JP6754617B2 - Manufacturing method of fiber reinforced resin molded product and fiber reinforced resin molded product - Google Patents

Manufacturing method of fiber reinforced resin molded product and fiber reinforced resin molded product Download PDF

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JP6754617B2
JP6754617B2 JP2016103883A JP2016103883A JP6754617B2 JP 6754617 B2 JP6754617 B2 JP 6754617B2 JP 2016103883 A JP2016103883 A JP 2016103883A JP 2016103883 A JP2016103883 A JP 2016103883A JP 6754617 B2 JP6754617 B2 JP 6754617B2
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吉田　武
武 吉田
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Renault SAS
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Description

本発明は、繊維強化樹脂成形品および繊維強化樹脂成形品の製造方法に関する。 The present invention relates to a fiber-reinforced resin molded product and a method for producing a fiber-reinforced resin molded product.

従来から、繊維強化樹脂成形品においては、剛性を向上させるために、マトリックス樹脂の内部に複数の粒状の固形充填材を充填（埋設）する技術が公知である（例えば、特許文献１参照）。この固形充填材の一例として、内部が中空に形成されたガラスビーズが適用される。 Conventionally, in a fiber-reinforced resin molded product, a technique of filling (embedding) a plurality of granular solid fillers inside a matrix resin in order to improve the rigidity has been known (see, for example, Patent Document 1). As an example of this solid filler, glass beads having a hollow inside are applied.

そして、ガラスビーズが埋設された繊維強化樹脂成形品の表面を研磨したのち、この研磨した表面に塗料を塗布して塗膜を形成することによって塗膜付き繊維強化樹脂成形品を作成する。 Then, after polishing the surface of the fiber-reinforced resin molded product in which the glass beads are embedded, a coating film is applied to the polished surface to form a coating film, thereby producing a fiber-reinforced resin molded product with a coating film.

特許第４４７８２７９号公報Japanese Patent No. 4478279

ここで、前記ガラスビーズは、ゴム等よりも延性が低く、脆性破壊しやすい。従って、マトリックス樹脂の表面からガラスビーズが突出している状態で、マトリックス樹脂の表面を研磨すると、ガラスビーズが割れるおそれがある。この場合、前述した塗装時に、ガラスビーズの割れ部から中空の内部に塗料が浸入するため、塗膜の表面が微細な凹凸となって、塗膜付き繊維強化樹脂成形品の外観品質が低下するという問題がある。 Here, the glass beads have lower ductility than rubber or the like and are easily broken by brittleness. Therefore, if the surface of the matrix resin is polished while the glass beads are protruding from the surface of the matrix resin, the glass beads may be cracked. In this case, during the above-mentioned painting, the paint penetrates into the hollow inside from the cracked portion of the glass beads, so that the surface of the coating film becomes fine irregularities and the appearance quality of the fiber-reinforced resin molded product with the coating film deteriorates. There is a problem.

そこで、本発明は、表面に塗膜を形成した場合に塗膜の外観品質が良好となる繊維強化樹脂成形品および繊維強化樹脂成形品の製造方法を提供することを目的とする。 Therefore, an object of the present invention is to provide a fiber-reinforced resin molded product and a method for producing a fiber-reinforced resin molded product, in which the appearance quality of the coating film is improved when a coating film is formed on the surface.

本発明に係る繊維強化樹脂成形品は、マトリックス樹脂と、前記マトリックス樹脂の内部に充填された繊維および複数の固形充填材と、を備える。前記固形充填材は、軟質体で形成されている。前記繊維強化樹脂成形品は、前記マトリックス樹脂の表面及び当該表面に露出した前記固形充填材の一部がそれぞれ研磨された状態で、前記マトリックス樹脂の表面及び前記研磨された部分の固形充填材にそれぞれ塗膜が形成されている。 The fiber-reinforced resin molded product according to the present invention includes a matrix resin, fibers filled inside the matrix resin, and a plurality of solid fillers. The solid filler is formed of a soft body. The fiber-reinforced resin molded product is applied to the surface of the matrix resin and the solid filler of the polished portion in a state where the surface of the matrix resin and a part of the solid filler exposed on the surface are polished, respectively. A coating film is formed on each.

