reinforced sheets 13a and 13b is degassed. As a result, the first half body 18a forming the main body portion 18 is molded. By heating under pressure while forming the molding space 33 in a vacuum state, it is possible to reduce the void ratio of the first half body 18a to be molded, and to increase the mechanical strength of the first half body 18a. You can Further, since the inside of the molding space 33 is in a vacuum state, the surface opposite to the surface in contact with the molding die 40 has a relatively clean finish.

The second half body 18b is also formed by the same procedure as the prepreg cutting process, the laminating process, the bagging process, and the molding process described so far.

(2-5. Drilling process)
As shown in FIG. 6, in the punching step, the punching process is performed on the planned drilling portions of the second base portion 22 and the tip portion 23 of the first half body 18a and the second half body 18b, respectively. Therefore, the holes 19b and 19c are formed. FIG. 6 shows a state in which holes 19b and 19c are formed in the first half body 18a. Holes 19b and 19c are similarly formed in the second half 18b. As the boring process, water jet process, laser process, or boring process using a tool such as a drill or an end mill can be adopted. However, the drilling process is not limited to this example.

(2-6. Joining process)
As shown in FIG. 6, in the joining step, the first half body 18a and the second half body 18b are joined to each other to produce the main body portion 18. The joining method is not particularly limited, and various methods such as joining with an adhesive, vibration fusion pressure bonding, and heat fusion pressure bonding can be adopted. In the example of the method of manufacturing the lower arm 20 according to the present embodiment, the hole 19a of the first base portion 21 is formed by joining the first half body 18a and the second half body 18b.

Further, when the first half body 18a and the second half body 18b are joined, the cylindrical member 27 is arranged in a portion corresponding to the hole portion 19a of the first base portion 21, and the hole portion 19a and the cylindrical member 27 are arranged. You may join and. In this case, since the inner surface of the hole 19a is not the surface formed by the molding surface of the molding die 40, the cylindrical member 27 may be joined after improving the surface accuracy by cutting or the like. Thereafter, although not shown, the cylindrical members 28 and 29 are arranged in the holes 19b and 19c formed in the main body 18, respectively, and the lower arm 20 is manufactured.

FIG. 8 schematically shows an example of a cross section of the manufactured lower arm 20 in which the arm portion 25b is cut so as to include the axis of the hole portion 19b of the second base portion 22. The left side of FIG. 8 is the tip side of the arm portion 25b. In the example of the lower arm 20, four prepregs 12 and three continuous fiber reinforcing sheets 13a and 13b are alternately laminated. In the arm portion 25b of the lower arm 20, a plurality of prepregs 12 are laminated and heat-cured. Therefore, the continuous fibers are oriented along the horizontal direction shown in the figure. In the arm portion 25b, since the continuous fibers are arranged without being cut, rigidity and strength are secured.

Further, in the portion of the periphery of the hole portion 19b located on the tip side of the arm portion 25b, the prepreg 12 and the continuous fiber reinforcing sheets 13a and 13b are alternately laminated and heat-cured. Among them, in the layer formed by the prepreg 12, the continuous fibers are oriented along the horizontal direction in the drawing. On the other hand, in the layer formed by the continuous fiber reinforcing sheets 13a and 13b, the continuous fibers are oriented along the depth direction shown in the figure. Therefore, although the continuous fibers contained in the prepreg 12 are cut into short pieces, the continuous fibers contained in the continuous fiber reinforcing sheets 13a and 13b are arranged around the holes 19b, and the rigidity of the holes 19b and The strength is secured.

As described above, in the method for manufacturing the fiber-reinforced resin structure according to the present embodiment, when the fiber-reinforced resin laminate 14 is manufactured by laminating the prepreg 12 made of the fiber-reinforced resin sheet, Continuous fiber reinforcing sheets 13a and 13b made of a UD material are arranged along the circumference. Therefore, even if the continuous fiber contained in the prepreg 12 is cut by the perforation process to generate a portion having a short fiber length, the continuous fiber contained in the continuous fiber reinforcing sheets 13a and 13b prevents the continuous fiber from surrounding the hole portion 19b. The continuity of the fibers is maintained. Therefore, the rigidity and strength of the hole 19b can be improved.

