JP6792313B2 - Method of manufacturing fiber reinforced resin structure, manufacturing system of fiber reinforced resin structure and fiber reinforced resin structure - Google Patents
Method of manufacturing fiber reinforced resin structure, manufacturing system of fiber reinforced resin structure and fiber reinforced resin structure Download PDFInfo
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- JP6792313B2 JP6792313B2 JP2017546419A JP2017546419A JP6792313B2 JP 6792313 B2 JP6792313 B2 JP 6792313B2 JP 2017546419 A JP2017546419 A JP 2017546419A JP 2017546419 A JP2017546419 A JP 2017546419A JP 6792313 B2 JP6792313 B2 JP 6792313B2
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- 229920005989 resin Polymers 0.000 title claims description 402
- 239000011347 resin Substances 0.000 title claims description 402
- 239000000835 fiber Substances 0.000 title claims description 91
- 238000004519 manufacturing process Methods 0.000 title claims description 59
- 229920001187 thermosetting polymer Polymers 0.000 claims description 132
- 238000000034 method Methods 0.000 claims description 38
- 238000000465 moulding Methods 0.000 claims description 35
- 238000010438 heat treatment Methods 0.000 claims description 17
- 239000004918 carbon fiber reinforced polymer Substances 0.000 claims description 15
- 229920002430 Fibre-reinforced plastic Polymers 0.000 claims description 11
- 238000007599 discharging Methods 0.000 claims description 5
- 239000011151 fibre-reinforced plastic Substances 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 5
- 229920005992 thermoplastic resin Polymers 0.000 claims description 5
- 238000005304 joining Methods 0.000 description 9
- 239000000945 filler Substances 0.000 description 8
- 239000000853 adhesive Substances 0.000 description 5
- 230000001070 adhesive effect Effects 0.000 description 5
- 239000006260 foam Substances 0.000 description 5
- 238000005187 foaming Methods 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 239000012783 reinforcing fiber Substances 0.000 description 4
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 3
- 239000003822 epoxy resin Substances 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000011521 glass Substances 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 2
- 229910052799 carbon Inorganic materials 0.000 description 2
- -1 for example Substances 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 239000012784 inorganic fiber Substances 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 229920000728 polyester Polymers 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 1
- 229920000271 Kevlar® Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 1
- 239000004760 aramid Substances 0.000 description 1
- 229920003235 aromatic polyamide Polymers 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 229910052796 boron Inorganic materials 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000011256 inorganic filler Substances 0.000 description 1
- 229910003475 inorganic filler Inorganic materials 0.000 description 1
- 239000004761 kevlar Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 238000010422 painting Methods 0.000 description 1
- 239000005011 phenolic resin Substances 0.000 description 1
- 229920002577 polybenzoxazole Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
- B29C65/02—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor by heating, with or without pressure
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/06—Fibrous reinforcements only
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Thermal Sciences (AREA)
- Oral & Maxillofacial Surgery (AREA)
- Health & Medical Sciences (AREA)
- Physics & Mathematics (AREA)
- Composite Materials (AREA)
- Moulding By Coating Moulds (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Laminated Bodies (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Molding Of Porous Articles (AREA)
Description
本出願は、２０１５年１０月２３日に出願された日本特許出願番号２０１５−２０８９４９に基づくもので、ここにその記載内容を援用する。 This application is based on Japanese Patent Application No. 2015-208949 filed on October 23, 2015, the contents of which are incorporated herein by reference.
本発明は、繊維強化樹脂構造物の製造方法、繊維強化樹脂構造物の製造システム及び繊維強化樹脂構造物に関する。 The present invention relates to a method for producing a fiber reinforced resin structure, a system for producing a fiber reinforced resin structure, and a fiber reinforced resin structure.
近年、軽くて丈夫な炭素繊維強化樹脂（ＣＦＲＰ）やガラス繊維強化樹脂（ＧＦＲＰ）等の繊維強化樹脂を用いた構造物が注目されている。例えばこのような繊維強化樹脂構造物は、コンピュータや携帯電話などの電子機器の筐体に採用されている（特許文献１参照）。 In recent years, structures using fiber reinforced resins such as light and durable carbon fiber reinforced plastic (CFRP) and glass fiber reinforced resin (GFRP) have been attracting attention. For example, such a fiber reinforced resin structure is used in a housing of an electronic device such as a computer or a mobile phone (see Patent Document 1).
