JP6751835B2 - Manufacturing method of fiber reinforced resin structure - Google Patents

Description

The present invention relates to a method for producing a fiber reinforced resin structure containing a fiber body and a resin.

Conventionally, a composite material composed of a reinforcing fiber body such as CFRP and a flexible body such as a foam has been proposed (see, for example, Patent Document 1).

Japanese Unexamined Patent Publication No. 63-31136

The method described in Patent Document 1 had excellent strength derived from fiber reinforced plastic while being partially curved, but could only produce a fiber reinforced resin structure having a fixed shape.

Therefore, it is an object of the present invention to provide a novel method for producing a fiber reinforced resin structure, which can have various shapes while having a predetermined excellent strength. Further, the second object of the present invention is to provide a novel fiber-reinforced resin structure that can be manufactured by the manufacturing method.

Invention (I)
A method for producing a fiber-reinforced resin structure containing at least a fiber body and a thermosetting resin impregnated in the fiber body.
A laminate having a columnar foam and a fiber body covering at least a part of a side surface portion of the foam, and the fiber body is impregnated with a thermosetting resin in an uncured state. Preparation process to prepare and
A deformation step of applying an external force to the laminate to deform the cross-sectional shape of the foam.
This is a method for producing a fiber reinforced resin structure, which includes a curing step of thermosetting the thermosetting resin contained in the laminate.
The invention (I)
A cooling step of cooling the aggregate after the curing step and
A removal step of removing the foam contained in the laminate after the cooling step may be included.
The invention (I)
The foam may be an olefin resin foam.

Invention (II)
A method for producing a fiber-reinforced resin structure containing at least a fiber body and a thermosetting resin impregnated in the fiber body.
A laminate having a columnar foam and a fiber body covering at least a part of a side surface portion of the foam, and the fiber body is impregnated with a thermosetting resin in an uncured state. Preparation process to prepare and
A bending step of bending the laminated body so that the column axis of the foam is curved,
This is a method for producing a fiber reinforced resin structure, which includes a curing step of thermosetting the thermosetting resin contained in the laminate.
The invention (II) is
A cooling step of cooling the aggregate after the curing step and
A removal step of removing the foam contained in the laminate after the cooling step may be included.
The invention (II) is
The foam may be an olefin resin foam.

Invention (III)
A method for producing a fiber-reinforced resin structure containing at least a fiber body and a thermosetting resin impregnated in the fiber body.
A columnar first foam, a fiber that covers at least a part of the side surface of the first foam, and a columnar second foam that is close to the first foam via the fiber. A preparatory step for preparing an aggregate having the above, and the fibrous body impregnated with an uncured thermosetting resin.
This is a method for producing a fiber reinforced resin structure, which comprises a curing step of thermosetting the thermosetting resin contained in the aggregate.
The invention (III)
A deformation step of applying an external force to the aggregate to deform the cross-sectional shapes of the first foam and the second foam may be included.
The invention (III)
A cooling step of cooling the aggregate after the curing step and
It may include a removal step of removing the first foam and the second foam contained in the aggregate after the cooling step.
The invention (III)
The first foam and the second foam may be olefin resin foams.

Invention (IV)
A method for producing a fiber-reinforced resin structure containing at least a fiber body and a thermosetting resin impregnated in the fiber body.
A columnar first foam, a fiber that covers at least a part of the side surface of the first foam, and a columnar second foam that is close to the first foam via the fiber. A preparatory step for preparing an aggregate having the above, and the fibrous body impregnated with an uncured thermosetting resin.
A bending step of bending the aggregate so that the column axis of the foam is curved,
This is a method for producing a fiber reinforced resin structure, which comprises a curing step of thermosetting the thermosetting resin contained in the aggregate.
The invention (IV)
A deformation step of applying an external force to the aggregate to deform the cross-sectional shapes of the first foam and the second foam may be included.
The invention (IV)
A cooling step of cooling the aggregate after the curing step and
It may include a removal step of removing the first foam and the second foam contained in the aggregate after the cooling step.
The invention (IV)
The first foam and the second foam may be olefin resin foams.

Moreover, the invention (IV)
A fiber-reinforced resin structure containing at least a fiber body and a resin impregnated in the fiber body.
At least a first communication hole, a second communication hole parallel to the first communication hole, and a wall portion defining the first communication hole and the second communication hole are provided.
The hole shaft of the first communication hole and the second communication hole is curved.
The wall portion may be a fiber reinforced resin structure including the fiber body.
The invention (IV)
The first communication hole and the second communication hole may have a polygonal cross-sectional shape in a cross section perpendicular to the hole axis.

According to the present invention, it is possible to provide a method for producing a novel fiber-reinforced resin structure which has excellent strength and can be formed into various shapes. Further, according to the present invention, it is possible to provide a novel fiber reinforced resin structure.

1A and 1B are views for explaining the first embodiment, and FIG. 1A is a perspective view for explaining a state in which a fiber sheet and a flexible body are directly laminated, and FIG. 1B is a perspective view. ) Is a perspective view showing the first multilayer laminated body. 2A and 2B are views for explaining the first embodiment, and FIG. 2A is a perspective view for explaining a state in which the fiber sheet and the flexible body are directly laminated, and FIG. 2B is ) Is a perspective view for explaining a state in which the fiber sheet is wound around the core material, and FIG. 2 (c) is a perspective view for explaining a state in which the fiber sheet is wound around the core material a plurality of times. FIG. 2D is a perspective view showing the uncured vortex laminate, and FIG. 2E is a perspective view showing the cured vortex laminate after curing. FIG. 3 is a diagram for explaining the first embodiment, and FIG. 3A is a perspective view for explaining a state in which the fiber sheet and the flexible body are directly laminated, and FIG. 3B is ) Is a perspective view explaining a state in which the fiber sheet is wound around the core material, and FIG. 3 (c) is a perspective view explaining a state in which the fiber sheet is wound a plurality of times around the core material. FIG. 3D is a perspective view showing the uncured first cylindrical laminated body, and FIG. 2E is a perspective view showing the cured first cylindrical laminated body after curing. 4A and 4B are views for explaining the first embodiment, in particular, FIG. 4A is a perspective view showing the first multilayer laminated body, and FIG. 4B is a perspective view showing the first multilayer laminated body. FIG. 4C is a perspective view for explaining a state of being cut, FIG. 4C is a perspective view for explaining a second multilayer laminate, and FIG. 4D is a fiber sheet wound around a core material. 4 (e) is a perspective view for explaining a state in which a fiber sheet is wound around a core material, and FIG. 4 (f) is a second perspective view for explaining a state in which a fiber sheet is wound around a core material. FIG. 4 (e) is a perspective view showing a cylindrical laminated body, and FIG. 4 (e) is a perspective view showing a cured second cylindrical laminated body after curing. 5A and 5B are views for explaining the first embodiment, in particular, FIG. 5A is a cross-sectional view for explaining a laminated state of a fiber sheet and a flexible body, and FIG. 5B is a cross-sectional view showing a fiber. FIG. 5C is a cross-sectional view illustrating a state in which the energetic cured resin impregnated in the sheet exudes into the flexible body, and FIG. 5C shows the energetic cured resin impregnated in the fiber sheet exuding into the flexible body. FIG. 5D is a cross-sectional view for explaining a state of being cured, and FIG. 5D is a cross-sectional view for explaining a state in which the energetic cured resin exuded into the flexible body is cured. 6A and 6B are views for explaining the first embodiment, and FIG. 6A is a perspective view for explaining a state in which the cured vortex laminate is cut to obtain a cut vortex laminate, and FIG. 6A is a perspective view. (B) is a perspective view explaining a state in which a cured 1st cylinder laminated body is cut to obtain a cut 1st cylindrical laminated body. 7A and 7B are views for explaining the first embodiment, in particular, FIG. 7A is a perspective view showing a cured first multilayer laminate, and FIG. 7B is a cured first multilayer laminate. FIG. 7 (c) is a perspective view for explaining a state in which the body is cut, and FIG. 7 (c) is a perspective view for explaining a state in which the second cut laminates are arranged side by side on the plate member. Is a perspective view illustrating a state in which a plurality of second cut laminates are interposed between a pair of plate members. FIG. 8 is a diagram for explaining the first embodiment, and FIG. 8A is a perspective view for explaining a state in which a plurality of cutting vortex laminates are interposed between a pair of plate members. 8 (b) is a perspective view illustrating a state in which a plurality of cut first cylindrical laminates are interposed between a pair of plate members. 9A and 9B are views for explaining a modified example of the first embodiment, in particular, FIG. 9A is a perspective view showing a third multilayer laminate, and FIG. 9B is a third multilayer laminate. FIG. 9C is a perspective view illustrating a state in which the laminate is cut, and FIG. 9C is a perspective view illustrating a state in which a fourth multilayer laminate is obtained by directly laminating a fiber sheet on the third multilayer laminate. 9 (d) is a perspective view showing the cured fourth laminated body. FIG. 10 is a plan view showing a bent columnar laminate according to the second embodiment. 11A and 11B are views for explaining the second embodiment, and FIG. 11A is a perspective view for explaining a state in which a fiber sheet is wound around a cylindrical foam to obtain a cylindrical laminated body. 11 (b) is a perspective view for explaining a state in which a columnar laminate group is obtained by arranging the columnar laminates in a row, and FIG. 11 (c) is a first cut by cutting the columnar laminate group. FIG. 11 (d) is a perspective view for explaining a state of obtaining a columnar laminated body group, and FIG. 11 (d) is a perspective view for explaining a state of sandwiching the first cut cylindrical laminated body group between a pair of fiber sheets. ) Is a perspective view illustrating a state in which a cured special flat plate laminate is obtained by performing a curing step on the special flat plate laminate. FIG. 13 is a diagram for explaining the second embodiment, and FIG. 13A is a perspective view for explaining a state in which a fiber sheet is wound around a cylindrical foam to obtain a cylindrical laminate. 13 (b) is a perspective view illustrating a state in which the columnar laminated bodies are superposed on each other, and FIG. 13 (c) is a second cut by cutting a plurality of columnar laminated bodies superposed on each other. It is a perspective view explaining the state which obtains the columnar laminated body group, FIG. 13D is a perspective view which shows the 2nd cut cylindrical laminated body group, and FIG. 13E is with respect to the special block laminated body. It is a perspective view explaining the state which obtains the cured special block laminated body by performing the curing step. FIG. 15 is a diagram for explaining the second embodiment, and FIG. 15A is a perspective view for explaining a state in which a fiber sheet is wound around a cylindrical foam to obtain a cylindrical laminate. 15 (b) is a perspective view for explaining a state in which a group of cylindrical laminates is bundled in a bundle, and FIG. 15 (c) shows a state in which a bundle of cylindrical laminates is cut to obtain a bundle of cut cylindrical laminates. 15 (d) is a perspective view showing a bundle of cut cylindrical laminates, and FIG. 15 (e) is a cured special cylinder by performing a curing step on the special cylindrical laminate. It is a perspective view explaining the state which obtains the laminated body. FIG. 14 is a perspective view showing a fiber reinforced resin structure according to the first embodiment and a method for manufacturing the same. FIG. 15 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the first embodiment. FIG. 16 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the first embodiment. FIG. 17 is a perspective view showing a fiber reinforced resin structure according to the second embodiment and a method for producing the same. FIG. 18 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the second embodiment. FIG. 19 is a perspective view showing a fiber reinforced resin structure and a method for manufacturing the same according to a modified example of the second embodiment. FIG. 20 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 21 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 22 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 23 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 24-1 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 24-2 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 25 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 26 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 27 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 28 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 29 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 30 is a perspective view showing a fiber reinforced resin structure according to a third embodiment and a method for producing the same. FIG. 31 is a perspective view showing a fiber reinforced resin structure according to the third embodiment and a method for producing the same. FIG. 32-1 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for producing the same. FIG. 32-2 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same. FIG. 33-1 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for producing the same. FIG. 33-1 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for producing the same. FIG. 34 is a perspective view showing a fiber reinforced resin structure according to the IV embodiment and a method for manufacturing the same.

Hereinafter, the present invention will be specifically described, but the present invention is not limited to the following. The present invention also includes a configuration obtained by combining the matters disclosed in one embodiment and the matters disclosed in another embodiment within a range that does not cause any contradiction.

Further, in the description of each embodiment, the matters already described in another embodiment may be omitted without particular explanation. For example, the description may be omitted or simplified by adding a similar reference numeral to a portion indicating the same material. Further, in each figure, the description may be omitted or simplified for the matters having the same reference numerals. If the same reference numerals are given to the first to second embodiments described later and the I to IV embodiments described later, it may be determined that different members are disclosed. Good.

In the present invention, the "circle" includes an ellipse.

In the present invention, when expressed as a "polygon" or the like, it has a structure different from that of a circle or an indeterminate form, such as having a linear side in a part, and can be judged to be approximately a polygon or a polygon as a whole. Anything is fine. Therefore, a shape in which some sides are rounded or a shape in which the sides are loosely connected is also included in the concept of "polygon". In addition, when it is simply referred to as a "polygon", it preferably indicates a regular polygon, but it also includes a configuration other than a regular polygon.

In the present specification, the vertical and horizontal directions are referred to as "up and down, left and right" as they are in the figure.

Hereinafter, the present invention will be described based on two viewpoints, that is, from the viewpoint of the first to second embodiments and from the viewpoint of the first to IV embodiments.

The first to second embodiments and the first to IV embodiments have overlapping parts and different parts from each other. The matters described in the description of the first to second embodiments and not described in the description of the first to IV embodiments are carried out in the first to second embodiments to the extent that there is no contradiction. It is possible to incorporate it into the form of.

<<<<<< Embodiments 1 and 2 >>>>>>
<<<<< First Embodiment >>>>>
First, the first embodiment will be described. In this first embodiment, the fiber body impregnated with the energy curable resin and the flexible body are directly laminated to obtain an uncured laminated body, or the fiber body and the flexible body are brought into direct contact with each other, and then the above-mentioned A laminating process of impregnating a fiber body with an energy-curing resin to obtain an uncured laminated body,
The reinforcing fiber body and the flexible body include a curing step of applying energy to the uncured laminated body to cure the energy-curable resin contained in the fiber body constituting the uncured laminated body. This is a method for producing a composite material. Hereinafter, the raw materials, processes, and composite materials will be described in this order.

<<1. Raw materials >>
(1-1. Fiber body)
The shape and size of the fiber body according to the present invention are not particularly limited, but for example, a sheet-shaped fiber sheet can be used. The fiber sheet is not particularly limited as long as it is a sheet in which fibers are aggregated, and examples thereof include woven fabrics (twill weave, double weave, triple weave, tatami weave, etc.) and non-woven fabrics.

The thickness of the fiber sheet is not particularly limited and can be appropriately selected. If the thickness of the fiber sheet is too thin, the mechanical properties such as the strength and elastic modulus of the fiber sheet may be lowered. Therefore, the thickness of the fiber sheet according to the present invention is preferably, for example, 20 μm to 500 μm, more preferably 30 μm to 200 μm. Needless to say, a fiber sheet having a thickness of several mm, such as a chopped strand mat or a core mat, may be used.