また、繊維強化樹脂成形品の製造方法は、軟質体を冷却することによって硬化させた樹脂を粉砕することによって粒状の固形充填材を作成し、前記粒状の固形充填材および繊維をマトリックス樹脂の内部に充填する。前記マトリックス樹脂の表面及び当該表面に露出した部分の固形充填材をそれぞれ研磨し、前記研磨したマトリックス樹脂の表面及び当該表面に露出した部分の固形充填材にそれぞれ塗膜を形成する。 Further, in the method for producing a fiber-reinforced resin molded product, a granular solid filler is produced by crushing a resin cured by cooling a soft body, and the granular solid filler and fibers are used inside the matrix resin. Fill in. The surface of the matrix resin and the solid filler of the portion exposed on the surface are polished, respectively, and a coating film is formed on the surface of the polished matrix resin and the solid filler of the portion exposed on the surface.

本発明に係る繊維強化樹脂成形品および繊維強化樹脂成形品の製造方法によれば、表面に塗膜を形成した場合に塗膜の外観品質が良好となる繊維強化樹脂成形品を得ることができる。 According to the method for producing a fiber-reinforced resin molded product and a fiber-reinforced resin molded product according to the present invention, it is possible to obtain a fiber-reinforced resin molded product in which the appearance quality of the coating film is good when a coating film is formed on the surface. ..

図１は、本発明の実施形態に係る繊維強化樹脂成形品の断面図である。FIG. 1 is a cross-sectional view of a fiber reinforced resin molded product according to an embodiment of the present invention. 図２は、図１の繊維強化樹脂成形品の表層部を拡大した断面図である。FIG. 2 is an enlarged cross-sectional view of the surface layer portion of the fiber-reinforced resin molded product of FIG. 図３は、表面を研磨した後の繊維強化樹脂成形品の断面図である。FIG. 3 is a cross-sectional view of the fiber reinforced resin molded product after the surface has been polished. 図４は、図３の研磨面の上に塗装を施した塗膜付き繊維強化樹脂成形品の断面図である。FIG. 4 is a cross-sectional view of a fiber-reinforced resin molded product with a coating film coated on the polished surface of FIG.

以下、本発明の実施形態を図面とともに詳述する。
[繊維強化樹脂成形品の構成]
まず、図１，２に示すように、本発明の実施形態に係る繊維強化樹脂成形品１の構成を説明する。 Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
[Composition of fiber reinforced plastic molded products]
First, as shown in FIGS. 1 and 2, the configuration of the fiber-reinforced resin molded product 1 according to the embodiment of the present invention will be described.

繊維強化樹脂成形品１は、マトリックス樹脂３と、マトリックス樹脂３の内部に充填された繊維５と、マトリックス樹脂３における少なくとも表層部に充填され、粒状に形成された複数の固形充填材７と、を備えている。以下、具体的に説明する。 The fiber-reinforced resin molded product 1 includes a matrix resin 3, fibers 5 filled inside the matrix resin 3, and a plurality of solid fillers 7 filled in at least the surface layer portion of the matrix resin 3 and formed in granular form. It has. Hereinafter, a specific description will be given.

母材となるマトリックス樹脂３は、例えばウレタン樹脂等の種々の樹脂が適用可能である。また、繊維５は、例えば、連続する複数の炭素繊維等が適用可能である。 As the matrix resin 3 as the base material, various resins such as urethane resin can be applied. Further, as the fiber 5, for example, a plurality of continuous carbon fibers and the like can be applied.

固形充填材７は、粒状の軟質体で形成されている。本明細書において、「軟質体」とは、ガラスよりも延性が高い軟らかく弾性を有する物質であり、例えば、ＡＣＭ（アクリルゴム）などのゴムを含むものとする。固形充填材７を充填する理由は、マトリックス樹脂３の剛性を向上させるためである。固形充填材７は、マトリックス樹脂３における少なくとも表層部９に充填されていればよいが、本実施形態では、マトリックス樹脂３の全体にほぼ均等な間隔をおいて配置した形態を示した。 The solid filler 7 is formed of a granular soft body. In the present specification, the "soft body" is a soft and elastic substance having higher ductility than glass, and includes, for example, rubber such as ACM (acrylic rubber). The reason for filling the solid filler 7 is to improve the rigidity of the matrix resin 3. The solid filler 7 may be filled at least in the surface layer portion 9 of the matrix resin 3, but in the present embodiment, the solid filler 7 is arranged at substantially equal intervals over the entire matrix resin 3.