ところで、上述のような電子機器の筐体等の構造物を成形する際には、繊維強化樹脂の本体部に、ボスやリブなどの細かい付加構造部を形成する必要がある。この付加構造部は、従来より金型内に繊維強化樹脂の本体部を固定し、そこに熱可塑性樹脂を注入するインサート成形を用いて形成されている。 By the way, when molding a structure such as a housing of an electronic device as described above, it is necessary to form a fine additional structure such as a boss or a rib on the main body of the fiber reinforced resin. This additional structure portion has been conventionally formed by using insert molding in which a main body portion of a fiber reinforced resin is fixed in a mold and a thermoplastic resin is injected therein.
しかしながら、上述のインサート成形を用いた場合、一般的に本体部の繊維強化樹脂の含浸樹脂は熱硬化性樹脂であり、付加構造部の樹脂は熱可塑性樹脂となるため、異種材料の樹脂同士の接着となり、接着強度が低くなる。またインサート成形時には、２００℃以上に加熱溶融された熱可塑性樹脂が高圧下で注入されるため、インサート成形後の製品に熱収縮による変形や歪みが発生しやすくなる。この結果、繊維強化樹脂製品の歩留まりの低下や品質の低下が引き起こされ、結果的に製品価格が高くなっていた。 However, when the above-mentioned insert molding is used, the impregnated resin of the fiber-reinforced resin in the main body is generally a thermosetting resin, and the resin in the additional structure is a thermoplastic resin. It becomes adhesive and the adhesive strength becomes low. Further, at the time of insert molding, since the thermoplastic resin heated and melted at 200 ° C. or higher is injected under high pressure, the product after insert molding is liable to be deformed or distorted due to heat shrinkage. As a result, the yield and quality of the fiber-reinforced resin product are lowered, and as a result, the product price is high.
本出願はかかる点に鑑みてなされたものであり、繊維強化樹脂構造物における繊維強化樹脂の本体部と付加構造部との接着強度を向上し、従来のインサート成形のような熱収縮による変形や歪みの発生を低減できる、繊維強化樹脂構造物の製造方法、繊維強化樹脂構造物の製造システム、繊維強化樹脂構造物を提供することをその目的の一つとする。 This application has been made in view of this point, and has improved the adhesive strength between the main body and the additional structure of the fiber reinforced resin in the fiber reinforced resin structure, and has been deformed by heat shrinkage as in conventional insert molding. One of the purposes thereof is to provide a method for manufacturing a fiber reinforced resin structure, a manufacturing system for a fiber reinforced resin structure, and a fiber reinforced resin structure capable of reducing the occurrence of strain.
本発明者らは、鋭意検討した結果、金型の溝に付加構造部となる熱硬化性樹脂を充填して熱硬化性樹脂が半硬化の状態の半硬化付加構造部を形成し、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成し、前記半硬化付加構造部と前記半硬化本体部とを圧接して加熱し、前記半硬化付加構造部及び前記半硬化本体部の熱硬化性樹脂を硬化して、付加構造部と本体部を接着することにより、上記問題を解決できることを見出し、本発明を完成するに至った。 As a result of diligent studies, the present inventors filled the groove of the mold with a thermosetting resin to be an additional structure part to form a semi-cured additional structure part in which the thermosetting resin is in a semi-cured state, and fiber-reinforced. The thermosetting resin of the resin forms a semi-cured main body portion, and the semi-cured additional structure portion and the semi-cured main body portion are pressed and heated to heat the semi-cured additional structure portion and the semi-cured additional structure portion. We have found that the above problems can be solved by curing the thermosetting resin of the main body portion and adhering the additional structure portion and the main body portion, and have completed the present invention.