The fibers forming the fiber sheet are not particularly limited, and known ones can be used, and at least one of metal fibers, inorganic fibers and organic fibers can be used. Examples of the fibers include metal fibers such as stainless steel fibers, nickel fibers, copper fibers, aluminum fibers, silver fibers, gold fibers, and titanium fibers; polyparaphenylene benzoxazole, polyethylene terephthalate (PET) resin, and polyvinyl. Polyolefin resin such as alcohol (PVA), polyethylene, polypropylene, polyvinyl chloride resin, aramid resin, acrylic resin, polyimide resin, polyparaphenylene benzoxazole (PBO) fiber, cellulose, vinylon, nylon, rayon, aramid , Phenole fiber, fluorine fiber, pulp (fiber), kenaf, hemp, bamboo fiber and other organic fibers; glass fiber, carbon fiber, silica fiber, rock wool, slag wool, alumina fiber, ceramic fiber, etc. Inorganic fibers; etc. can be mentioned. One or a plurality of these can be used in combination. The fiber according to the present invention is preferably a fiber having a Young's modulus higher than the Young's modulus such as a resin or a matrix resin used for a sealing material, and more preferably a metal fiber or an inorganic fiber. The higher the Young's modulus of the fiber, the higher the rigidity of the fiber sheet, and when embedded in the resin, the rigidity of the resin can be effectively improved. Therefore, it is possible to obtain a sealing material having high rigidity and not easily damaged.

(1-1-2. Method for manufacturing fiber sheet)
As a method for producing the fiber sheet, a known method can be used. For example, as a preferable method for producing a non-woven fabric, a dry method such as a carding method or an air-laid method, a wet papermaking method for forming by straining like paper, a fleece forming method such as a spunbond method or a melt blow method; thermal Examples include a fleece bonding method such as a bond method, a chemical bond method, a needle punch method, a spunlace method (water flow entanglement method), a stitch bond method, and a steam jet method. Of these, the manufacturing method by the wet papermaking method is suitable because the fiber sheet can be made thin and is excellent in terms of uniformity.

(1-2. Energy curable resin)
The energy curable resin is not particularly limited, and for example, a thermosetting resin, an energy ray curable resin, or the like can be used.

Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, polyvinyl ester resin, phenol resin, polyurethane resin, acrylic resin, melanin resin, melamine resin, urea resin, benzoguanamine resin, rosin-modified maleic acid resin, and rosin. A modified fumaric acid resin or the like can be used. These may be used alone or in combination of two or more.

Examples of the energy ray-curable resin include epoxy resin, acrylic resin, silicone resin, polyester resin and the like. These may be used alone or in combination of two or more.
(1-2. Flexible body)
The flexible body is not particularly limited, but for example, a foam can be used. This foam may be a closed cell foam or an open cell foam. The closed cell foam shown here does not mean only those in which all the bubbles are completely independent, but some of the bubbles may communicate with the adjacent bubbles, and the closed cells as a whole may be used. It is sufficient that each bubble is independent to the extent that it can be understood as a foam.

The resin constituting the foam is not particularly limited, and an olefin resin, a urethane resin, a styrene resin, a phenol resin, a silicone resin, or the like may be appropriately selected depending on the intended use. In addition, natural rubber (NR), chloroprene rubber (CR), ethylene propylene diene rubber (EPDM), nitrile rubber (NBR), etc. are also used as constituents of the foam, and these are also appropriately selected according to the application. do it.

The foam may contain known additive components such as thickeners, plasticizers, lubricants, fillers, flame retardants, colorants, antioxidants, reinforcing agents, conductive materials and the like.

The density of the foam is not particularly limited, but is, for example, 5 to 800 kg / m ³ .

Such a foam can be produced by a known method. As a method for producing a foam, for example, a raw material preparation step which is a step of obtaining a liquid raw material mixture containing at least an aqueous liquid dispersion medium and an aqueous dispersible resin, and a foaming step of foaming the liquid raw material mixture to obtain a foamed mixture. And a drying step of evaporating the dispersion medium in the foamed mixture. Further, before or after the foaming step, the liquid raw material mixture or the foamed mixture is coated with a doctor knife or a doctor roll, or the liquid raw material mixture or the foamed mixture is extruded or injection molded to form a sheet of the foamed mixture. It may be molded into a shape. Further, a rubber sponge or the like may be molded into a desired shape, or a foam foam formed into a block shape may be sliced into a desired shape such as a sheet shape, a string shape, or a columnar shape. In addition, these steps may be carried out partly or all at the same time.

Examples of the foaming means in the foaming step include a method of forming bubbles by blending a foaming agent that generates gas by a chemical reaction with the liquid raw material mixture, and a pressure after dissolving an appropriate gas in the liquid raw material mixture under high pressure. A method of forming bubbles by lowering or heating, a method of removing soluble substances mixed in the liquid raw material mixture and forming bubbles as voids, a method of forming bubbles so that air or an appropriate gas is embraced. Examples thereof include a method of mechanically stirring (mechanical floss).

The foaming conditions (temperature, time, etc.) in the foaming step and the drying conditions (temperature, time, etc.) in the drying step can be appropriately changed depending on the raw material of the foam, the foaming means used, and the like.

The shape and size of the flexible body are not particularly limited, and in addition to the sheet-shaped flexible body sheet and the cylindrical flexible body, the columnar shape, the square columnar shape, the hexagonal columnar shape, or the cross-sectional shape is a star shape or a semicircle. A flexible body having a shape or the like can be appropriately selected, and the same applies when a foam is used as the flexible body.

<<2. Process >>
(2-1. Laminating process)
This laminating step is generally a step of directly laminating the fiber sheet and the flexible body. In this laminating step, fibrous bodies and flexible bodies of various shapes and thicknesses can be used. The pattern of this laminating process is not particularly limited, and examples thereof include various patterns listed below.

(2-1-1. Laminating process pattern 1)
In this pattern 1, as shown in FIG. 1, a fiber sheet 1 in an uncured state impregnated with an energy curable resin in advance and a plate-shaped flexible body 3 are used. As a method of impregnating the fiber sheet 1 with an energy-curable resin in advance, for example, dipping in which the fiber sheet 1 is dipped in an uncured viscous liquid raw material of the energy-curable resin, or a fiber sheet 1 between a plurality of horizontal hard rolls. Roll coating, which is applied with the above-mentioned uncured viscous liquid raw material, or a so-called hand lay-up molding method, RIMP (resin infusion) molding method, or the like can be mentioned, but is not limited thereto. The fiber sheet 1 may be used as one sheet or as a stack of a plurality of sheets, and is not particularly limited. The same applies thereafter.

In this pattern 1, as shown in FIG. 1A, the lower surface of the flexible body 3 is directly superposed on the upper surface of the fiber sheet 1 placed on a flat surface, and another fiber sheet 1 is placed on the upper surface of the flexible body 3. After the lower surface of the fiber sheet 1 is directly overlapped with each other, the upper surface of the other fiber sheet 1 and the lower surface of the other flexible body 3 are directly overlapped with each other repeatedly. As a result, each fiber sheet 1 and each flexible body 3 are in surface contact with each other, and the flexible body 3 is temporarily adhered to the fiber sheet 1 by the uncured energy-curing resin impregnated in the fiber sheet 1. It will be in the state of being. By the pattern 1 of such a laminating step, as shown in FIG. 1B, a block-shaped first multilayer laminated body 5 in which the fiber sheet 1 and the flexible body 3 are stacked in many layers is obtained.

(2-1-2. Laminating process pattern 2)
In this pattern 2, the fiber sheet 1 and the flexible body 3 described in the above pattern 1 are used. As shown in FIGS. 2A and 3A, the pair of fiber sheets 1 are formed by directly superimposing the fiber sheets 1 and 1 on the upper surface and the lower surface of the flexible body 3 (both sides of the flexible body 3), respectively. A single-layer laminated body 7 in a state in which the flexible body 3 is interposed between 1 is obtained. The single-layer laminated body 7 may be a single-layer laminated body 7 in which the fiber sheet 1 is directly laminated only on one side of the flexible body 3.

(2-1-3. Laminating process pattern 3)
In this pattern 3, the first cut laminate 5a obtained through the cutting step shown in FIG. 4 (b) (which will be described later) with respect to the above-mentioned first multilayer laminate 5 shown in FIG. 4 (a). Is used. As shown in FIG. 4C, by directly laminating other fiber sheets 1A and 1B similar to the above-mentioned fiber sheet 1 on both sides of the first cut laminated body 5a along the cutting direction, respectively. , The second multilayer laminated body 8 shown in FIG. 4D is obtained.

The above-mentioned patterns 1 to 3 of the laminating step have been described by taking the case where the fiber sheet is impregnated with the energy curable resin in advance as an example, but instead of this, the fiber sheet 1 and the flexible body 3 are used. Needless to say, the fiber sheet 1 may be impregnated with the energy-curable resin in the same manner as the impregnation method described in the above-mentioned pattern 1 after being directly laminated.

(2-2. Winding process)
In this winding step, the laminated bodies 7 and 8 obtained in the above patterns 2 and 3 are wound. Since these laminated bodies 7 and 8 are composed of the fiber sheet 1 and the flexible body 3, they are flexible even in this state, and deformation processing such as bending and twisting can be easily performed. .. In the present embodiment, among these deformation processes, the winding process, which is a kind of bending process, is adopted as an example and described below, but it goes without saying that the present invention is not limited to this.

(2-2-1. Winding process pattern 1)
In this pattern 1, the single-layer laminated body 7 obtained in the pattern 2 of the above-mentioned laminating step is used (see FIG. 2A). As shown in FIGS. 2 (b) and 2 (c), the single laminated body 7 is wound a plurality of times around a core S made of, for example, a metal pipe, a resin tube, and a foam formed in a cylindrical shape. Turn. Therefore, the length of the single-layer laminated body 7 of this pattern 1 is set to about several times the outer peripheral length of the core S (about according to the number of turns). As shown in FIG. 2D, a plurality of single-layer laminated bodies 7 are formed by winding the single-layer laminated body 7 around the core S a plurality of times and then pulling out the core S (by removing the core S). A laminated spiral vortex laminate 9 is obtained.

(2-1-2. Winding process pattern 2)
Also in this pattern 2, the single-layer laminated body 7 obtained in the pattern 2 of the above-mentioned laminating step is used (see FIG. 3A). In this pattern 2, as shown in FIGS. 3 (b) and 3 (c), the single laminate 7 is wound around the core S in multiple layers. That is, a single laminated body 7 having substantially the same length as the outer peripheral length of the core S is wound so that both end faces thereof are joined to each other, and further outside the single laminated body 7, which is slightly longer than the above-mentioned single layer laminated body 7. The single laminated body 7 is wound a plurality of times so that both end faces thereof are joined to each other. Then, by pulling out the core S, as shown in FIG. 3D, a cylindrical first cylindrical laminated body 11 in which a plurality of single laminated bodies 7 are laminated is obtained.

(2-1-3. Winding process pattern 3)
In this pattern 3, the second multilayer laminate 8 obtained in the pattern 3 of the above-mentioned lamination step, and the length of which is set to substantially the same as the outer peripheral length of the core S, is set. Use. As shown in FIGS. 4D and 4E, the second multilayer laminate 8 is wound around the core S. That is, the second multilayer laminate 8 is wound so that both end faces in the winding direction are joined to each other, and then the core S is pulled out to form the cylindrical second cylindrical laminate 13 shown in FIG. 4 (f). To get.

In the second cylindrical laminate 13, the outer peripheral surface of the other fiber sheet 1A directly laminated on one surface of the second multilayer laminate 8 forms the outer peripheral surface of the second cylindrical laminate 13. The outer peripheral surface of the other fiber sheet 1B directly laminated on the other surface of the second multilayer laminate 6 forms the inner peripheral surface of the second cylindrical laminate 13. Further, between these fiber sheets 1A and 1B, the fiber sheet 1 and the flexible body 3 of the first cut laminate 5a extend along the longitudinal direction of the second cylindrical laminate 13, and other fiber sheets. It has a positional relationship that intersects 1A and 1B. In other words, the fiber sheet 1 and the flexible body 3 each have a rib structure that stands up against the other fiber sheets 1A and 1B and extends along the longitudinal direction of the second cylindrical laminate 13.

The inner diameter of the hollow portion along the central axis of each of the above-mentioned vortex laminate 9, the first cylindrical laminate 11, and the second cylindrical laminate 13 can be appropriately adjusted by using cores S having different diameters. Needless to say, there is. Further, in the above-mentioned winding process patterns 1 to 3, the core S was used to wind the various laminated bodies 7 and 8, but the present invention is not limited to this, and various types of the core S are not used. By directly winding the laminated bodies 7 and 8 in a spiral shape from the end thereof, a spiral laminated body 9 can be obtained, or various laminated bodies 7 and 8 are directly bent so as to be wound, and the winding direction thereof. The first cylindrical laminate 11 and the second cylindrical laminate 13 may be obtained by temporarily adhering both end portions of the above to each other with an uncured energy-curable resin impregnated in the fiber sheet 1.

(2-3. Curing process)
In this curing step, the first multilayer laminate 5, the single-layer laminate 7, the second multilayer laminate 8 obtained in patterns 1 to 3 of the above-mentioned lamination step, and the vortex lamination obtained in patterns 1 to 3 of the winding step Energy is applied to the body 9, the first cylindrical laminated body 11, and the second cylindrical laminated body 13 (hereinafter, these are collectively referred to as “laminated body 5 and the like”). Examples of the energy to be applied include those obtained by heating the laminated body 5 and the like, those caused by irradiating energy rays, and the like, but are not particularly limited. As shown in FIGS. 5 (a) to 5 (c), the energy curable resin impregnated in the fiber sheet 1 of the laminated body 5 or the like in the temporarily bonded state by the lamination is impregnated by applying energy to the laminated body 5 or the like. It hardens while exuding (entering) into each of the flexible bodies 3.

The cured energy-curable resin serves as an adhesive portion G that adheres (anchor effect) the fiber sheet 1 and the flexible body 3, and the fiber sheet 1 and the flexible value 3 are integrated. Further, the fiber sheet 1 becomes a cured fiber sheet 1X by curing the impregnated energy-curable resin. As a result, the first multilayer laminate 5 becomes a cured first multilayer laminate 5A (see FIG. 7A), the single-layer laminate 7 becomes a cured single-layer laminate (not shown), and the second multilayer laminate 8 Is a cured second multilayer laminate (not shown), the vortex laminate 9 is a cured vortex laminate 9A (see FIG. 2E), and the first cylindrical laminate 11 is a cured first cylindrical laminate 11A (FIG. 3). (See (e)), the second cylindrical laminate 13 becomes the cured second cylindrical laminate 13A (see FIG. 4 (g)) (hereinafter, these are collectively referred to as “cured laminate 5A and the like”). By going through the curing step in this way, a cured laminate 5A or the like as a composite material can be obtained. With respect to the cured laminate 5A and the like thus obtained, since an adhesive or the like is not used for joining the fiber sheet 1 and the flexible body 3, damage due to deterioration of the adhesive or the like can be prevented.

Next, among the cured laminates 5A and the like, the configuration of the illustrated cured laminate 5A will be described with reference to the drawings. That is, the cured first multilayer laminate 5A shown in FIG. 7A has a plurality of layers of a cured fiber sheet 1X obtained by curing an impregnated energy-curable resin and a flexible body 3, and these cured fiber sheets 1X and the cured fiber sheet 1X. The flexible body 3 is integrated with the adhesive portion G.

Further, in the cured vortex laminate 9A shown in FIG. 2 (e), the cured fiber sheet 1X obtained by curing the impregnated energy-curable resin and the flexible body 3 are wound a plurality of times around the central axis, and also. A plurality of layers expanding in the radial direction with respect to the central axis are formed, and the cured fiber sheets 1X and 3 in these layers are integrated by the adhesive portion G.