Further, in the lower arm 20 manufactured by the method for manufacturing the fiber-reinforced resin structure according to the present embodiment, the rigidity and strength of the holes 19b and 19c in which the cylindrical members 28 and 29 are arranged are improved, and the second base 22 is formed. Also, the mechanical strength of the tip portion 23 is increased. Therefore, it is possible to obtain the lower arm 20 having excellent durability against a load caused by a load or vibration.

The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to these examples. It is obvious that a person having ordinary knowledge in the technical field to which the present invention pertains can come up with various changes or modifications within the scope of the technical idea described in the claims. Of course, it is understood that these also belong to the technical scope of the present invention.

For example, in the above embodiment, the punching process is performed after joining the first half body 18a and the second half body 18b, but the order of the joining step and the punching step may be reversed. In this case, after the first half body 18a and the second half body 18b are perforated, the first half body 18a and the second half body 18b are joined to form the main body portion 18. It

Further, in the above embodiment, the manufacturing method including the bagging step and the molding step using the autoclave device has been described as an example, but the present invention is not limited to such an example. For example, the present invention can be applied even to a manufacturing method including a step of heating and melting a fiber-reinforced resin laminate using a thermoplastic resin and then molding while cooling.

Further, in the above-described embodiment, the lower arm 20 is described as an example of the fiber-reinforced resin structure, but the fiber-reinforced resin structure to which the present invention is applicable is not limited to the lower arm. The present invention can be applied to structural members used for various purposes other than the structural members of the vehicle body.

5 Fiber Reinforced Resin Sheet 12 Prepreg 13a, 13b Continuous Fiber Reinforced Sheet 14 Fiber Reinforced Resin Laminate 18 Main Body 18a First Half 18b Second Half 19a, 19b, 19c Hole 20 Fiber Reinforced Resin Structure (Lower Arm) )
21 1st base part 22 2nd base part 23 Tip part 27,28,29 Cylindrical member 40 Mold

Claims (5)

A method for producing a fiber-reinforced resin structure, comprising producing a fiber-reinforced resin structure by curing a fiber-reinforced resin laminate obtained by laminating a plurality of fiber-reinforced resin sheets impregnated with a matrix resin to reinforcing fibers,
A laminating step of producing the fiber-reinforced resin laminate by laminating the plurality of fiber-reinforced resin sheets,
A molding step of curing the fiber-reinforced resin laminate to mold the fiber-reinforced resin structure,
The fiber-reinforced resin structure is subjected to a perforating process, a perforating step of forming a hole portion,
The method for producing a fiber-reinforced resin structure, wherein, in the laminating step, a continuous fiber reinforcing sheet obtained by impregnating continuous fibers oriented in one direction with a matrix resin is arranged along the periphery of a portion corresponding to the hole. The method for producing a fiber-reinforced resin structure according to claim 1, wherein the continuous fiber-reinforced sheet is laminated between the fiber-reinforced resin sheets. The method for producing a fiber-reinforced resin structure according to claim 1, wherein when a plurality of the continuous fiber-reinforced sheets are arranged, all or a part of the plurality of continuous fiber-reinforced sheets are arranged so as to be displaced. The method for producing a fiber-reinforced resin structure according to claim 1, further comprising: disposing a cylindrical member in the hole. A fiber reinforced resin structure formed by curing a fiber reinforced resin laminate in which a plurality of fiber reinforced resin sheets impregnated with a matrix resin in a reinforced fiber are laminated,
A hole portion provided by perforating the fiber-reinforced resin laminate,
A fiber-reinforced resin structure, comprising: a continuous fiber-reinforced sheet that is arranged along the periphery of the hole and is impregnated with a matrix resin into continuous fibers that are oriented in one direction.

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