すなわち、本発明は以下の態様を含む。
（１）熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、その本体部の表面に形成される付加構造部とを有する繊維強化樹脂構造物の製造方法であって、付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し、当該熱硬化性樹脂が半硬化の状態の半硬化付加構造部を形成する工程と、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成する工程と、前記金型の溝の前記半硬化付加構造部と前記半硬化本体部とを圧接して加熱し、前記半硬化付加構造部及び前記半硬化本体部の熱硬化性樹脂を硬化して、付加構造部と本体部を接着する工程と、前記金型を前記付加構造部から離脱させる工程と、を有する、繊維強化樹脂構造物の製造方法。
（２）前記金型の溝に前記熱硬化性樹脂を充填する工程は、ノズルから金型の溝に熱硬化性樹脂を吐出することにより行う、（１）に記載の繊維強化樹脂構造物の製造方法。
（３）前記半硬化本体部を形成する工程は、複数種類の繊維強化樹脂のプリプレグ片を組み合わせて板状体を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシートで挟むことにより行う、（１）又は（２）に記載の繊維強化樹脂構造物の製造方法。
（４）前記半硬化本体部を形成する工程は、第１の種類の繊維強化樹脂のプリプレグ片の開口部に、第２の種類の繊維強化樹脂のプリプレグ片を入れ込むことで板状体を形成する、（３）に記載の繊維強化樹脂構造物の製造方法。
（５）前記第１の種類の繊維強化樹脂は、ＣＦＲＰであり、前記第２の種類の繊維強化樹脂は、誘電体からなる繊維強化樹脂である、（４）に記載の繊維強化樹脂構造物の製造方法。
（６）前記半硬化本体部を形成する工程は、発泡樹脂を含有する板状体を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシートで挟むことにより行う、（１）又は（２）に記載の繊維強化樹脂構造物の製造方法。
（７）前記板状体の発泡樹脂は、前記プリプレグシートで挟んでから発泡させる、（６）に記載の繊維強化樹脂構造物の製造方法。
（８）前記板状体の発泡樹脂は、前記プリプレグシートで挟む前に発泡させる、（６）に記載の繊維強化樹脂構造物の製造方法。
（９）前記半硬化本体部に段差を形成する工程をさらに有する、（６）〜（８）のいずれかに記載の繊維強化樹脂構造物の製造方法。
（１０）前記半硬化本体部の厚みを調整する工程をさらに有する、（６）〜（９）のいずれかに記載の繊維強化樹脂構造物の製造方法。
（１１）前記半硬化本体部の厚みを１ｍｍ以下に調整する、（１０）に記載の繊維強化樹脂構造物の製造方法。
（１２）前記板状体は、熱硬化性樹脂を含有する、（６）〜（１１）のいずれかに記載の繊維強化樹脂構造物の製造方法。
（１３）前記付加構造部と前記本体部を接着する工程において、前記半硬化本体部を所望の形状にプレス成形する、（１）〜（１２）のいずれかに記載の繊維強化樹脂構造物の製造方法。
（１４）前記付加構造部と前記本体部を接着する工程は、前記金型の前記半硬化付加構造部を前記半硬化本体部に押し付けて圧接するプレス成形を用いて行われる、（１）〜（１２）のいずれかに記載の繊維強化樹脂構造物の製造方法。
（１５）前記付加構造部と前記本体部を接着する工程は、前記金型の前記半硬化付加構造部と前記半硬化本体部を真空引きして圧接するオートクレーブ成形又は真空バック成形を用いて行われる、（１）〜（１２）のいずれかに記載の繊維強化樹脂構造物の製造方法。
（１６）前記半硬化本体部を形成する工程と前記付加構造部と前記本体部を接着する工程は、ＲＴＭ成形又はＶａＲＴＭ成形を用いて行われる、（１）又は（２）に記載の繊維強化樹脂構造物の製造方法。
（１７）熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、その本体部の表面に形成される付加構造部とを有する繊維強化樹脂構造物の製造方法であって、付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し、当該熱硬化性樹脂を硬化させて付加構造部を形成する工程と、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成する工程と、前記金型の溝の前記付加構造部と前記半硬化本体部とを圧接して加熱し、前記半硬化本体部の熱硬化性樹脂を硬化して、付加構造部と本体部を接着する工程と、前記金型を前記付加構造部から離脱させる工程と、を有する、繊維強化樹脂構造物の製造方法。
（１８）熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、その本体部の表面に形成される付加構造部とを有する繊維強化樹脂構造物の製造方法であって、付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し、当該熱硬化性樹脂を硬化させて付加構造部を形成する工程と、熱硬化性樹脂を含有する繊維強化樹脂の第１のプリプレグシートを前記付加構造部に接触させた状態で加熱し、前記第１のプリプレグシートの熱硬化性樹脂を硬化して、前記第１のプリプレグシートを前記付加構造部に接着させる工程と、熱硬化性樹脂を含有する繊維強化樹脂の第２のプリプレグシートと、未発泡の発泡樹脂を含有するシートを重ねて接着させる工程と、加熱により前記シートの発泡樹脂を発泡させて板状体を形成しつつ、当該板状体を前記第１のプリプレグシートに接着させて、前記板状体とその両面に接着された第１のプリプレグシート及び第２のプリプレグシートからなる本体部と前記付加構造部とを接着した状態にする工程と、前記金型を前記付加構造部から離脱させる工程と、を有する、繊維強化樹脂構造物の製造方法。
（１９）熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、その本体部の表面に形成される付加構造部とを有する繊維強化樹脂構造物の製造システムであって、付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し当該熱硬化性樹脂が半硬化の状態の半硬化付加構造部を形成し、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成し、前記金型の溝の前記半硬化付加構造部と前記半硬化本体部とを圧接して加熱し前記半硬化付加構造部及び前記半硬化本体部の熱硬化性樹脂を硬化して付加構造部と本体部を接着し、前記金型を前記付加構造部から離脱させる、繊維強化樹脂構造物の製造システム。