Further, the cured first cylindrical laminate 11A shown in FIG. 3 (e) also has a cured fiber sheet 1X formed in a cylindrical shape and cured with an impregnated energy-curable resin, and an inner peripheral surface or an outer periphery of the fiber body. It has a cylindrical flexible body 3 bonded to at least one surface of the surface, and these cured fiber sheets 1X and the flexible body 3 are integrated by an adhesive portion G.

Further, as shown in FIG. 4 (g), the cured second cylindrical laminate 13A has a first cylindrical fiber body 1Y formed in a cylindrical shape and obtained by curing an impregnated energy-curable resin, and the first cylindrical fiber. It is formed in a cylindrical shape having a diameter smaller than that of the body Y, and is arranged in a hollow portion of the first cylindrical fiber body 1Y so as to be concentric with the first cylindrical fiber body 1Y, and the impregnated energy-curable resin is cured. The first cylinder extends along the longitudinal direction of the first and second cylindrical fiber bodies 1Y and 1Z in a state of being interposed between the second cylindrical fiber body 1Z and the first and second cylindrical fiber bodies 1Y and 1Z. An elongated plate-shaped intervening fiber 1K that is in contact with the inner peripheral surface of the fiber 1Y and the outer peripheral surface of the second cylindrical fiber 1Z and is obtained by curing an impregnated energy-curable resin, and the first and first cylinders. The two cylindrical fiber bodies 1Y and 1Z are arranged in an internal space formed by a pair of intervening fiber bodies 1K and 1K facing each other, and the inner peripheral surface of the first cylindrical fiber body 1Y and the second cylindrical fiber body 1Z. It is provided with a flexible body 3 in contact with each other on the outer peripheral surface and the intervening fiber bodies 1K and 1K facing each other.

Further, the cured second cylindrical laminate 13A is integrated with the contact portion between the first and second cylindrical fiber bodies 1Y and 1Z and the intervening fiber bodies 1K and 1K in the flexible body 3 by an adhesive portion G. It has become. Further, the contact portions between the first and second cylindrical fiber bodies 1Y and 1Z and the plurality of intervening fiber bodies 1K are also bonded and integrated by the adhesive portion G. In this example, since no adhesive or the like is used for joining the fiber sheet 1 and the flexible body 3 and for adhering the fiber sheets 1, 1A and 1B, damage due to deterioration of the adhesive or the like can be prevented. Further, a plurality of intervening fibers 1K are arranged between the inner first cylindrical fiber body 1Y and the outer second cylindrical fiber body 1Z like ribs standing up against the respective fiber bodies 1Y and 1Z. Therefore, it is possible to obtain a cured second cylindrical laminated body 13A that is harder to be deformed by increasing its strength as compared with a simple cylindrical one.

(2-4. Cutting process)
In this cutting step, the laminated body 5 and the like before curing obtained in the above-mentioned laminating step and winding step, the cured laminated body 5A after curing obtained in the curing step, and the like are cut smaller than these. In this cutting step, the laminated body 5 or the like or the cured laminated body 5A or the like may be cut into any shape or size, and the pattern thereof is not particularly limited, but some examples of these will be described below.

(2-4-1. Cutting process pattern 1)
In this pattern 1, the first multilayer laminated body 5 before curing obtained in pattern 1 of the laminating step is cut. As shown in FIG. 4B, the first multilayer laminate 5 is vertically thinly cut in a state where the fiber sheet 1 and the flexible sheet 3 are placed on a flat surface so as to be horizontal. The first cut laminated body 5a before curing used in the pattern 3 of the laminating step is obtained. As described above, the first cut laminate 5a was designated as the second multilayer laminate 8 in the pattern 3 of the lamination process, and was designated as the second cylindrical laminate 13 in the pattern 3 of the winding process. After that, it undergoes a curing step to obtain a cured second cylindrical laminate 13A as a composite material.

(2-4-2. Cutting process pattern 2)
In this pattern 2, the cured first multilayer laminate 5A after the curing step shown in FIG. 7A is cut. As shown in FIG. 7B, the cured first multilayer laminated body 5A is vertically thinly cut in a state where the fiber sheet 1 and the flexible body sheet 3 are placed on a flat surface so as to be horizontal. , A cured second cut laminate 5B after curing is obtained.

(2-4-3. Cutting process pattern 3)
In this pattern 3, the cured vortex laminate 9A and the cured first cylindrical laminate 11A that have been cured through the curing step are cut. As shown in FIGS. 6 (a) and 6 (b), the cured vortex laminate 9A and the cured first cylindrical laminate 11 are sliced (sliced) to a predetermined width in the longitudinal direction to form a composite material. The hard-cut vortex laminate 9B and the hard-cut first cylindrical laminate 11B are obtained. Although not shown, it goes without saying that the cured second cylindrical laminate 13A may be cut in the same manner to obtain a cured cut second cylinder laminate as a composite material.

<<3. Composite material >>
Here, the composite material obtained through each of the above steps will be described.
(3-1. Composite material pattern 1)
As shown in FIG. 7, this pattern 1 is an example using the cured second cut laminate 5B, 5C, and 5D as the composite material obtained in the pattern 2 of the cutting step (note that in FIG. 7, it is complicated. In order to avoid this, only 5B, 5C, and 5D are added as the symbols of the cured second cut laminate, and the entire mass composed of these is referred to as the cured second laminate group 5Z). As shown in FIG. 7, a plurality of second cut laminates 5B, 5C, and 5D are formed with respect to the upper surface of the lower first plate member 15 among the first plate members 15 and 17 such as resin plates and the like. The cured fiber sheet 1X and the flexible body 3 of the second cut laminates 5B, 5C, and 5D stand up like ribs (in other words, the cured fiber sheet 1X with respect to the plate surfaces of the plate members 15 and 17). It is placed so that it extends in the direction in which the flexible body 3 and the flexible body 3 intersect (in the vertical direction in FIG. 7C).

Further, at the time of this placement, the extending direction of the cured fiber sheet 1X and the flexible body 3 of the cured second cut laminate 5B and another cured second cut laminate adjacent to the cured second cut laminate 5B. One cured second cut laminate 5C and another cured so that the extending directions of the cured fiber sheet 1X of 5C and 5D and the flexible body 3 intersect each other (orthogonal in FIG. 7C). The second cut laminate 5D is placed. This is repeated to obtain a cured second laminated body group 5Z formed by spreading the cured second cut laminated bodies 5B, 5C, and 5D over substantially the entire upper surface of the first plate member 15. Then, in a state where the upper surface of the first plate member 15 and the lower surface of the cured second laminated body group 5Z are adhered, the lower surface of the upper second plate member 17 and the upper surface of the cured second laminated body group 5Z are adhered to each other. , The plate members 15 and 17 can be reinforced. In this pattern 1, a pair of plate members 15 and 17 is used, but the present invention is not limited to this, and it goes without saying that only one of the plate members 15 and 17 may be used.

(3-2. Composite material pattern 2)
As shown in FIGS. 8 (a) and 8 (b), this pattern 2 has a plurality of cured cutting vortex laminates 9B or a plurality of cured products between the plate members 15 and 17 similar to the pattern 1 of the composite material. The cut first cylindrical laminates 11B are arranged side by side so as to be adjacent to each other. After that, the upper surface of the plate member 15 and the lower surfaces of the plurality of cured cutting vortex laminates 9B or the plurality of cured cut first cylindrical laminates 11B are adhered to each other, and the lower surface of the plate member 17 and the plurality of cured cut vortex laminates 9B are bonded. Alternatively, the upper surfaces of the plurality of hard-cut first cylindrical laminates 11B are bonded to each other. As a result, the plate members 15 and 17 can be reinforced.

In this pattern 2, the cut laminate 9B or the cut first cylindrical laminate 11B and the plate members 15 and 17 were bonded to each other, but the present invention is not limited to this, and the plate members 15 and 17 are penetrated, for example. The plate member may be reinforced by forming a hole and fitting the cut laminate 9B or the cut first cylindrical laminate 11B into the through hole. Further, the same foam as the flexible body 3 is used as the plate members 15 and 17, and after forming the same through holes as described above in the plate members 15 and 17, the uncured vortex laminated body 9 and the third are formed in the through holes. A cured plate member may be obtained by performing a curing step after fitting the 1-cylindrical laminate 11 and the second cylindrical laminate 13. In this case, when a plate member having no through hole is desired, for example, various laminated bodies 7 and 8 are spirally wound directly from the end thereof without using the core S, so that there is no hollow portion. The vortex laminate 9 may be provided and fitted into the through hole of the plate member.

The present invention is not limited to the above-described first embodiment, and various modifications can be made without departing from the gist thereof. In this modification, the description thereof will be omitted or simplified by adding the same reference numerals to the parts similar to those in the first embodiment described above.

In the above-described first embodiment, in the pattern 1 of the laminating step, as shown in FIG. 1 (b) and the like, flexible bodies 3 having the same width (thickness) are used, but the present invention is not limited to this, and each other Flexible bodies having different widths, hardnesses, densities, etc. may be used. As an example of this specific example, the one shown in FIG. 9 can be mentioned, and this will be described below while interweaving the various steps described above.

In the example shown in FIG. 9, the laminating step is performed using the fiber sheet 1, the flexible body 3a having a predetermined width, and the flexible body 3b having a width smaller than this. As shown in FIG. 9A, a block-shaped third multilayer laminated body 19 in which the fiber sheet 1 and the flexible bodies 3a and 3b are stacked in multiple layers is obtained. That is, the central portion of the third multilayer laminate 19 extending vertically is formed by alternately stacking the relatively thin flexible body 3b and the fiber sheet 1, and the upper and lower portions of the third multilayer laminate 19 are relative to each other. The thick flexible body 3a and the fiber sheet 1 are alternately stacked.

Next, as shown in FIG. 9B, the third cut laminate 23 is obtained by performing a cutting step of vertically thinly cutting the third multilayer laminate 19. Then, as shown in FIG. 9C, a fourth multilayer laminate 25 is obtained by further performing a lamination step of directly laminating another fiber sheet 24 on one side of the third cut laminate 23. Since the fourth multilayer laminate 25 is composed of the uncured fiber sheet 1 and the flexible body 3, it has flexibility even in this state, and can be easily deformed by bending, twisting, or the like. Can be done. Therefore, the bending step of lightly bending the fourth multilayer laminated body 25 around the central portion thereof can be performed (see FIG. 9D). Then, the above-mentioned curing step is performed on the bent fourth multilayer laminated body 25.

Here, in the fourth multilayer laminated body 25, as shown in FIG. 9C, each fiber sheet 1 extends in a state of being substantially vertically erected like a rib with respect to the fiber sheet 24. Further, the flexible body 3 which stands up from the fiber sheet 24 and is interposed between the fiber sheets 1 and 1 adjacent to each other is in surface contact with the fiber sheets 1, 1 and 24 and is in a temporarily bonded state. It has become. Therefore, as shown in an enlarged manner in FIG. 9E, when the curing step is performed, the energetic cured resin exuded from the fiber sheets 1, 1 and 24 exudes into the flexible body 3 as described above. Hardens. That is, the fiber sheets 1, 1 and 24 become the cured fiber sheets 1X, 1X and 24X, respectively, by the curing step, and the energetic cured resin exuded into the flexible body 3 and cured is the flexible body 3 and the cured fiber sheet 1X. It becomes an adhesive portion G with 1X and 24X, and these are integrated. Similarly, the contact portions of the fiber sheets 1, 1 and 24 are also bonded and integrated by the adhesive portion G made of the exuded and cured energy-curable resin. Thereby, the cured fourth multilayer laminated body 25A as a composite material can be obtained. Instead of the uncured fiber sheets 1, 1 and 24, at least one of these may be the cured fiber sheets 1X, 1X and 24X, and even in this case, the same effect is exhibited.

In other words, the cured fourth multilayer laminate 25A is arranged in an upright state with respect to the cured fiber sheet 24X, which is the first fiber body obtained by curing the impregnated energy-curable resin, and the cured fiber sheet 24X. A plurality of cured fiber sheets 1X and 1X, which are second fibers obtained by curing the impregnated energy-curable resin, and a flexible body 3 in contact with the cured fiber sheets 24X and the adjacent cured fiber sheets 1X and 1X, respectively. When the energy-curable resin impregnated in the cured fiber sheets 1X, 1X, 24X is applied with energy to be cured at the contact portion with the cured fiber sheets 1X, 1X, 24X in the flexible body 3. In addition, it can be said that the adhesive portion G made of the energy-curable resin impregnated in at least one of the cured fiber sheets 1X, 1X, and 24X is exuded and cured.

The cured fourth multilayer laminate 25A thus obtained has a cured fiber sheet 24C and a plurality of cured fiber sheets 1C standing up against the cured fiber sheet 24C, and thus has a simple plate shape. Higher strength than the hardened fiber sheet of. Further, as described above, in the state before curing, deformation processing such as bending and twisting can be easily performed, so that it is easy to obtain a composite material having a desired shape. In addition, in the above-mentioned pattern 1 of the composite material, when the curing step is performed using the fiber sheet 1 impregnated with the energy-curing resin instead of the plate members 15 and 17, the same action and effect can be obtained. Needless to say.

Here, in the example shown in FIG. 9, the width of the central flexible body 3a is larger than the width of the upper and lower flexible bodies 3b, but the width is not limited to this, and for example, the upper and lower flexible bodies 3b The width of the flexible body 3a in the central portion may be larger than the width of the flexible body 3a, and the bendable angle can be adjusted to some extent by these widths. The point is that the flexible body 3 having a width suitable for the intended use may be used, and the width and the like can be appropriately set.

Further, in the example shown in FIG. 9, a cured fourth multilayer laminate 25 as a composite material was obtained by performing a curing step on the fourth multilayer laminate 25, but the present invention is not limited to this, and for example, FIG. 9 By performing the curing step on the third multilayer laminate 19 shown in (a), a cured third multilayer laminate of the composite material can be obtained, or the third cut laminate 23 shown in FIG. 9B can be obtained. Needless to say, the cured third cut laminate as a composite material may be obtained by performing the curing step. In this case, for example, a composite material can be obtained by laminating the fiber sheet 24 on a releasable mold having a curved surface and arranging the cured third cut laminate there. Further, the cured third cut laminate may be used instead of the plurality of second laminates 5b, 5c and 5d (see FIG. 7) described in the above-mentioned pattern 1 of the composite material.

In the above-described first embodiment, in the laminating step, the horizontal fiber sheet 1 and the flexible body 3 are alternately laminated with each other. For example, the fiber sheet is laminated with respect to the core S shown in FIG. A cylindrical laminate is obtained by repeatedly winding 1 one or more times, winding the flexible body 3 on the outside thereof, and further winding the fiber sheet 1 on the outside one or more times. You may do so. Further, the fiber sheet 1 may be laminated on at least one of each side surface of the first multilayer laminated body 5. In short, it is not particularly limited as long as the fiber sheet 1 and the flexible body 3 are directly laminated. Further, the fiber sheet 1 may be cured after laminating the fiber sheet 1 on at least one of the upper surface, the lower surface, and each side surface of the cured second laminated body group 5Z shown in FIG. 7, and the laminating after curing. The body and the uncured fiber sheet may be combined as appropriate.