また、固形充填材７の形状は、球殻状、多孔質状、中実状などの各種の中空状の粒状体を適用可能である。本実施形態では、球殻状の固形充填材７を適用したが、これに限定されない。なお、球殻状とは、内方が中空で気体が封入されたバルーン状の形態を示すものとし、完全な球でなくとも多少変形したものも含む。さらに、固形充填材７は、多孔質の軟質体であってもよい。このように固形充填材７は、弾性を有するため、押圧荷重や摩擦力が入力された場合に弾性変形し、破損等の脆性破壊が起こりにくいという性質がある。 Further, as the shape of the solid filler 7, various hollow granules such as spherical shell, porous, and solid can be applied. In the present embodiment, the spherical shell-shaped solid filler 7 is applied, but the present invention is not limited to this. The spherical shell shape means a balloon-like shape in which the inside is hollow and gas is sealed, and includes a balloon-like shape that is not a perfect sphere but is slightly deformed. Further, the solid filler 7 may be a porous soft body. As described above, since the solid filler 7 has elasticity, it is elastically deformed when a pressing load or a frictional force is input, and has a property that brittle fracture such as breakage is unlikely to occur.

[繊維強化樹脂成形品の製造方法]
次いで、繊維強化樹脂成形品１の製造方法を手順を追って説明する。 [Manufacturing method of fiber reinforced plastic molded products]
Next, the manufacturing method of the fiber-reinforced resin molded product 1 will be described step by step.

（１）まず、固形充填材７の製造方法を説明する。 (1) First, a method for producing the solid filler 7 will be described.

（１−１）冷却工程
通常の発泡ゴムシート（軟質体）を準備し、この発泡ゴムシートを冷却することにより、硬化させる。例えば、ゴムの種類としてＡＣＭ（アクリルゴム）を用いた場合、冷却温度を−２０℃程度に設定することが望ましい。その他のゴムを用いた場合は、そのゴムに適した冷却温度に適宜設定すればよい。 (1-1) Cooling Step A normal foam rubber sheet (soft body) is prepared, and the foam rubber sheet is cooled to cure it. For example, when ACM (acrylic rubber) is used as the type of rubber, it is desirable to set the cooling temperature to about −20 ° C. When other rubber is used, the cooling temperature suitable for the rubber may be appropriately set.

（１−２）粉砕工程
この冷却によって硬化した樹脂を粉砕して、粒状の固形充填材７を作成する。具体的には、冷却して硬化させた発泡ゴムシートを粉砕機を用いて粉砕する。この発泡ゴムシートから作成される固形充填材７は、多孔質の軟質体で形成される。 (1-2) Crushing Step The resin cured by this cooling is crushed to prepare a granular solid filler 7. Specifically, the foamed rubber sheet that has been cooled and cured is crushed using a crusher. The solid filler 7 made from this foam rubber sheet is formed of a porous soft body.

（２）次に、繊維強化樹脂成形品１の成形手順を説明する。 (2) Next, the molding procedure of the fiber reinforced resin molded product 1 will be described.

（２−１）充填工程
充填工程においては、前記粒状の固形充填材７をマトリックス樹脂３の内部に充填する。具体的には、熱硬化性樹脂の場合、軟化状態のマトリックス樹脂３に繊維５と固形充填材７を混ぜ込んで捏ねたのち、この捏ねた軟化状態の樹脂を、加熱した金型の内部に流入させることにより、マトリックス樹脂３を加熱して硬化させる。これにより、硬化したマトリックス樹脂３内に繊維５と固形充填材７が充填された状態となる。なお、図２に示すように、マトリックス樹脂３の表面４から固形充填材７が露出していると、金型の内面が固形充填材７の露出部分を押圧しながら加熱することにより、球殻状の固形充填材７におけるマトリックス樹脂３の表面４に露出している部分が平坦状に変形する場合がある。 (2-1) Filling Step In the filling step, the granular solid filler 7 is filled inside the matrix resin 3. Specifically, in the case of a thermosetting resin, the fiber 5 and the solid filler 7 are mixed with the softened matrix resin 3 and kneaded, and then the kneaded softened resin is placed inside the heated mold. By flowing in, the matrix resin 3 is heated and cured. As a result, the cured matrix resin 3 is filled with the fibers 5 and the solid filler 7. As shown in FIG. 2, when the solid filler 7 is exposed from the surface 4 of the matrix resin 3, the inner surface of the mold heats the exposed portion of the solid filler 7 while pressing the spherical shell. The portion of the solid filler 7 exposed on the surface 4 of the matrix resin 3 may be deformed into a flat shape.

（３）次に、塗膜付き繊維強化樹脂成形品１１の製造手順を説明する。
（３−１）研磨工程
繊維強化樹脂成形品１の表面４に研磨を施して、図３に示すように、表面４が研磨面１０になった繊維強化樹脂成形品１が形成される。 (3) Next, the manufacturing procedure of the fiber-reinforced resin molded product 11 with a coating film will be described.
(3-1) Polishing Step The surface 4 of the fiber-reinforced resin molded product 1 is polished to form the fiber-reinforced resin molded product 1 having the surface 4 as the polished surface 10 as shown in FIG.