（２０）繊維強化樹脂構造物であって、熱硬化性樹脂を含有する繊維強化樹脂からなる本体部と、前記本体部の表面に設けられた、熱硬化性樹脂からなる付加構造部と、を有し、前記本体部は、複数種類の繊維強化樹脂片を組み合わせた板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有する、繊維強化樹脂構造物。
（２１）前記板状体は、開口部を有する第１の種類の繊維強化樹脂片と、当該開口部に配置された、第２の種類の繊維強化樹脂片とを有する、（２０）に記載の繊維強化樹脂構造物。
（２２）前記第１の種類の繊維強化樹脂片は、ＣＦＲＰであり、前記第２の種類の繊維強化樹脂片は、誘電体からなる繊維強化樹脂である、（２１）に記載の繊維強化樹脂構造物。
（２３）繊維強化樹脂構造物であって、熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、前記本体部の表面に設けられた、熱硬化性樹脂からなる付加構造部と、を有し、前記本体部は、発泡樹脂を含有する板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有する、繊維強化樹脂構造物。
（２４）前記板状体は、熱可塑性樹脂を含有する、（２３）に記載の繊維強化樹脂構造物。
（２５）前記本体部は、段差を有する、（２３）又は（２４）に記載の繊維強化樹脂構造物。
（２６）前記本体部の厚みが、１ｍｍ以下である、（２３）〜（２５）のいずれかに記載の繊維強化樹脂構造物。That is, the present invention includes the following aspects.
(1) A method for manufacturing a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion, which is a method of manufacturing the additional structure portion. A process of filling a groove of a mold formed corresponding to a shape with a thermosetting resin to form a semi-cured additional structure portion in a semi-cured state of the thermosetting resin, and a thermosetting of a fiber-reinforced resin. The step of forming the semi-cured main body portion in which the resin is semi-cured, and the semi-cured additional structure portion of the groove of the mold and the semi-cured main body portion are pressed and heated to heat the semi-cured additional structure portion and A fiber-reinforced resin structure having a step of curing the thermosetting resin of the semi-cured main body portion to bond the additional structure portion and the main body portion, and a step of separating the mold from the additional structure portion. Production method.
(2) The fiber-reinforced resin structure according to (1), wherein the step of filling the groove of the mold with the thermosetting resin is performed by discharging the thermosetting resin from the nozzle into the groove of the mold. Production method.
(3) In the step of forming the semi-cured main body, a plate-like body is formed by combining a plurality of types of fiber-reinforced resin prepreg pieces, and both sides thereof are fiber-reinforced resin prepreg sheets containing a thermosetting resin. The method for producing a fiber-reinforced resin structure according to (1) or (2), which is carried out by sandwiching the resin.
(4) In the step of forming the semi-cured main body portion, the plate-like body is formed by inserting the prepreg piece of the second type of fiber reinforced resin into the opening of the prepreg piece of the first type of fiber reinforced resin. The method for producing a fiber reinforced resin structure according to (3).
(5) The fiber-reinforced resin structure according to (4), wherein the first type of fiber-reinforced resin is CFRP, and the second type of fiber-reinforced resin is a fiber-reinforced resin made of a dielectric. Manufacturing method.