<<<<<< Second Embodiment >>>>>
Next, the second embodiment will be described.
This second embodiment is
The fiber body impregnated with the energy-curable resin and the flexible body are directly laminated to obtain an uncured laminate, or the fiber body and the flexible body are brought into direct contact with each other, and then the fiber body is impregnated with the energy-curable resin. And the laminating process to obtain an uncured laminate,
The deformation step of deforming the uncured laminate and
A curing step of applying energy to the uncured laminate deformed in the deformation step to cure the energy curable resin contained in the fibrous body constituting the uncured laminate.
It is a method of manufacturing a reinforcing fiber body including.
Hereinafter, the raw materials and the process will be described in this order, but in the description thereof, the same parts as those in the above-described first embodiment are designated by the same reference numerals to omit or simplify the description.

<<1. Raw materials >>
Since the raw materials in the second embodiment are the same as those in the first embodiment described above, the description thereof will be omitted.

<<2. Process >>
(2-1. Laminating process)
This laminating step is performed by directly laminating the fibrous body and the flexible body. In this laminating step, fibrous bodies and flexible bodies of various shapes and thicknesses can be used. Specifically, as shown in FIGS. 11 (a), 12 (a), and 13 (a), the fiber sheet 1 in an uncured state impregnated with an energy curable resin in advance and the core material are used. A columnar flexible body 31 is used. By directly winding the fiber sheet 1 around the flexible body 31, a cylindrical laminated body 33 in which the fiber sheet 1 and the flexible body 31 are directly laminated is obtained. In the cylindrical laminated body 33, the length of the flexible body 31 is longer than the vertical width of the fiber sheet 1, and the fiber sheet 1 is wound around the flexible body 31 to form a cylindrical shape from both ends in the longitudinal direction. , Both ends of the flexible body 31 are in a protruding state. Needless to say, as in the first embodiment, the fiber sheet 1 may be directly laminated on the flexible body 31 and then impregnated with the energy curable resin.

(2-2. Deformation process)
This deformation step is a step of variously deforming the uncured cylindrical laminate 33, which is easily deformed, and the deformation is not particularly limited, but the patterns listed below can be mentioned.

(2-2-1. Deformation process pattern 1)
In this pattern 1, as shown in FIG. 10, one columnar laminated body 33 is deformed by bending it into a curved line as it is. Needless to say, the curvature is not particularly limited here. Further, in addition to bending into a curved shape such as L-shaped, U-shaped, S-shaped, etc., the deformation may be performed by bending at a predetermined angle (30 degrees, 90 degrees, etc.) according to the intended use. As a result, a bent columnar laminated body 35 having a special shape bent into various shapes is obtained.

(2-2-2. Deformation process pattern 2)
In this pattern 2, as shown in FIG. 11 (b), a plurality of cylindrical laminated bodies 33 are arranged in a row to form a columnar laminated body group 33a, and then as shown in FIG. 11 (c), they protrude from the fiber sheet 1. By performing a cutting step of cutting the vicinity of both ends of the flexible body 3, the first cut columnar laminated body group 33b in which both end faces of the respective columnar laminated bodies 33 are flush with each other is obtained. The cutting step shown in FIG. 11C may be omitted. This also applies to the subsequent cutting steps.

Then, as shown in FIG. 11D, the cut columnar laminated body group 33b is sandwiched between the other pair of fiber sheets 35, 37, and pressure is applied. As a result, as shown in FIG. 11 (e), the cross-sectional shape of the fiber sheet 1 of the first cut columnar laminated body group 33b is deformed into a hollow quadrangular prism shape, and is located in each of these hollow portions. The cross-sectional shape of each flexible body 31 is deformed into a quadrangular prism shape, and as a whole, a special flat plate laminated body 39 having a special shape deformed into a flat plate shape is obtained. The method of applying pressure may be performed by directly applying a load, or may be performed by depressurizing the first cut columnar laminated body group 33b in a sealed state, and is not particularly limited. This also applies to the subsequent deformation steps.

Although the pattern 2 is formed in the shape of a quadrangular prism, the present invention is not limited to this, and the special flat plate laminate 39 having a pentagonal or hexagonal cross section can be formed by adjusting the direction in which pressure is applied to the columnar laminate group 33a. You may try to get it. Further, without using the other pair of fiber sheets 35, 37, the pressure is directly applied to the first cut columnar laminated body group 33b, or the pressure is directly applied to the columnar laminated body group 33a. Even in this case, the same effect is obtained.

(2-2-3. Deformation process pattern 3)
In this pattern 3, as shown in FIG. 12B, a plurality of cylindrical laminated body groups 33a described in the above-mentioned deformation step pattern 2 are prepared, and these cylindrical laminated body groups 33a are overlapped with each other in a parallel state. After that, as shown in FIG. 12 (c), by performing a cutting step of cutting the vicinity of both ends of the flexible body 3 protruding from the fiber sheet 1, as shown in FIG. 12 (d), the columnar laminated body group. A second cut columnar laminated body group 33c is obtained in which both end surfaces of 33a are flush with each other.

Then, as shown in FIG. 12E, by applying pressure to the second cut columnar laminated body group 33c, the cross-sectional shape of the fiber sheet 1 of the second cut columnar laminated body group 33c becomes a hollow hexagonal column shape. Along with the deformation, the cross-sectional shape of each of the flexible bodies 33 located in each of these hollows is deformed into a hexagonal column shape, and a block-shaped special block laminated body 41 is obtained as a whole. Needless to say, also in this pattern 3, similarly to the above-mentioned pattern 2, the special block laminate 41 having various cross-sectional shapes can be obtained by adjusting the direction of applying pressure and the like.

(2-2-4. Deformation process pattern 4)
In this pattern 4, as shown in FIG. 13 (b), a plurality of cylindrical laminated bodies 33 are bundled in a bundle to form a columnar laminated body bundle 43, and as shown in FIG. 13 (c), the cylinder laminated body protrudes from the fiber sheet 1. As shown in FIG. 13D, by performing a cutting step of cutting the vicinity of both ends of the flexible body 3, the cut columnar laminated body 33d has both end faces of the respective columnar laminated bodies 33 flush with each other. A cut cylindrical laminated body bundle 43a composed of bundles is obtained.

Then, as shown in FIG. 13 (e), by applying pressure to the cut cylindrical laminated body bundle 43a, among the cut cylindrical laminated body bundles 43a, the peripheral cut cylindrical laminated body 33d surrounding the central cut cylindrical laminated body 33d Each fiber sheet 1 of the above is deformed into a hollow pentagonal column shape. Along with this, each of the flexible bodies 33 located in the hollow of these cut cylindrical laminated bodies 33d is deformed into a pentagonal prism shape. Further, the central cut columnar laminated body 33d is deformed into a hollow hexagonal column shape, and the flexible body 33 located in the hollow is deformed into a hexagonal column shape. As a result, a special columnar laminated body 45 having a special shape deformed into a columnar shape is obtained as a whole. Needless to say, also in this pattern 4, similarly to the above-mentioned pattern 2, the special block laminated body 45 having various cross-sectional shapes can be obtained by adjusting the direction of applying pressure and the like. Further, in FIG. 13E, in order to clearly indicate that the fiber sheet 1 of the central cut columnar laminate 33d has a hexagonal cross-sectional shape, the hollow portion of the central cut columnar laminate 33d is intentionally formed. Although the flexible body 33 is shown in a removed state, the hollow portion is actually filled with the flexible body 33.

(2-3. Curing process)
In this curing step, the first bending columnar laminate 35, the special flat plate laminate 39, the special block laminate 41, and the second columnar laminate 41, which are uncured laminates deformed in each of the above-mentioned deformation steps, are first formed. By applying energy in the same manner as in the embodiment, the energy-curable resin impregnated in the sheet fibers is cured. As a result, the bent columnar laminate 35 becomes the first reinforcing fiber (not shown), the special flat plate laminate 39 becomes the second reinforcing fiber 39A (see FIG. 11E), and the special block laminate 41 becomes the first reinforcing fiber. The 3 reinforcing fiber body 41A becomes (see FIG. 12 (e)), and the special columnar laminate 45 becomes the 4th reinforcing fiber body 45A (see FIG. 13 (e)). In each of the reinforcing fiber bodies 39A, 41A, and 45A, a removing step of removing the flexible body 33 may be performed by punching out or melting the respective flexible body 33.

As described above, in the second embodiment, the uncured laminate obtained in the laminating step is easily deformed, and in this state, it is extremely deformed into a desired special shape and then the curing step is performed. A reinforcing fiber having a desired special shape can be obtained by a simple method.

The present invention is not limited to the above-mentioned second embodiment, and various modifications can be made without departing from the gist thereof. For example, in the cutting steps shown in FIGS. 11 (c), 12 (c), and 13 (c), as shown in FIGS. 11 (b), 12 (b), and 13 (b), respectively, This was performed after the columnar laminate 33 was formed into the columnar laminate group 33a and the columnar laminate bundle 43, but the present invention is not limited to this, and after the columnar laminate group 33a and the columnar laminate bundle 43 are formed, pressure is applied to them as they are. It may be performed after the deformation, and the timing of the cutting process is not particularly limited as long as it is before the curing process.

<<<< Summary of the first and second embodiments >>>>
The first and second embodiments described above can be summarized as follows.

Invention (1-1)
The fiber body impregnated with the energy-curable resin and the flexible body are directly laminated to obtain an uncured laminate, or the fiber body and the flexible body are brought into direct contact with each other, and then the energy-curable resin is applied to the fiber body. The laminating process of impregnating and obtaining an uncured laminate,
The reinforcing fiber body and the flexible body include a curing step of applying energy to the uncured laminated body to cure the energy-curable resin contained in the fiber body constituting the uncured laminated body. This is a method for producing a composite material.
Invention (1-2)
The production method of the present invention (1-1), wherein the flexible body is a foam.
Invention (1-3)
The method according to the invention (1-1) or (1-2), further comprising a winding step of winding the uncured laminate after the laminating step.
The inventions (1-4) further include a step of cutting the uncured laminate or the cured laminate cured by the curing step into smaller pieces than the cured laminate, according to the inventions (1-1) to (1-). The method according to any one of 3).

According to the above invention, it is possible to prevent the composite material (composite material of the reinforcing fiber and the flexible body) from being damaged due to deterioration of the pressure-sensitive adhesive, the adhesive, etc., and to easily manufacture the composite material having a desired shape. be able to.

Invention (2-1)
The fiber body impregnated with the energy-curable resin and the flexible body are directly laminated to obtain an uncured laminate, or the fiber body and the flexible body are brought into direct contact with each other, and then the energy-curable resin is applied to the fiber body. The laminating process of impregnating and obtaining an uncured laminate,
The deformation step of deforming the uncured laminate and
A curing step of applying energy to the uncured laminate deformed in the deformation step to cure the energy curable resin contained in the fibrous body constituting the uncured laminate.
It is a method of manufacturing a reinforcing fiber body including.
Invention (2-2)
The production method of the present invention (2-1), wherein the flexible body is a foam.

According to the above invention, a reinforcing fiber body having a special shape can be easily produced.

Invention (3-1)
The first fiber body obtained by curing the impregnated energy-curable resin and
The second fiber body, which is arranged in an upright state with respect to the first fiber body and has the impregnated energy-curable resin cured, and
The first fiber body and the flexible body in contact with the second fiber body adjacent to each other are provided.
The contact portions of the flexible body with the first and second fiber bodies are said to be cured by applying energy to the thermosetting resin impregnated by the first and second fiber bodies. The composite material is characterized by having an adhesive portion made of an energy-curable resin in which at least one of the first and second fibers has been impregnated and cured by exuding the energy-curable resin.

According to the above invention, it is possible to prevent the composite material from being damaged due to deterioration of the pressure-sensitive adhesive, the adhesive or the like.

Invention (4-1)
A first cylindrical fiber body formed in a cylindrical shape and cured with an impregnated energy-curable resin,
It is formed in a cylindrical shape having a diameter smaller than that of the first cylindrical fiber body, is arranged in a hollow portion of the first cylindrical fiber body so as to be concentric with the first cylindrical fiber body, and is impregnated with energy curing. A second cylindrical fiber body with a cured sex resin and
It extends along the longitudinal direction of the first and second cylindrical fiber bodies in a state of being interposed between the first and second cylindrical fiber bodies, and the inner peripheral surface of the first cylindrical fiber body and the second cylindrical fiber body. Intervening fibers in which the energy-curable resin impregnated while being in contact with the outer peripheral surfaces of the fibers are cured.
It is arranged in an internal space formed by the first and second cylindrical fibers and a pair of intervening fibers facing each other, and the inner peripheral surface of the first cylindrical fibers and the second cylindrical fibers. The outer peripheral surface of the body and the flexible body in contact with one surface of the intervening fiber body are provided.
The contact portion between the first and second cylindrical fibers and the intervening fibers in the foam is thermosetting, which is impregnated by the first and second cylindrical fibers and the intervening fibers. When the resin is cured by applying energy, the energy-curable resin impregnated with at least one of the first and second fibers and the intervening fibers exudes and is cured from the energy-curable resin. It is a composite material characterized by having an adhesive portion.

According to the above invention, it is possible to prevent the composite material from being damaged due to deterioration of the pressure-sensitive adhesive, the adhesive or the like.

<<<<<< Embodiments I to IV >>>>>>
Next, the first to second embodiments will be described from a viewpoint different from the first to second embodiments. It should be noted that the embodiments I to IV can be considered to be an arrangement of the fiber-reinforced resin structure obtained by using, applying, changing, etc. the concept explained in the second embodiment and the manufacturing method thereof. it can.

In the first to IV embodiments, the members corresponding to the flexible bodies described in the first to second embodiments are specifically described as foams, but flexible bodies other than foams are described. Does not preclude the use of.

The size of the fiber-reinforced resin structure described below, the thickness of the thick portion of the fiber-reinforced resin structure, the diameter of the communication hole H of the fiber-reinforced resin structure, etc. are not limited at all and can be appropriately adjusted according to the application. Is.

<<<<<< Embodiment I >>>>>
<<< Structure >>>
The fiber-reinforced resin structure 100-1 according to the first embodiment is a tubular fiber-reinforced resin structure containing at least a fiber body 10 and a resin 20 impregnated in the fiber body 10 (FIG. 14). (C).

More specifically, the resin 20 impregnated in the tubular fiber body 10 becomes a thick portion, and the tubular fiber reinforced resin structure 100-1 is formed as a whole.

The fiber reinforced resin structure 100-1 may have the foam 30 inserted inside the cylinder. In each of the following embodiments and modifications, each fiber reinforced resin structure may or may not contain the foam 30.

<<< Raw materials >>
<< Fiber 10 >>
The shape and size of the fiber body 10 are not particularly limited, but for example, a sheet-shaped fiber sheet is preferable. This fiber sheet is not particularly limited as long as it is a sheet in which fibers are aggregated, and is, for example, a woven fabric (plain weave, twill weave, double weave, triple weave, tatami weave, etc.), a non-woven fabric, and a unidirectional reinforcing material (UD). Material) and the like.

The thickness of the fiber sheet is not particularly limited and can be appropriately selected. If the thickness of the fiber sheet is too thin, the mechanical properties such as the strength and elastic modulus of the fiber sheet may be lowered. Therefore, the thickness of the fiber sheet according to the present invention is preferably, for example, 20 μm to 500 μm, more preferably 30 μm to 200 μm. Needless to say, a fiber sheet having a thickness of several mm, such as a chopped strand mat or a core mat, may be used.