（３−２）塗装工程
図３の研磨面１０の上に塗料を塗布すると塗膜付き繊維強化樹脂成形品１１が完成する。なお、塗膜１３の表面１４は研磨面１０に沿った平坦な形状になる。 (3-2) Painting Process When the paint is applied on the polished surface 10 of FIG. 3, the fiber-reinforced resin molded product 11 with a coating film is completed. The surface 14 of the coating film 13 has a flat shape along the polished surface 10.

以下に、本実施形態による作用効果を説明する。
[１]本実施形態に係る繊維強化樹脂成形品１は、母材となるマトリックス樹脂３と、マトリックス樹脂３の内部に充填された繊維５と、マトリックス樹脂３における少なくとも表層部９に充填され、粒状に形成された複数の固形充填材７と、を備えている。固形充填材７は、軟質体で形成されている。 The action and effect of this embodiment will be described below.
[1] The fiber-reinforced resin molded product 1 according to the present embodiment is filled with a matrix resin 3 as a base material, fibers 5 filled inside the matrix resin 3, and at least a surface layer portion 9 of the matrix resin 3. A plurality of solid fillers 7 formed in a granular form are provided. The solid filler 7 is made of a soft body.

固形充填材７が、ガラスなどよりも延性が高い軟質体で形成されている。このため、マトリックス樹脂３の表面４を研磨する場合、固形充填材７における表面４から露出している部分が研磨時に脆性破壊を起こしにくい。従って、マトリックス樹脂３の研磨面１０の上に塗料を塗布したとき、塗膜１３の表面１４は凹凸が少ない平滑面になるため、表面１４の外観品質が良好な塗膜付き繊維強化樹脂成形品１１を得ることができる。 The solid filler 7 is formed of a soft body having higher ductility than glass or the like. Therefore, when the surface 4 of the matrix resin 3 is polished, the portion of the solid filler 7 exposed from the surface 4 is less likely to cause brittle fracture during polishing. Therefore, when the paint is applied on the polished surface 10 of the matrix resin 3, the surface 14 of the coating film 13 becomes a smooth surface with few irregularities, so that the fiber-reinforced resin molded product with a coating film has a good appearance quality of the surface 14. 11 can be obtained.

[２]固形充填材７の軟質体は、多孔質に形成されている。
固形充填材７は多孔質に形成されているため、中実状の固形充填材をマトリックス樹脂３に充填した場合よりも、繊維強化樹脂成形品１の重量を低減することができる。 [2] The soft body of the solid filler 7 is formed to be porous.
Since the solid filler 7 is formed to be porous, the weight of the fiber-reinforced resin molded product 1 can be reduced as compared with the case where the matrix resin 3 is filled with the solid filler in a solid state.

[３]本実施形態に係る繊維強化樹脂成形品１を製造する製造方法は、軟質体を冷却することによって硬化させる冷却工程と、この硬化した樹脂を粉砕して、粒状の固形充填材７を作成する粉砕工程と、粒状の固形充填材７をマトリックス樹脂３の内部に充填する充填工程と、を有する。 [3] The manufacturing method for producing the fiber-reinforced resin molded product 1 according to the present embodiment includes a cooling step of curing the soft body by cooling and crushing the cured resin to form a granular solid filler 7. It has a pulverization step for producing and a filling step for filling the inside of the matrix resin 3 with the granular solid filler 7.

軟質体は、常温では粉砕が困難であるため、軟質体から粒状の固形充填材７を作成することは困難である。しかし、本実施形態では、軟質体を冷却することによって硬化させる冷却工程を有するため、マトリックス樹脂３の内部に充填される固形充填材７を軟質体にすることが容易にできる。このため、マトリックス樹脂３の表面４を研磨する場合、固形充填材７の露出部分が研磨時に脆性破壊を起こしにくい。従って、マトリックス樹脂３の研磨面１０の上に塗料を塗布したとき、塗膜１３の表面１４は凹凸が少ない平滑面になるため、塗膜１３の表面１４の外観品質が良好な塗膜付き繊維強化樹脂成形品１１を得ることができる。 Since it is difficult to pulverize the soft body at room temperature, it is difficult to prepare a granular solid filler 7 from the soft body. However, since the present embodiment has a cooling step of curing the soft body by cooling it, the solid filler 7 filled inside the matrix resin 3 can be easily made into a soft body. Therefore, when the surface 4 of the matrix resin 3 is polished, the exposed portion of the solid filler 7 is less likely to cause brittle fracture during polishing. Therefore, when the paint is applied on the polished surface 10 of the matrix resin 3, the surface 14 of the coating film 13 becomes a smooth surface with few irregularities, so that the appearance quality of the surface 14 of the coating film 13 is good. A reinforced resin molded product 11 can be obtained.