(6) The step of forming the semi-cured main body portion is performed by forming a plate-like body containing a foamed resin and sandwiching both sides thereof with a prepreg sheet of a fiber-reinforced resin containing a thermosetting resin. The method for producing a fiber reinforced resin structure according to 1) or (2).
(7) The method for producing a fiber-reinforced resin structure according to (6), wherein the foamed resin of the plate-shaped body is sandwiched between the prepreg sheets and then foamed.
(8) The method for producing a fiber-reinforced resin structure according to (6), wherein the foamed resin of the plate-shaped body is foamed before being sandwiched between the prepreg sheets.
(9) The method for producing a fiber-reinforced resin structure according to any one of (6) to (8), further comprising a step of forming a step on the semi-cured main body.
(10) The method for producing a fiber-reinforced resin structure according to any one of (6) to (9), further comprising a step of adjusting the thickness of the semi-cured main body.
(11) The method for producing a fiber-reinforced resin structure according to (10), wherein the thickness of the semi-cured main body is adjusted to 1 mm or less.
(12) The method for producing a fiber-reinforced resin structure according to any one of (6) to (11), wherein the plate-like body contains a thermosetting resin.
(13) The fiber-reinforced resin structure according to any one of (1) to (12), wherein the semi-cured main body is press-molded into a desired shape in the step of adhering the additional structure and the main body. Production method.
(14) The step of adhering the additional structure portion and the main body portion is performed by using press molding in which the semi-cured additional structure portion of the mold is pressed against the semi-cured main body portion and pressure-welded. The method for producing a fiber reinforced resin structure according to any one of (12).
(15) The step of adhering the additional structure portion and the main body portion is performed by using autoclave molding or vacuum back molding in which the semi-cured additional structure portion and the semi-cured main body portion of the mold are vacuum-pulled and pressure-welded. The method for producing a fiber-reinforced resin structure according to any one of (1) to (12).
(16) The fiber reinforced according to (1) or (2), wherein the step of forming the semi-cured main body portion and the step of adhering the additional structure portion and the main body portion are performed by using RTM molding or VaRTM molding. A method for manufacturing a resin structure.
(17) A method for manufacturing a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion, wherein the additional structure portion The process of filling the groove of the mold formed corresponding to the shape with a thermosetting resin and curing the thermosetting resin to form an additional structure, and the process of semi-curing the thermosetting resin of the fiber reinforced resin. The step of forming the semi-cured main body portion in the above state and the additional structure portion of the groove of the mold and the semi-cured main body portion are pressed and heated to cure the thermosetting resin of the semi-cured main body portion. A method for manufacturing a fiber-reinforced resin structure, comprising a step of adhering the additional structure portion and the main body portion and a step of separating the mold from the additional structure portion.
(18) A method for manufacturing a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion, wherein the additional structure portion A step of filling a groove of a mold formed corresponding to a shape with a thermosetting resin and curing the thermosetting resin to form an additional structure portion, and a fiber-reinforced resin containing the thermosetting resin. A step of heating the first prepreg sheet in contact with the additional structure portion, curing the thermosetting resin of the first prepreg sheet, and adhering the first prepreg sheet to the additional structure portion. A step of stacking and adhering a second prepreg sheet of a fiber-reinforced resin containing a thermosetting resin and a sheet containing an unexpanded foamed resin, and a plate-like structure in which the foamed resin of the sheet is foamed by heating. While forming a body, the plate-shaped body is adhered to the first prepreg sheet, and the main body portion including the plate-shaped body and the first prepreg sheet and the second prepreg sheet bonded to both sides thereof and the said A method for producing a fiber-reinforced resin structure, comprising a step of bringing the additional structure portion into a bonded state and a step of separating the mold from the additional structure portion.
(19) A production system for a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion, which is a manufacturing system of the additional structure portion. The groove of the mold formed corresponding to the shape is filled with a thermosetting resin to form a semi-cured additional structure portion in which the thermosetting resin is semi-cured, and the thermosetting resin of the fiber reinforced resin is semi-cured. A semi-cured main body portion in a cured state is formed, and the semi-cured additional structure portion and the semi-cured main body portion of the groove of the mold are pressed and heated to heat the semi-cured additional structure portion and the semi-cured main body portion. A fiber-reinforced resin structure manufacturing system in which a thermosetting resin is cured to bond an additional structure portion and a main body portion, and the mold is separated from the additional structure portion.