The fibers forming the fiber sheet are not particularly limited, and known ones can be used, and at least one of metal fibers, inorganic fibers and organic fibers can be used.

Examples of the fibers constituting the fiber body 10 include, for example.
Metallic fibers such as stainless steel fiber, nickel fiber, copper fiber, aluminum fiber, silver fiber, gold fiber, titanium fiber;
Polyparaphenylene benzoxazole, polyethylene terephthalate (PET) resin, polyvinyl alcohol (PVA), polyolefin resin such as polyethylene and polypropylene, polyvinyl chloride resin, aramid resin, acrylic resin, polyimide resin, polyparaphenylene benz Organic fibers such as oxazole (PBO) fiber, cellulose, vinylon, nylon, rayon, aramid, phenolic fiber, fluorine fiber, pulp (fiber), kenaf, hemp, bamboo fiber;
Inorganic fibers such as glass fiber, carbon fiber, silica fiber, rock wool, slag wool, alumina fiber, and ceramic fiber;
And so on.
As the fiber, one or a plurality of these can be used in combination. For example, non-crimp fiber (NCF) having a two-layer structure containing carbon fiber and polyester fiber can also be used.

The fiber is preferably a fiber having a Young's modulus higher than the Young's modulus such as a resin or a matrix resin used for a sealing material, and more preferably a metal fiber or an inorganic fiber. The higher the Young's modulus of the fiber, the higher the rigidity of the fiber sheet, and when embedded in the resin, the rigidity of the resin can be effectively improved. Therefore, it is possible to obtain a sealing material having high rigidity and not easily damaged.

The fiber sheet may be one in which fibers are woven into a tubular shape.

The fiber sheet may be partially punched or the like to form pores as long as the effect of the present invention is not impaired.

The fiber sheet may be a bias sheet (bias-cut sheet).

<Manufacturing method of fiber sheet>
As a method for producing the fiber sheet, a known method can be used. For example, as a preferable method for producing a non-woven fabric, a dry method such as a carding method or an air-laid method, a wet papermaking method for forming by straining like paper, a fleece forming method such as a spunbond method or a melt blow method; thermal Examples include a fleece bonding method such as a bond method, a chemical bond method, a needle punch method, a spunlace method (water flow entanglement method), a stitch bond method, and a steam jet method. Of these, the manufacturing method by the wet papermaking method is suitable because the fiber sheet can be thinned and is excellent in terms of uniformity.

When the fiber sheet has a tubular shape, it can be manufactured in the same manner as the braid, for example.

The method for producing a fiber sheet may include a step of performing bias cutting.

<< Resin 20 >>
As the resin 20, a known resin used as a fiber reinforced resin can be used, and a thermoplastic resin or the like can also be used, but in order to improve workability, an energy curable resin is preferable.

<Energy curable resin>
The energy curable resin is not particularly limited, and for example, a thermosetting resin, an energy ray curable resin, or the like can be used. The energy curable resin is preferably a thermosetting resin.

Examples of the thermosetting resin include epoxy resin, unsaturated polyester resin, polyvinyl ester resin, phenol resin, polyurethane resin, acrylic resin, melanin resin, melamine resin, urea resin, benzoguanamine resin, rosin-modified maleic acid resin, and rosin. A modified fumaric acid resin or the like can be used. These may be used alone or in combination of two or more.

Examples of the energy ray-curable resin include epoxy resin, acrylic resin, silicone resin, polyester resin and the like. These may be used alone or in combination of two or more.

In the following description, the resin 20 will be described as a thermosetting resin, but as long as there is no particular contradiction, "heat curing" may be read as "curing" or "energy ray curing" in the following description. It is possible.

<< Foam 30 >>
The foam may be a closed cell foam or an open cell foam. The closed cell foam shown here does not mean only those in which all the bubbles are completely independent, but some of the bubbles may communicate with the adjacent bubbles, and the closed cells as a whole may be used. It is sufficient that each bubble is independent to the extent that it can be understood as a foam.

The resin constituting the foam is not particularly limited, and an olefin resin, a urethane resin, a styrene resin, a phenol resin, a silicone resin, or the like may be appropriately selected depending on the intended use. The foam is preferably an olefin resin foam. With this configuration, it is easy to remove the foam from the fiber reinforced resin structure. In addition, natural rubber (NR), chloroprene rubber (CR), ethylene propylene diene rubber (EPDM), nitrile rubber (NBR), etc. are also used as constituents of the foam, and these are also appropriately selected according to the application. do it.

The foam may contain known additive components such as thickeners, plasticizers, lubricants, fillers, flame retardants, colorants, antioxidants, reinforcing agents, conductive materials and the like.

The density of the foam is not particularly limited, but for example, 1 kg / m ³ or more, 2 kg / m ³ or more, 3 kg / m ³ or more, 4 kg / m ³ or more, 5 kg / m ³ or more, 10 kg / m ³ or more, 15 kg. / ^{m 3} may be a more, also, 800 kg / ^{m 3} or less, 700 kg / ^{m 3} or less, 600 kg / ^{m 3} or less, 500 kg / ^{m 3} or less, 250 kg / ^{m 3} or less, 100 kg / ^{m 3} or less, 50 kg / m ^It may be ³ or less. The upper limit value and the lower limit value can be arbitrarily combined to obtain a desired numerical range.

<Manufacturing method of foam>
The foam can be produced by a known method. As a method for producing a foam, for example, a raw material preparation step which is a step of obtaining a liquid raw material mixture containing at least an aqueous liquid dispersion medium and an aqueous dispersible resin, and a foaming step of foaming the liquid raw material mixture to obtain a foamed mixture. And a drying step of evaporating the dispersion medium in the foamed mixture. Further, before or after the foaming step, the liquid raw material mixture or the foamed mixture is coated with a doctor knife or a doctor roll, or the liquid raw material mixture or the foamed mixture is extruded or injection molded to form a sheet of the foamed mixture. It may be molded into a shape. Further, a rubber sponge or the like may be molded into a desired shape, or a foam foam formed into a block shape may be sliced into a desired shape such as a sheet shape, a string shape, or a columnar shape. In addition, these steps may be carried out partly or all at the same time.

Examples of the foaming means in the foaming step include a method of forming bubbles by blending a foaming agent that generates gas by a chemical reaction with the liquid raw material mixture, and a pressure after dissolving an appropriate gas in the liquid raw material mixture under high pressure. A method of forming bubbles by lowering or heating, a method of removing soluble substances mixed in the liquid raw material mixture and forming bubbles as voids, a method of forming bubbles so that air or an appropriate gas is embraced. Examples thereof include a method of mechanically stirring (mechanical floss).

The foaming conditions (temperature, time, etc.) in the foaming step and the drying conditions (temperature, time, etc.) in the drying step can be appropriately changed depending on the raw material of the foam, the foaming means used, and the like.

The shape, size, etc. of the foam are not particularly limited, and in addition to the cylindrical foam, a columnar, square columnar, hexagonal columnar, or a foam having a star-shaped or semicircular cross-sectional shape can be appropriately used. It is selectable. Further, the foam is not only foam-molded to have a desired shape, but also a block-shaped one formed by cutting or carving, a sheet-shaped foam wound up, and the like. You may.

<<< Manufacturing method >>>
The method for producing the fiber reinforced resin structure 100-1 is, for example,
A laminate 50 having a columnar foam 30 and a fibrous body 10 that covers at least a part of a side surface portion of the foam 30. The fibrous body 10 is a thermosetting resin (uncured resin) in an uncured state. A preparatory step for preparing the laminate 50 impregnated with 25) and
This method includes a curing step of thermosetting the resin (uncured resin 25) impregnated in the fiber body 10 to obtain the resin 20.

The method for producing the fiber-reinforced resin structure 100-1 includes a cutting step of cutting the foam 30, a cooling step of cooling the foam 30 and the resin 20 after the curing step, a removing step of pulling out the foam 30 after the curing step, and the like. May include.

Further, although not particularly described, the method for producing the fiber reinforced resin structure 100-1 may include a shaving step or a polishing step of treating the surface of the fiber reinforced resin structure 100-1 after the curing step.

<< Preparation process >>
The preparatory step includes a columnar foam 30 and a fibrous body 10 that covers at least a part of the side surface of the foam 30, and the fibrous body 10 is a thermosetting resin (uncured resin 25) in an uncured state. This is a step of preparing the laminated body 50 impregnated with.

The preparatory step may be carried out by purchasing the laminated body 50 from the outside or the like.

Further, the preparation step may include an impregnation step and a laminating step.

<Immersion process>
In the impregnation step, the uncured resin 25 and the fiber body 10 are brought into contact with each other to impregnate the fiber body 10 with the uncured resin 25.

The impregnation method is not particularly limited, and may be, for example, roll coating, hand lay-up molding method, infusion molding method, VaRTM molding method, RTM molding method, or the like, and the fibrous body 10 is placed in a tank containing the uncured resin 25. It may be a method of submerging (dipping) or the like.

The impregnation conditions can be adjusted according to the type of the fiber body 10 and the uncured resin 25. When it is difficult to impregnate the fiber body 10 with the uncured resin 25, the impregnation time may be lengthened or the fiber body 10 may be impregnated while being pressurized.

<Lamination process>
In the laminating step, at least a part of the side surface of the foam 30 is covered with the fiber body 10 (see FIGS. 14 (a) and 14 (c)).

The method of covering the side surface of the foam 30 with the fiber 10 is not particularly limited. For example, when the fiber body 10 is a fiber sheet, the fiber body 10 may be wound around the foam 30. The number of windings is preferably one or more, and may be two or more.

Further, in the laminating step, the fibrous body 10 after covering the foam 30 may be temporarily fastened. For example, when the fiber body 10 is impregnated with the uncured resin 25, the fiber body 10 can be temporarily adhered to the side surface of the foam 30 due to the adhesiveness of the uncured resin 25.

In the laminating step, as shown in FIG. 14, it is not necessary to cover the entire side surface of the foam 30 from the upper end to the lower end with the fiber body 10, but the entire side surface of the foam 30 is covered with the fiber body 10. Is also possible.

It is possible to adjust the thickness of the fiber body 10 in the laminating step. For example, when the fiber body 10 is a fiber sheet, the thickness of the fiber body 10 can be increased by increasing the number of times the fiber body 10 is wound. Further, the fiber sheet may be a single sheet or may be used as a stack of a plurality of sheets, and is not particularly limited. The fiber body 10 may be used in combination of two or more kinds. When the fiber 10 is a woven fabric or a UD material, the orientation (bias, etc.) of the fibers is taken into consideration in consideration of the thermal expansion of the foam, the deformation step, the bending step, etc. in another embodiment. ) May be adjusted to perform winding. Further, when a fiber body 10 having an adjusted fiber orientation is used, the fiber body 10 may be configured so that the fiber orientation is adjusted over the entire fiber body 10. It may be configured so that the fiber orientation is adjusted only in a part of the region (for example, the fiber orientation is adjusted only in the easily deformable region).

When the fiber body 10 is long, the laminating step can be carried out by winding the fiber body 10 around the side surface of the foam body 30 while moving the fiber body 10 in the axial direction. For example, the laminating step may be carried out based on a filament winding method, a braiding method, or the like.

Further, the fiber body 10 may be formed in a tubular shape in advance, and the foam 30 may be inserted into the cylinder.

In the laminating step, the side surface of the foam 30 is covered with the fiber body 10, but when the fiber body 10 is arranged on the side surface of the foam body 30, the foam body 30 is flexibly deformed. Therefore, for example, when the fiber body 10 is used as a fiber sheet and the fiber body 10 is wound around the foam body 10, distortions and the like that may occur in the fiber body 10 are absorbed by the deformation of the foam body 30, and in a somewhat natural state. The fibrous body 10 can be retained.

Here, the impregnation step may be carried out before the laminating step, at the same time as the laminating step, or after the laminating step. When the fiber body 10 is a fiber sheet, the fiber body 10 is impregnated with a resin (uncured resin 25) before the laminating step in order to surely impregnate the fiber body 10, and the fiber body 10 is not impregnated. It is preferable to carry out the laminating step in a state where the cured resin 25 is impregnated. In the description of each embodiment, the preparatory step is described as a step of carrying out the laminating step after carrying out the impregnation step, but is not limited thereto.

<< Curing process >>
By carrying out the curing step, the uncured resin 25 impregnated in the fiber body 10 is cured, and the resin 20 is obtained (see FIG. 14 (c)).

In the curing step, the curing method and the curing conditions may be selected so that the uncured resin 25 is sufficiently cured according to the type of the resin (uncured resin 25) used. For example, in the case of a thermosetting resin, heat can be applied to the uncured resin 25 to cure it.

In order to improve the shape retention of the laminate 50 (foam 30), the curing step is carried out in a state where the laminate 50 is fitted into a mold or a shrink tape is arranged around the laminate 50. You may.

<< Cooling process >>
The cooling step is a step of cooling the resin 20 and the foam 30 obtained by thermosetting before carrying out the foam removing step or the like.

It is considered that by performing thermosetting in the curing step, the foam 30 thermally expands and a force in the direction of pushing the fiber 10 is generated. By cooling the foam 30 after the uncured resin 25 is heat-cured, the foam 30 shrinks, promoting the separation between the resin 20 and the foam 30, and facilitating the removal step described later. It is thought that it can be done.

The cooling method is not particularly limited, and any method such as natural cooling, ventilation, leaving in a cold air atmosphere, or the like may be used. The temperature after cooling may be set to room temperature or higher, room temperature, or room temperature or lower. As an example, the cooling step can be carried out by cooling the temperature at 10 ° C. or higher, 20 ° C. or higher, 30 ° C. or higher, 40 ° C. or higher, or 50 ° C. or higher than the temperature at the time of thermosetting.

<< Cutting process >>
The cutting step may be a step of cutting only the foam 30 protruding from the fiber body 10, or may be a step of cutting the foam 30 and the fiber body 10 at the same time. For example, the laminate 50 may be adjusted to a desired length by a cutting step.

The cutting step may be carried out before the curing step or after the curing step.

<< Removal process >>
By removing the foam 30 contained in the laminate 50, a hollow fiber-reinforced resin structure 100-1 containing no foam 30 can be obtained (see FIG. 14 (c)).

By carrying out the preparation step (for example, laminating step, impregnation step) and the curing step, the uncured resin 25 is cured in a state where the foam 30 and the uncured resin 25 are in contact with each other. When the foam 30 is a foam or the like, the uncured resin 25 can invade the bubbles existing on the surface of the foam. By carrying out the curing step in this state, the foam and the resin 20 can be fixed. Therefore, when carrying out the removal step, the material of the foam and the density of the foam (foaming ratio) are adjusted so that the foam and the resin 20 are difficult to be fixed, or the foam and the resin 20 are fixed. Even if it is done, the foam may be easily removed.

In addition to physically removing the foam 30, the removal step may be carried out by dissolving the foam 30.

<<< Example of modification of the first embodiment >>>
The fiber reinforced resin structure 100-1 is not limited to a cylindrical one. Hereinafter, the fiber-reinforced resin structure 100-1 other than the cylindrical shape will be described as a modified example of the first embodiment.

<< structure >>
The fiber-reinforced resin structure 100-1 may have a polygonal tubular structure (a cylindrical structure having a polygonal cross section perpendicular to the tubular axis) instead of the cylindrical structure shown in FIG. .. For example, the fiber reinforced resin structure 100-1 may have a square tubular shape as shown in FIG. 15 (c) or a hexagonal tubular shape as shown in FIG. 16 (c). Further, the polygonal tubular shape of the fiber body 10 may be a triangular tubular shape, or a polygonal tubular shape of a hexagonal tubular shape or more.