[４]本実施形態に係る繊維強化樹脂成形品１の製造方法に用いる固形充填材７の軟質体は、多孔質に形成されている。 [4] The soft body of the solid filler 7 used in the method for producing the fiber-reinforced resin molded product 1 according to the present embodiment is formed to be porous.

固形充填材７は多孔質に形成されるため、中実状の固形充填材をマトリックス樹脂３に充填した場合よりも、繊維強化樹脂成形品１の重量を低減することができる。 Since the solid filler 7 is formed to be porous, the weight of the fiber-reinforced resin molded product 1 can be reduced as compared with the case where the matrix resin 3 is filled with the solid filler in a solid state.

ところで、本発明は前述の実施形態に例をとって説明したが、この実施形態に限ることなく本発明の要旨を逸脱しない範囲で他の実施形態を各種採用することができる。 By the way, the present invention has been described by taking an example in the above-described embodiment, but the present invention is not limited to this embodiment, and various other embodiments can be adopted without departing from the gist of the present invention.

１ 繊維強化樹脂成形品
３ マトリックス樹脂
５ 繊維
７ 固形充填材
９ 表層部 1 Fiber reinforced resin molded product 3 Matrix resin 5 Fiber 7 Solid filler 9 Surface layer

Claims (4)

母材となるマトリックス樹脂と、前記マトリックス樹脂の内部に充填された繊維と、前記マトリックス樹脂における少なくとも表層部に充填され、粒状に形成された複数の固形充填材と、を備え、
前記固形充填材は、軟質体で形成され、
前記マトリックス樹脂の表面及び当該表面に露出した前記固形充填材の一部がそれぞれ研磨された状態で、前記マトリックス樹脂の表面及び前記研磨された部分の固形充填材にそれぞれ塗膜が形成されていることを特徴とする繊維強化樹脂成形品。 A matrix resin serving as a base material, fibers filled inside the matrix resin, and a plurality of solid fillers filled in at least the surface layer portion of the matrix resin and formed into granules are provided.
The solid filler is formed of a soft body and is formed of a soft material .
A coating film is formed on the surface of the matrix resin and the solid filler of the polished portion, respectively, in a state where the surface of the matrix resin and a part of the solid filler exposed on the surface are polished. A fiber-reinforced resin molded product characterized by this. 請求項１に記載の繊維強化樹脂成形品であって、
前記固形充填材の軟質体は、多孔質に形成されていることを特徴とする繊維強化樹脂成形品。 The fiber-reinforced resin molded product according to claim 1.
A fiber-reinforced resin molded product characterized in that the soft body of the solid filler is formed porous. 繊維強化樹脂成形品を製造する製造方法であって、
軟質体を冷却することによって硬化させる冷却工程と、
この硬化した樹脂を粉砕して、粒状の固形充填材を作成する粉砕工程と、
前記粒状の固形充填材を、その固形充填材の一部がマトリックス樹脂の表面に露出するように、マトリックス樹脂の内部に充填する充填工程と、
前記マトリックス樹脂の表面及び当該表面に露出した部分の固形充填材をそれぞれ研磨する研磨工程と、
前記研磨したマトリックス樹脂の表面及び当該表面に露出した部分の固形充填材にそれぞれ塗膜を形成する塗膜形成工程と、
を有することを特徴とする繊維強化樹脂成形品の製造方法。 It is a manufacturing method for manufacturing fiber reinforced resin molded products.
A cooling process that cures the soft body by cooling it,
A crushing step of crushing this cured resin to create a granular solid filler, and
A filling step of filling the inside of the matrix resin with the granular solid filler so that a part of the solid filler is exposed on the surface of the matrix resin.
A polishing step of polishing the surface of the matrix resin and the solid filler of the portion exposed on the surface, respectively.
A coating film forming step of forming a coating film on the surface of the polished matrix resin and the solid filler of the portion exposed on the surface, respectively.
A method for producing a fiber-reinforced resin molded product, which comprises. 請求項３に記載の繊維強化樹脂成形品の製造方法であって、
前記固形充填材の軟質体は、多孔質に形成されていることを特徴とする繊維強化樹脂成形品の製造方法。 The method for producing a fiber-reinforced resin molded product according to claim 3.
A method for producing a fiber-reinforced resin molded product, wherein the soft body of the solid filler is formed porous.
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