Further, the fiber reinforced resin structure 100-1 does not need to have the same outer shape (the shape of the outer surface of the cylinder) and the inner shape (the shape of the inner side surface of the cylinder). For example, the fiber reinforced resin structure 100-1 may have a structure in which the outer shape is prismatic and the inner shape is columnar.

<< Manufacturing method >>
The method for producing the fiber reinforced resin structure 100-1 according to the modified example is, for example,
A laminate 50 having a columnar foam 30 and a fibrous body 10 that covers at least a part of a side surface portion of the foam 30. The fibrous body 10 is a thermosetting resin (uncured resin) in an uncured state. A preparatory step for preparing the laminate 50 impregnated with 25) and
A deformation step of applying an external force to the laminate 50 to deform the cross-sectional shape of the foam 30 and
This method includes a curing step of thermosetting the resin (uncured resin 25) impregnated in the fiber body 10 to obtain the resin 20.

The preparation process, curing process, etc. are as described above. Further, as described above, the cooling step, the cutting step and the removing step may be carried out.

<Transformation process>
In the deformation step, an external force is applied to the laminated body 50 to deform the cross-sectional shape of the foam 30 (see FIGS. 15 (a), 15 (b), 16 (a), and 16 (b)). More specifically, for example, the laminated body 50 can be deformed into a prismatic shape by applying an external force to the side surface portion of the laminated body 50.

The foam 30 and the fiber 10 are deformed by applying an external force to the side surface of the laminate 50, but the fiber 10 is not crushed by the foam 30 and retains a predetermined shape (for example, a tubular shape). can do.

The deformation step can be carried out, for example, by fitting the laminated body 50 into a mold or the like having a predetermined shape.

In the deformation step, the shape of the laminated body 50 can be freely changed by adjusting the direction in which the external force is applied and the position in which the external force is applied.

For example, as shown in FIG. 15A, when an external force is evenly applied to the side surface of the laminated body 50 (foam 30) from four directions, the laminated body 50 may have a square tubular shape. As shown in FIG. 16A, when an external force is evenly applied to the side surface of the laminate 50 (foam 30) from six directions, the laminate 50 has a hexagonal tubular shape. it can.

Further, the external force applied to one surface of the laminated body 50 and the external force applied to the other surface may be made different, or the direction and strength of the external force applied to the upper side of the laminated body 50 and the lower side of the laminated body 50 may be changed. By doing so, it is possible to make the laminated body 50 asymmetric with respect to the vertical direction (axial direction) of the laminated body 50 or the left-right front-rear direction (direction perpendicular to the axis) of the laminated body 50. is there.

The fiber-reinforced resin structure 100-1 is made into a fiber-reinforced resin structure 100-1 having a different shape by changing the outer diameter of the foam 30 according to the axial direction (for example, providing a taper). Is also possible.

The fiber-reinforced resin structure 100-1 having a polygonal cylinder can be obtained by forming the foam 30 into a prismatic shape in advance and then carrying out the same manufacturing method as in the first embodiment. In this case, the fiber is likely to be loaded, and the strength may be inferior.

<<<<<< Embodiment II >>>>>
<<< Structure >>>
The fiber reinforced resin structure 100-2 according to the second embodiment is as shown in FIG. 17 (d).
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fiber body 10 is a fiber-reinforced resin structure having a curved tubular shape (or the tubular shaft B is curved).

In other words, the fiber reinforced resin structure 100-2 has a curved portion 60 in which at least a part of the structure of the fiber reinforced resin structure 100-2 is curved. Further, the fiber reinforced resin structure 100-2 has a tubular structure held in the curved portion 60. Further, when the fiber reinforced resin structure 100-2 has a curved portion 60 and a non-curved portion, the curved portion 60 and the non-curved portion are smoothly connected. Further, the fiber-reinforced resin structure 100-2 may have the same shape in the curved portion 60 and the non-curved portion when observing the cross section perpendicular to the tubular shaft B.

The fiber reinforced resin structure 100-2 may have a plurality of curved portions 60. In this case, the direction of bending, the degree of bending, and the like can be designed for each curved portion 60.

The degree of curvature of the tubular shaft B or the curvature of the curved portion 60 is not particularly limited. The degree of curvature of the tubular shaft B or the curvature of the curved portion 60 can be bent into a curved shape such as L-shaped, U-shaped, S-shaped, bow-shaped, etc., and also at a predetermined angle (30) depending on the application. It may be curved to degrees, 45 degrees, 90 degrees, etc.).

The fiber body 10 is not limited to a cylindrical shape, and may be a polygonal tubular shape.

The structure according to the fiber reinforced resin structure 100-2 can be expressed as the fiber reinforced resin structure 100-1 being curved in a predetermined direction while maintaining the cross-sectional shape along the axis.

<<< Manufacturing method >>>
The method for producing the fiber reinforced resin structure 100-2 is, for example,
A laminate 50 having a columnar foam 30 and a fibrous body 10 that covers at least a part of a side surface portion of the foam 30. The fibrous body 10 is a thermosetting resin (uncured resin) in an uncured state. A preparatory step for preparing the laminate 50 impregnated with 25) and
The bending step of bending the laminated body 50 so that the column axis A of the foam is curved, and
This method includes a curing step of curing the resin (uncured resin 25) impregnated in the fiber body 10 to obtain the resin 20.

The preparation process, curing process, etc. are as described above. Further, as described above, the cutting step, the cooling step and the removing step may be carried out.

<< Curving process >>
In the bending step, an external force is applied to the laminated body 50 so that the column shaft A of the foam 30 is curved. As a result, the axis A of the foam 30 is curved, so that the axis of the entire laminated body 50 is curved. Therefore, when the laminated body 50 includes the tubular fiber body 10, the tubular shaft of the fiber body 10 is curved. B will be curved in the same manner.

The foam 30 and the fiber 10 are deformed by applying an external force to the side surface of the laminate 50, but the fiber 10 is not crushed by the foam 30 and retains a predetermined shape (for example, a tubular shape). can do.

As a method of bending, an external force may be applied to the laminated body 50 from a predetermined direction (see FIGS. 17 (b) and 17 (c)). The magnitude of the external force may be appropriately set in consideration of the material of the laminated body 50, the degree of curvature, and the like.

The bending step can be carried out, for example, by fitting the laminated body 50 into a predetermined mold or the like having a curved structure. If it is desired to have a complicated curved shape, the form may be divisible.

The laminate 50 includes the fibrous body 10 and the foam 30. Therefore, the laminated body 50 is unlikely to break even if it is curved. In particular, when the fiber body 10 is a fiber sheet and the foam 30 is a foam, the fiber sheet and the foam are flexibly deformed, so that the laminated body 50 is smoothly curved (it is difficult to have a buckled portion). can do.

At the time of bending, the density of the fibrous body 10 becomes dense in the compressed portion, and the density of the fibrous body 10 becomes sparse in the pulled portion. In consideration of this point, the thickness of the fiber body 10 at the portion where the curved portion 60 can be formed may be adjusted in advance in the laminating step.

In the case of the fiber-reinforced resin structure 100-2 having a plurality of curved portions, a mold having a shape having a plurality of curved portions may be used, or the bending step may be performed a plurality of times.

<<< Example of modification of the second embodiment >>>
In the second embodiment, as shown in FIG. 17, the fiber reinforced resin structure 100-2 having an overall cylindrical shape has been described, but the fiber reinforced resin structure 100-2 is shown in FIG. Therefore, it may be configured to have a polygonal cylinder shape as a whole.

In the structure according to the modified example of the fiber reinforced resin structure 100-2, the structure according to the modified example of the fiber reinforced resin structure 100-1 is curved in a predetermined direction while maintaining the cross-sectional shape along the axis. It can also be expressed as being done.

The fiber-reinforced resin structure 100-2 according to the modified example of the second embodiment can be manufactured by carrying out the above-mentioned deformation step and the above-mentioned bending step on the laminated body 50 (FIG. FIG. 18). In FIG. 18, the display of the foam 30 is omitted for the sake of simplicity.

The cross-sectional shape of the laminated body 50 (foam 30) is deformed into a prismatic shape by the deformation step, and the column axis A of the laminated body 50 is curved by the bending step.

In these steps, the foam 30 and the fiber 10 are deformed by applying an external force to the side surface portion of the laminate 50, but the fiber 10 is not crushed by the foam 30 and has a predetermined shape (for example, for example). Can hold a tubular shape).

The deformation step and the bending step may be carried out in a state where the laminated body 50 contains the foam 30 and before the resin is cured (in other words, a state where the uncured resin 25 is contained), and the deformation step. It may be any of a form in which the bending step is carried out after the bending step, a form in which the deformation step is carried out after the bending step, and a form in which the deformation step and the bending step are carried out at the same time.

When the deformation step and the bending step are carried out at the same time, for example, it can be carried out by fitting the laminated body 50 into a mold having a predetermined bending structure and a predetermined cross-sectional shape.

Further, when manufacturing the fiber reinforced resin structure 100-2, as shown in FIG. 19, the plurality of laminated bodies 50 are in a state before the resin is cured (a state in which the laminated body 50 contains the uncured resin 25). ) May further include a step of providing a step of bringing them into contact with each other (see FIG. 19B).

For example, in the manufacturing method shown in FIG. 19, first, a plurality of laminated bodies 50 having a curved structure obtained by carrying out a bending step are prepared (see FIG. 19A), and these plurality of laminated bodies 50 are mutually arranged. By arranging them in contact with each other, performing a deformation step in that state (see FIG. 19B), and finally curing the fibers, a plurality of communication holes are provided and these communication holes are parallel to each other. It is possible to manufacture the fiber-reinforced resin structure 100-2 which does not become.

In addition, in FIG. 19A and FIG. 19B, the foam 30 is omitted for the sake of simplicity.

The contact step, the deformation step, and the bending step can be carried out in any order, and a part or all of them may be carried out at the same time.

When the contacting step, the deforming step, and the bending step are carried out at the same time, for example, a mold having a predetermined curved structure, a predetermined cross-sectional shape, and a plurality of laminated bodies 50 can be arranged at a predetermined position. It can be carried out by fitting a plurality of laminated bodies 50 into the structure.

In this way, after the resin is brought into contact with the plurality of laminated bodies 50 in a state before being cured (a state in which the laminated body 50 contains the uncured resin 25), other members or the like containing the uncured resin 25 are brought into contact with each other. By curing the resin, it is also possible to obtain a structure integrated with the resin 20. The concept that a plurality of laminated bodies 50 and the like are brought into contact with each other in a state before the resin is cured and integrated can be similarly applied in all the embodiments. That is, with respect to the combination of all the structures described in each embodiment and the combination of all the structures described in each embodiment and the known structure, each structure is integrated via the resin. The structure is understood to be within the scope of the present invention.

<<<<<< Third Embodiment >>>>>
<<< Structure >>>
The fiber reinforced resin structure 100-3 according to the third embodiment is, for example,
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
At least a first communication hole H, a second communication hole H parallel to the first communication hole H, and a wall portion defining the first communication hole H and the second communication hole H are provided.
The wall contains the fibrous body 10,
It is a fiber reinforced resin structure.

The fiber-reinforced resin structure 100-3 includes a plurality of communication holes H arranged in parallel with each other so that the hole axes C are arranged perpendicularly to a predetermined direction (for example, a certain straight line). The number of communication holes H of the fiber-reinforced resin structure 100-3 may be two or more. For example, in FIG. 20 (f), a structure having four communication holes H, in FIG. 21 (f), a structure having 13 communication holes H, and in FIG. 22 (f), 12 structures. A structure having communication holes H, FIG. 23 (f) shows a structure having seven communication holes H.

The first communication hole H and the second communication hole H are provided so as to be parallel to each other. It should be noted that the fact that the first communication hole H and the second communication hole H are parallel means that, as a whole, the hole axis C of the communication hole H on one side and the hole axis C of the communication hole H on the other side. It is shown that is regularly arranged to the extent that is understood to be parallel.

The wall portion (for example, the thick resin 20) that defines each communication hole H includes the fiber body 10. It is preferable that the fibrous body 10 is present on the entire wall portion around each communication hole H, in other words, the fiber body 10 is provided so as to continuously surround the communication hole H for one or more rounds.

In the present embodiment, the fibrous body 10 is included in the wall portion (the wall portion existing between the one communication hole H and another communication hole H) that separates one communication hole H and another communication hole H. With this configuration, the strength of the fiber reinforced resin structure 100-3 in the thickness direction (direction perpendicular to the direction in which the communication holes H are lined up) can be increased.

In the fiber-reinforced resin structure 100-3, the foam 30 may be inserted through a part or all of the communication holes (see FIG. 20E and the like).

The fiber-reinforced resin structure 100-3 has a structure as shown in FIG. 20 (c), in which a plurality of cylindrical fiber bodies 10 are arranged and are in close proximity to each other via the resin. It may be cured. On the other hand, in the fiber-reinforced resin structure 100-3, as shown in FIG. 21 (f), a plurality of polygonal tubular fiber bodies 10 are arranged, and these are in close proximity to each other via the resin. It may be hardened with. Further, the fiber reinforced resin structure 100-3 may be obtained by combining a cylindrical fiber body 10 and a polygonal tubular fiber body 10.

According to another expression, the fiber reinforced resin structure 100-3 according to the third embodiment
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fibrous body 10 includes at least the first tubular fibrous body 10 and the second tubular fibrous body 10, which are polygonal tubular fibrous bodies.
It is a fiber reinforced resin structure in which the flat surface portion forming the outer surface of the first tubular fiber body and the flat surface portion forming the outer surface of the second tubular fiber body are in contact with or close to each other.

From this point of view, the fiber reinforced resin structure 100-3 includes a plurality of polygonal tubular fiber bodies 10. Further, the plurality of fiber bodies 10 are regularly arranged so that the side surfaces of the plurality of fiber bodies 10 are in contact with each other or close to each other.

The number of polygonal tubular fiber bodies 10 contained in the fiber reinforced resin structure 100-3 is not particularly limited, and may be two or more.

In the fiber reinforced resin structure 100-3, the foam 30 may be inserted into all the cylinders of each tubular fiber body (for example, the first tubular fiber body and the second tubular fiber body). , The foam 30 does not have to be inserted inside all the cylinders, and while the foam 30 is inserted inside some cylinders, the foam 30 is not inserted inside the remaining cylinders. You may.

As a method of arranging the communication holes H (or the fiber body 10), as shown in FIG. 20, a method of arranging the plurality of communication holes H (or the plurality of fiber bodies 10) so as to be arranged in a single layer, FIG. As shown in FIG. 22, a method of stacking a plurality of layers in which a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged and arranging them in a honeycomb shape, as shown in FIG. 22, a plurality of communication holes H. A method of stacking a plurality of layers in which (or a plurality of fiber bodies 10) are arranged and arranging them in a grid pattern, as shown in FIG. 23, a plurality of communication holes H (or a plurality of fiber bodies 10) are formed in a circle. Examples thereof include a method of arranging the fibers so as to be arranged in a pattern.

As shown in FIG. 24, the fiber-reinforced resin structure 100-3 has a plurality of layers in which a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged, and one layer and another layer. Therefore, the direction of the hole axis C of the communication hole H (or the tubular axis direction of the fiber body 10) may be arranged so as to be different.

The wall portion (or the tubular shape of the fiber body 10) that defines the communication hole H is not particularly limited, and may be a square tubular shape, a pentagonal tubular shape or more, or a plurality of shapes. (For example, as shown in FIG. 21, a combination of a pentagonal cylinder and a hexagonal cylinder) may be used.

In the fiber reinforced resin structure 100-3, as shown in FIG. 25 (1), a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged so that the hole axes are arranged perpendicularly to a certain curve. They may be arranged parallel to each other.

As shown in FIG. 25 (2), the fiber-reinforced resin structure 100-3 may have the end portion (opening surface) of the communication hole H sealed (or may be crushed). For example, the fiber reinforced resin structure 100-3 may have a shape in which the upper end portion and / or the lower end portion thereof is crushed. The end portion crushed in this way can be used as a surface for installing a fixing member such as a screw.

In the fiber reinforced resin structure 100-3, only one end (opening surface) of the communication hole H may be sealed (or may be crushed), or both of the communication holes H may be sealed. The end (opening surface) may be sealed (or may be crushed).

In this case, the fiber reinforced resin structure 100-3 may or may not contain the foam 30.

Similarly, the fiber-reinforced resin structure described in each embodiment may have a structure in which the end portion of the communication hole H is sealed (or crushed).

As shown in FIGS. 26 (f) and 31 (f), the fiber-reinforced resin structure 100-3 has holes at locations where the plurality of communication holes H (or the plurality of fiber bodies 10) are close to each other. You may be doing it.

The fiber reinforced resin structure 100-3 may have a reinforcing member 15 as shown in FIG. 27 (f). The reinforcing member 15 is impregnated with a resin (resin 20) and integrated as a fiber reinforced resin structure 100-3. By having the reinforcing member 15, it is possible to reinforce the part where the fiber body 10 is insufficient and improve the strength of the fiber reinforced resin structure 100-3.

The place where the reinforcing member 15 is arranged is not particularly limited, and can be appropriately arranged at a place where the strength may be insufficient due to the lack of the fiber body 10. For example, as shown in FIG. 27, the reinforcing member 15 may be arranged at a location where a plurality of communication holes H (or a plurality of fiber bodies 10) are close to each other, or at an end portion of the fiber reinforced resin structure 100-3. it can.

The material of the reinforcing member 15 is not particularly limited, but may be the same material as the fibers constituting the fiber body 10. That is, the reinforcing member 15 may be made of fibers. The shape of the reinforcing member 15 is not limited, and may be an appropriate shape. For example, as the reinforcing member 15, a unidirectional reinforcing material (UD material), a twisted material thereof, or the like may be used, or a sheet shape, a rod shape obtained by rolling the sheet, or the like may be used, and the portion to be reinforced may be used. It can be changed according to the shape. The content of the reinforcing member 15 can be appropriately used according to the strength of the desired fiber reinforced resin structure 100-3 and the like.

As shown in FIG. 28 (f), the fiber-reinforced resin structure 100-3 may have different hole diameters (or cylinder inner diameters of the plurality of fiber bodies 10) of the plurality of communication holes H.

As shown in FIGS. 29 (e) and 30 (e), the fiber-reinforced resin structure 100-3 has a wall thickness (or a tubular fiber body 10 and a resin 20) that surrounds the communication hole H. The fiber thickness of the fibrous body 10 (or the tubular fibrous body 10) may be different for each communication hole H. Further, in this case, as shown in FIGS. 29 (e) and 30 (e), the hole diameters of the plurality of communication holes H (or the inner diameters of the cylinders of the plurality of fiber bodies 10) are different for each communication hole H. You may.

As the structure according to the fiber reinforced resin structure 100-3, the structure according to the fiber reinforced resin structure 100-1 and / or the structure according to the modified example of the fiber reinforced resin structure 100-1 are regularly used. It can also be expressed as having a structure in which they are arranged and integrated via a resin.

<<< Manufacturing method >>>
The method for producing the fiber reinforced resin structure 100-3 is, for example,
A columnar first foam 30, a fibrous body 10 that covers at least a part of the side surface of the first foam 30, and a columnar second foam that is close to the first foam 30 via the fibrous body 10. A preparatory step for preparing an aggregate 55 having the foam 30 and at least the aggregate 55 having the fibrous body 10 impregnated with a thermosetting resin (uncured resin 25) in an uncured state.
This method includes a curing step of thermosetting the thermosetting resin (uncured resin 25) contained in the aggregate 55.

The curing step and the like are as described above. As shown in FIG. 20 (e), by carrying out the curing step, the plurality of fibrous bodies 10 and the like contained in the aggregate 55 are integrated via the thermosetting resin.

Further, as described above, the cooling step, the cutting step and the removing step may be carried out.

Further, in the method for producing the fiber reinforced resin structure 100-3, a sealing step (crushing step) for crushing the end portion (opening surface) of the aggregate 55 may be provided before the curing step.

When the sealing step (crushing step) is carried out, the length of the fiber body 10 may be made longer than the length of the foam body 30 (configured so that the fiber body 10 protrudes from the foam body 30).

The sealing step (crushing step) may be performed only on one end (opening surface) of the assembly 55, or may be performed on both ends (opening surface) of the assembly 55. May be good.

When the sealing step (crushing step) is performed, the removing step may or may not be carried out. The sealing step (crushing step) is preferably carried out in a state where the aggregate 55 contains the foam 30.

The sealing step (crushing step) may be carried out so that the end portion (opening surface) of the assembly 55 is completely closed, or may be carried out within the range where the end portion of the assembly 55 has an opening.

<< Preparation process >>
In the preparatory step, there are at least a fibrous body 10 that covers at least a part of the side surface portion of the first foam 30 and a columnar second foam 30 that is close to the first foam 30 via the fibrous body 10. Then, the aggregate 55 impregnated with the uncured thermosetting resin (uncured resin 25) is prepared in the fiber body 10.

More specifically, in the preparation step, an aggregate 55 in which a plurality of laminated bodies 50 are arranged so as to be in contact with or close to each other is prepared (see FIGS. 20 (a) to 20 (c) and the like). According to another expression, the foams 30 contained in the laminated body 50 are arranged so as to be close to each other via the fibrous body 10.

The number of laminated bodies 50 included in the aggregate 55 and the arrangement of the laminated bodies 50 are not particularly limited, and may be adjusted according to the desired structure of the fiber reinforced resin structure 100-3.

The aggregate 55 is, for example, one in which a plurality of laminated bodies 50 are arranged so as to be arranged in one layer as shown in FIG. 20, and a layer in which a plurality of laminated bodies 50 are arranged as shown in FIG. 21. A plurality of layers stacked in a honeycomb shape, as shown in FIG. 22, a plurality of layers in which a plurality of laminated bodies 50 are arranged are stacked in a grid pattern, as shown in FIG. 23. , Such as those in which a plurality of laminated bodies 50 are arranged so as to be arranged in a circle.

As shown in FIG. 24, the aggregate 55 includes a layer formed by arranging a plurality of laminated bodies 50 so that the hole axes C of the communication holes H (or a plurality of fibrous bodies 10) face a certain direction. The plurality of laminates 50 are arranged so as to have another layer formed by arranging the plurality of laminates 50 so that the hole axes C of the communication holes H (or the plurality of fiber bodies 10) face different directions. It may be the one that has been done.

Here, as shown in FIG. 20D, the aggregate 55 may have a plate-shaped outer peripheral body 70 provided so as to be in contact with the side portion of the laminated body 50.

The outer peripheral body 70 includes, for example, fibers similar to the fibers constituting the fiber body 10 and an uncured resin 25. By using such an outer peripheral body 70, the strength of the fiber reinforced resin structure can be improved.

The thickness of the outer peripheral body 70 and the like can be appropriately used according to the strength of the desired fiber reinforced resin structure 100-3 and the like.

The shape of the outer peripheral body 70 is not particularly limited, but may be, for example, a flat plate.

Further, the outer peripheral body 70 may be configured to orbit the entire side surface of the aggregate 55 by one or more rounds. With this configuration, the outer peripheral body 70 after curing becomes the outer wall of the fiber reinforced resin structure 100-3, so that the strength of the fiber reinforced resin structure 100-3 can be easily improved.

The outer peripheral body 70 may be provided so as to come into contact with the plurality of laminated bodies 50. When the outer peripheral body 70 comes into contact with the plurality of laminated bodies 50, the laminated body 50 is arranged along the outer peripheral body 70.

Other members may or may not be present between the laminated bodies 50. For example, as shown in FIG. 27, the assembly 55 may include a reinforcing member 15. In the fiber reinforced resin structure 100-3, the reinforcing member 15 is integrated with the fiber body 10 and the like via the resin 20. Therefore, it is preferable that the reinforcing member 15 is impregnated with the uncured resin 25 at any timing. The uncured resin 25 contained in the laminate 50 may be moved to the reinforcing member 15 by bringing the laminate 50 containing the uncured resin 25 into contact with the reinforcing member 15 not containing the uncured resin 25, or the uncured resin 25 may be moved to the reinforcing member 15. Although the aggregate 55 may be subjected to the impregnation step after forming the aggregate 55 including the laminate 50 and the reinforcing member 15 which does not contain the resin 25, the reinforcing member 15 is impregnated with the uncured resin 25 in advance. It is preferable to keep it.

The shape, material, and the like of the foam 30 and the fiber 10 may be different between one laminate 50 and another laminate 50. For example, as shown in FIG. 28, the aggregate 55 may include a plurality of foams 30 (laminates 50) having different diameters.

Further, as shown in FIGS. 29, 30, and 31, the aggregate 55 includes a plurality of laminates 50, one or more foams 30 (foams 30 that are not previously covered with the fiber 10), and the aggregate 55. May be arranged. When configured in this way, the thickness of the fiber body 10 contained in the wall portion of the obtained fiber reinforced resin structure 100-3 may differ depending on the location. Further, in the case of such a configuration, the diameter of the communication hole H included in the fiber reinforced resin structure 100-3 may differ greatly depending on the location. Further, in this configuration, the pitch between the walls (dense / sparse of the communication holes H) can be adjusted. As described above, when it is desired to adjust the required wall thickness (amount of fiber 10), the size of the communication hole H, etc. in consideration of design, strength, cost, weight, etc., it is further specified. Such a method can be adopted when it is desired to design the region to have high strength.

<< Deformation process >>
In the deformation step, an external force is applied to the plurality of laminated bodies 50 in a state where the plurality of laminated bodies 50 are arranged as an aggregate 55.

Further, since the laminated body 50 contains the foam 30, the axis of the laminated body 50 (the column axis A of the foam 30) is unlikely to shift when the deformation step is performed. Therefore, before and after the deformation step, the method of arranging the plurality of laminated bodies 50 as a whole (particularly, the method of arranging the column shafts A of the foam 30) is maintained almost unchanged. As a result, in the obtained fiber-reinforced resin structure 100-3, the hole axes C of the communication holes H can be made parallel to each other.

Further, since the laminated body 50 contains the foam 30, the side surfaces of the laminated body 50 are in contact with each other or close to each other, or a surface different from the side surface of the laminated body 50 (for example, an inner surface of a predetermined mold). When an external force is applied to the laminated body 50 in a state of contact with the fixed surface and the outer peripheral body 70), a compressive force and a repulsive force act on the foam 30. As a result, the side surface of the laminated body 50 is deformed so as to be flattened, and a prismatic laminated body 50 is formed. When the fiber body 10 is provided in a tubular shape in the laminated body 50, it constitutes a flat surface portion forming an outer surface of one tubular fiber body 10 and an outer surface of another tubular fiber body 10. It is possible to form a fiber-reinforced resin structure in which the flat surfaces to be formed are in contact with or close to each other (that is, such flat surfaces are parallel to each other).

The method of applying an external force in the deformation step is not particularly limited.

The external force can be applied, for example, by fitting the aggregate 55 into a predetermined mold.

The external force may be applied by sandwiching the aggregate 55 with the outer peripheral body 70. Further, by carrying out the curing step with the aggregate 55 sandwiched between the outer peripheral bodies 70, the fiber reinforced resin structure 100-3 having the outer peripheral body 70 as an outer shell can be manufactured. When the aggregate 55 is sandwiched from the front and back by using two outer peripheral bodies 70, the laminated bodies 50 existing at the left end and the right end are open because there are no adjacent members (laminated body 50 or outer peripheral body 70). Will have the side surface. When the deformation step is carried out in a situation where such an open side surface exists, there is no force for suppressing the deformation of the assembly 55 in the side surface direction, so that the end side surface (stacking existing at the end portion) of the assembly 55 The side surface of the body 50) can form a curved structure along the expansion of the foam 30.

When the outer peripheral body 70 is applied to the aggregate 55, the outer peripheral body 70 may be cured first, the cured outer peripheral body 70 may be brought into contact with the aggregate 55, and the uncured resin contained in the aggregate 55 may be cured. However, it is preferable that the outer peripheral body 70 containing the uncured resin is brought into contact with the aggregate 55 to simultaneously cure the uncured resin contained in the aggregate 55 and the outer peripheral body 70.

The external force may be applied by tying the entire assembly 55 with a string or the like.

The application of the external force is preferably carried out in a reduced pressure atmosphere. In this case, the compressive force due to decompression may be used as the external force. The conditions for reducing the pressure are not particularly limited, and the pressure may be reduced to such an extent that it contributes to the compression of the foam 30.

When the external force is applied, the fiber reinforced resin structure 100-3 having various structures can be obtained by adjusting the direction of the external force application.

By applying an external force to the aggregate 55 from the front-rear direction (or the front-back direction and the left-right direction), the fiber-reinforced resin structure 100- as a whole is rectangular parallelepiped as shown in FIG. 3 can be obtained.

By applying an external force to the aggregate 55 substantially evenly from the peripheral direction of the aggregate 55, a cylindrical fiber reinforced resin structure 100-3 as a whole as shown in FIG. 23 (f) or the like is formed. Obtainable.

By changing the shape of the surface (for example, the inner surface of the mold to be used) that comes into contact with the aggregate 55 when an external force is applied, a plurality of communication holes H (or) as shown in FIG. 25 (1) are used. Can obtain a fiber reinforced resin structure 100-3 in which a plurality of fiber bodies 10) are arranged in parallel with each other so that the pore axes are arranged perpendicularly to a certain curve.

In the deformation step, the degree of deformation of the foam 30 and the degree of deformation of the laminated body 50 can be adjusted by adjusting the external force. For example, when the external force on the aggregate 55 is weakened, the deformation of the laminated body 50 is suppressed, and a region (vacancy region) in which the external force does not sufficiently contribute to the laminated body 50 can be formed. As a result, as shown in FIG. 26, the curved surface shape can be maintained at the portion corresponding to the corner portion of the laminated body 50. Similarly, when the mold is used when applying an external force, a region (non-following region) in which the deformation of the laminated body 50 does not follow the corners of the mold may be formed. When it is not preferable to have such a pore region or a non-following region, it is preferable to arrange the reinforcing member 15 in advance at a location that can correspond to these regions.

In the method shown in FIG. 20, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIG. 20A), and the plurality of laminates 50 are brought into contact with or close to each other. (FIG. 20 (b)), a plurality of laminated bodies 50 arranged by the two outer peripheral bodies 70 are sandwiched to form an aggregate 55 (FIG. 20 (c)), and an external force is applied to the aggregate 55. The entire body is compressed to deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then cured to form the fiber-reinforced resin structure 100-3 (FIG. 20 (e)). The foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 20 (f)).

In the method shown in FIGS. 21 and 22, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIGS. 21 (a) and 22 (a)), and the plurality of laminates 50 are prepared. Are arranged in a single row so that the fibrous bodies 10 are in contact with each other or close to each other, and the rows of the plurality of laminated bodies 50 are arranged in a plurality of rows to form an aggregate 55 (FIGS. 21 (b) to 21 (d)). 22 (b) to 22 (d)), an external force is applied to the aggregate 55 to compress the whole body, deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then cure. As a result, the fiber-reinforced resin structure 100-3 is formed (FIGS. 21 (e) and 22 (e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 21 (f)). ), FIG. 22 (f)).

In the method shown in FIG. 23, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIG. 23 (a)), and the periphery of the laminate 50 is surrounded by the plurality of laminates 50. In addition, the laminated bodies 50 are arranged so that the fibrous bodies 10 are in contact with each other or close to each other to form an aggregate 55 (FIGS. 23 (b) to 23 (d)), and an external force is applied to the aggregate 55 to make the whole. The fiber-reinforced resin structure 100-3 is formed by compressing, deforming the cross-sectional shape perpendicular to the axis of the laminated body 50 (foam 30), and then curing the laminate 50 (foam 30) (FIG. 23 (e)). The foam 30 is removed from the structure 100-3 (FIG. 23 (f)).

In the method shown in FIG. 24, a laminate 50 containing the foam 30, the fiber body 10, and the uncured resin 25 is prepared (FIG. 24 (a)), and the fiber bodies 10 come into contact with or approach the plurality of laminates 50. The rows of the plurality of laminated bodies 50 are arranged in one row in this manner, and the rows of the plurality of laminated bodies 50 are stacked so as to have different orientations to form an aggregate 55 (FIGS. 24 (b) to 24 (d)). A fiber-reinforced resin structure 100-3 is formed by applying an external force to the body to compress the whole body, deform the cross-sectional shape of the laminate 50 (foam 30) perpendicular to the axis, and then cure the laminate 50 (foam 30) (FIG. 24). (E)), the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 24 (f)).

In the method shown in FIG. 26, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIG. 26A), and the plurality of laminates 50 are brought into contact with or close to each other. (FIGS. 26 (b) to (c)), an external force is applied to the aggregate 55, and the whole is compressed until the portions where the ends of the three or more laminated bodies 50 are assembled are not in close contact with each other. The fiber-reinforced resin structure 100-3 is formed by deforming the cross-sectional shape of the laminate 50 (foam 30) perpendicular to the axis ((FIG. 26 (d)) and then curing it (FIG. 26 (e)). )), The foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 26 (f)).

In the method shown in FIG. 27, a laminate 50 including a foam 30, a fiber body 10, and an uncured resin 25 and a reinforcing member 15 are prepared (FIG. 27 (a)), and a plurality of laminates 50 are made into fibers. The bodies 10 are arranged so as to be in contact with each other or close to each other, and the reinforcing member 15 is arranged between the plurality of laminated bodies 50 (FIGS. 27 (b) to (c)), and an external force is applied to the aggregate 55 as a whole. The cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) is deformed ((FIG. 27 (d))), and then cured to form the fiber-reinforced resin structure 100-3 (FIG. 27). 27 (e)), the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 27 (f)).

In the method shown in FIG. 28, the laminate 50 having a relatively large diameter including the foam 30, the fibrous body 10, and the uncured resin 25, and the relatively large diameter including the foam 30, the fibrous body 10, and the uncured resin 25 are included. (FIG. 28 (a)), and a plurality of relatively large-diameter laminates 50 are arranged so as to surround the relatively small-diameter laminate 50 (FIGS. 28 (b) to (b)). (C)), an external force is applied to the aggregate 55 to compress the whole body, deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) ((FIG. 28 (d)), and then cure. , The fiber-reinforced resin structure 100-3 is formed (FIG. 28 (e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 28 (f)).

In the method shown in FIG. 29, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 and a foam 30 to which the fiber 10 is not arranged are prepared, and the laminate 50 and the foam are prepared. 30 and 30 are alternately arranged (FIG. 29 (a)), and the laminated body 50 and the foam 30 arranged by the two outer peripheral bodies 70 are sandwiched to form an aggregate 55 (FIG. 29 (b)), and the aggregate 55 is formed. A fiber-reinforced resin structure 100-3 is formed by applying an external force to compress the entire body, deforming the cross-sectional shape of the laminate 50 (foam 30) perpendicular to the axis (FIG. 29 (c)), and then curing the laminate 50 (foam 30). (FIG. 29 (d)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 29 (e)).

In the method shown in FIG. 30, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 and the foam 30 to which the fiber 10 is not arranged are prepared, and the laminate 50 and the foam are prepared. The foams 30 are arranged so as to be lined up with 30 and the foams 30 are arranged so as to be continuously arranged (FIG. 30A), and the laminated body 50 and the foams 30 arranged by the two outer peripheral bodies 70 are sandwiched and aggregated. It is set to 55 (FIG. 30 (b)), and an external force is applied to the aggregate 55 to compress the whole and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 30 (c)). After that, the fiber-reinforced resin structure 100-3 is formed by curing (FIG. 30 (d)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 30 (e)).

In the method shown in FIG. 31, a laminate 50 of the foam 30, the fiber 10, and the uncured resin 25, and the foam 30 to which the fiber 10 is not arranged are prepared (FIG. 31 (a)). A plurality of laminated bodies 50 are arranged so as to surround the foam 30 (FIGS. 31 (b) to (c)), and an external force is applied to the aggregate 55 to compress the entire body 50 (foam 30). The vertical cross-sectional shape is deformed ((FIG. 31 (d)) and then cured to form the fiber reinforced resin structure 100-3 (FIG. 31 (e)), and the fiber reinforced resin structure 100-3 is formed. The foam 30 is removed from the body (FIG. 31 (f)).

<<<<<< Embodiment IV >>>>>
<<< Structure >>>
The fiber reinforced resin structure 100-4 according to the IV embodiment is
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
At least a first communication hole H, a second communication hole H parallel to the first communication hole H, and a wall portion defining the first communication hole H and the second communication hole H are provided.
The hole shaft C of the first communication hole H and the second communication hole H is curved.
The wall contains the fibrous body 10,
It is a fiber reinforced resin structure.

Further, the first communication hole H and the second communication hole H may have a polygonal cross-sectional shape in a cross section perpendicular to the hole axis C.

The number of communication holes H contained in the fiber reinforced resin structure 100-4 may be two or more.

The fiber-reinforced resin structure 100-4 has a plurality of communication holes H, has a plurality of communication holes H having a curved hole axis C, and the communication holes H are arranged so as to be parallel to each other. ing. As described above, the fiber-reinforced resin structure can be provided with the features of the modified example of the fiber-reinforced resin structure 100-1 and the features of the fiber-reinforced resin structure 100-3. Therefore, all the matters described for each embodiment can be applied to the fiber reinforced resin structure 100-4.

According to other expressions, the fiber reinforced resin structure 100-4 according to the IV embodiment
It contains at least the fiber body 10 and the resin 20 impregnated in the fiber body 10.
The fibrous body 10 includes at least a first tubular fibrous body 10 and a second tubular fibrous body 10.
The first tubular fiber body 10 has a curved polygonal tubular structure in which the tubular shaft B is curved, and has an outer surface parallel to the tubular shaft B.
The second tubular fiber body has a curved polygonal tubular structure in which the tubular shaft B is curved, and has an outer surface parallel to the tubular shaft B.
It is a fiber reinforced resin structure in which the outer surface of the first tubular fiber body and the outer surface of the second tubular fiber body are in contact with or close to each other.

In yet another expression, the fiber reinforced resin structure 100-4 includes a plurality of polygonal tubular fiber bodies 10 which are regularly arranged and provided in contact with or in close proximity to each other, and a plurality of fibers. It has a curved portion 60 that is curved in a predetermined direction and is present over the body 10.

The degree of curvature of the hole axis C of the communication hole H (or the curvature of the curved portion of the fiber body 10) can be freely designed as appropriate. Further, the degree of curvature may be the same or different in the plurality of communication holes H.

The direction in which the fiber-reinforced resin structure 100-4 is curved is not particularly limited. For example, as shown in FIG. 32 (g), a plurality of communication holes H (or a plurality of fiber bodies 10) are arranged and formed in the front direction of the fiber reinforced resin structure 100-4, in other words, a plurality of communication holes H (or a plurality of fiber bodies 10). It may be curved in a direction perpendicular to the virtual plane, or as shown in FIG. 33 (g), the side surface direction of the fiber reinforced resin structure 100-4, in other words, a plurality of communication holes H. (Or a plurality of fiber bodies 10) may be curved in the same direction as the arrangement direction.

Further, as shown in FIG. 33, the fiber reinforced resin structure 100-4 may have a plurality of curved portions 60.

As shown in FIG. 34, the fiber reinforced resin structure 100-4 may have a plurality of communication holes H (or a plurality of fiber bodies 10) arranged in a plurality of rows.

A form in which the entire fiber-reinforced resin structure 100-4 is twisted is also within the scope of the present invention.

In the structure according to the fiber reinforced resin structure 100-4, the structure according to the modified example of the fiber reinforced resin structure 100-2 and / or the fiber reinforced resin structure 100-2 is regularly arranged, and the resin It can also be expressed as having an integrated structure via. Further, in the structure according to the fiber reinforced resin structure 100-4, the structure according to the fiber reinforced resin structure 100-3 is curved in a predetermined direction as a whole while maintaining the cross-sectional shape along the axis. It can also be expressed as a thing.

<<< Manufacturing method >>>
The method for producing the fiber reinforced resin structure 100-4 is, for example,
A columnar first foam 30, a fibrous body 10 that covers at least a part of the side surface of the first foam 30, and a columnar second foam that is close to the first foam 30 via the fibrous body 10. A preparatory step of preparing an aggregate 55 having the foam 30 and the fibrous body 10 impregnated with a thermosetting resin (uncured resin 25) in an uncured state.
A deformation step of applying an external force to the aggregate 55 to deform the cross-sectional shapes of the first foam 30 and the second foam 30.
A bending step of bending the aggregate 55 so that the column axis A of the foam 30 is curved, and
This method includes a curing step of thermosetting the thermosetting resin (uncured resin 25) contained in the aggregate 55.

The method for producing the fiber-reinforced resin structure 100-4 may be a method in which the assembly 55 as shown in FIG. 20C is not subjected to the deformation step and the bending step is carried out. Although it is good, it is preferable to carry out the deformation step and the bending step. That is, the method for producing the fiber-reinforced resin structure 100-4 may further include a deformation step of applying an external force to the aggregate 55 to deform the cross-sectional shapes of the first foam 30 and the second foam 30. preferable.

The preparatory step can be carried out in the same manner as the manufacturing method of the fiber reinforced resin structure 100-3.

Regarding the bending step, the above-mentioned contents can be referred to except that the object to be curved is changed from the laminated body 50 to the aggregate 55. That is, in the bending step, in a state where the plurality of laminates 50 are arranged as the aggregate 55, an external force is applied to the plurality of laminates 50 so that the column axes A of the plurality of foams 30 included in the aggregate 55 are curved. Is added. As a method of applying an external force, as described above, the assembly 55 can be fitted into the mold.

For the deformation process, the above-mentioned contents can be referred to. That is, in the deformation step, in a state where the plurality of laminated bodies 50 are arranged as the aggregate 55, an external force is applied to the plurality of laminated bodies 50 to deform the cross-sectional shapes of the plurality of foams 30. As a method of applying an external force, as described above, the assembly 55 can be fitted into the mold.

As described above, the deformation step and the bending step may be carried out at the same time or separately.

The curing step is as described above. As shown in FIG. 32 (f), by carrying out the curing step, the plurality of fibrous bodies 10 and the like contained in the aggregate 55 are integrated via the thermosetting resin.

Further, as described above, the cooling step, the cutting step and the removing step may be carried out.

In the method shown in FIGS. 32 and 33, a laminate 50 containing the foam 30, the fiber 10, and the uncured resin 25 is prepared (FIGS. 32 (a) and 33 (a)), and the plurality of laminates 50 are prepared. Is arranged so that the fibrous bodies 10 are in contact with each other or close to each other, and a plurality of laminated bodies 50 arranged by the two outer peripheral bodies 70 are sandwiched to form an aggregate 55 (FIGS. 32 (b) to 32 (d), FIGS. 33 (b) to 33 (d)), an external force is applied to the aggregate 55 to compress the whole, deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and the side surface of the aggregate 55. An external force is applied from the portion so as to bend the shaft of the laminated body 50 (foam 30) (FIGS. 32 (e) and 33 (e)), and then cured to have the curved portion 60 (communication hole H). The fiber-reinforced resin structure 100-4 (in which the pore axis C is curved) is formed (FIGS. 32 (f) and 33 (f)), and the foam 30 is removed from the fiber-reinforced resin structure 100-4. (FIG. 32 (g), FIG. 33 (g)).

In the method shown in FIG. 34, although details are not shown, a laminate 50 containing the foam 30, the fibrous body 10, and the uncured resin 25 is prepared so that the fibrous bodies 10 come into contact with or approach the plurality of laminates 50. And arranged in one row, the rows consisting of the plurality of laminated bodies 50 are arranged so as to form a plurality of rows to form an aggregate 55, and an external force is applied to the aggregate 55 to compress the whole body 50 (foam 30). ), While deforming the cross-sectional shape perpendicular to the axis, an external force is applied from the side surface portion of the assembly 55 so as to bend the axis of the laminated body 50 (foam 30), and then the curved portion 60 is cured. The fiber-reinforced resin structure 100-4 having the structure (the hole axis C of the communication hole H is curved) is formed, and the foam 30 is removed from the fiber-reinforced resin structure 100-4.

In each embodiment, the pillar shaft A, the cylinder shaft B, and the hole shaft C can be considered to exist at substantially the same positions, so that the pillar shaft A, the cylinder shaft B, and the cylinder shaft B are used. The hole shaft C can be read and explained respectively.

100-1 to 100-4 Fiber reinforced resin structure 10 Fiber body 15 Reinforcing member 20 Resin (cured resin)
25 resin (uncured resin)
30 Foam 50 Laminated 55 Assembled 60 Curved part 70 Outer peripheral body A Pillar axis B Cylindrical axis C Hole axis H Communication hole

Claims (5)

A laminate having a columnar foam that is a flexible body and a fiber that covers at least a part of the side surface of the foam, and the fiber is impregnated with a thermosetting resin in an uncured state. A step of preparing the laminated body, bending the laminated body so that the column axis of the foam is curved, and thermosetting the thermosetting resin contained in the laminated body is included.
A method for producing a fiber-reinforced resin structure, wherein the foam is a medium substance (a foam capable of secondary foaming as the foam; a thermosetting resin in an uncured state and a gas can be exuded). Except for the method using a covering body having a bleed hole and covering the laminated body; In the laminate, prior Symbol fibrous body, the are wound over one circumference on the side surface of the foam manufacturing method according to claim 1. The production method according to claim 1 or 2, wherein the foam is an olefin resin foam. The production method according to any one of claims 1 to ³ , wherein the foam has a density of 1 to 800 kg / m ³ . After the thermosetting step, the laminate is cooled to shrink the foam.
The production method according to any one of claims 1 to 4, further comprising a step of removing the foam contained in the laminate after the step of shrinking the foam.