(20) A fiber-reinforced resin structure having a main body made of a fiber-reinforced resin containing a thermosetting resin and an additional structure made of a thermosetting resin provided on the surface of the main body. The main body has a plate-like body in which a plurality of types of fiber-reinforced resin pieces are combined, and a fiber-reinforced resin sheet containing a thermosetting resin provided on both sides of the plate-like body. Fiber reinforced resin structure.
(21) The plate-like body has a first type fiber reinforced resin piece having an opening and a second type fiber reinforced resin piece arranged in the opening, according to (20). Fiber reinforced plastic structure.
(22) The fiber-reinforced resin according to (21), wherein the first type of fiber-reinforced resin piece is CFRP, and the second type of fiber-reinforced resin piece is a fiber-reinforced resin made of a dielectric. Structure.
(23) A fiber-reinforced resin structure having a main body having a fiber-reinforced resin containing a thermosetting resin, and an additional structure made of a thermosetting resin provided on the surface of the main body. A fiber-reinforced resin structure having a main body having a plate-like body containing a foamed resin and a fiber-reinforced resin sheet containing a thermosetting resin provided on both sides of the plate-like body. ..
(24) The fiber-reinforced resin structure according to (23), wherein the plate-like body contains a thermoplastic resin.
(25) The fiber-reinforced resin structure according to (23) or (24), wherein the main body has a step.
(26) The fiber-reinforced resin structure according to any one of (23) to (25), wherein the thickness of the main body is 1 mm or less.
本発明によれば、繊維強化樹脂構造物における繊維強化樹脂を有する本体部と付加構造部との接着強度を向上し、従来のインサート成形のような熱収縮による変形や歪みの発生を低減できるので、繊維強化樹脂構造物の歩留まりや品質が向上し、繊維強化樹脂製品の価格を下げることができる。 According to the present invention, it is possible to improve the adhesive strength between the main body portion having the fiber reinforced plastic and the additional structure portion in the fiber reinforced resin structure and reduce the occurrence of deformation and strain due to heat shrinkage as in conventional insert molding. , The yield and quality of fiber reinforced plastic structures can be improved, and the price of fiber reinforced resin products can be reduced.
以下、図面を参照して、本発明の好ましい実施の形態について説明する。なお、同一の要素には同一の符号を付し、重複する説明を省略する。また、上下左右等の位置関係は、特に断らない限り、図面に示す位置関係に基づくものとする。さらに、図面の寸法比率は、図示の比率に限定されるものではない。また、以下の実施の形態は、本発明を説明するための例示であり、本発明はこの実施の形態に限定されるものではない。 Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. The same elements are designated by the same reference numerals, and duplicate description will be omitted. Further, unless otherwise specified, the positional relationship such as up, down, left, and right shall be based on the positional relationship shown in the drawings. Furthermore, the dimensional ratios in the drawings are not limited to the ratios shown. In addition, the following embodiments are examples for explaining the present invention, and the present invention is not limited to this embodiment.
本実施の形態にかかる繊維強化樹脂構造物は、熱硬化性樹脂を含有する繊維強化樹脂を有する本体部に、熱硬化性樹脂からなる付加構造部を付加した構造を有している。例えば図１に示すように繊維強化樹脂構造物１がモバイル機器の筐体である場合には、繊維強化樹脂構造物１は、トレイ状の本体部１０と、本体部１０の表面に形成されたリブやボスなどの突状物からなる付加構造部１１を有している。 The fiber-reinforced resin structure according to the present embodiment has a structure in which an additional structure portion made of a thermosetting resin is added to a main body portion having a fiber-reinforced resin containing a thermosetting resin. For example, as shown in FIG. 1, when the fiber reinforced resin structure 1 is a housing of a mobile device, the fiber reinforced resin structure 1 is formed on the tray-shaped main body 10 and the surface of the main body 10. It has an additional structure portion 11 made of a projecting object such as a rib or a boss.
なお、本明細書において「熱硬化性樹脂」には、樹脂単体のものだけでなく、フィラーなどの含有物を含むものも含まれる。フィラーには、例えばチョップドガラスフィラー、ミルドガラスフィラー、カーボンブラック、チョップドカーボンフィラー、ミルド カーボンフィラー、シリカフィラー、中空ガラスフィラー等の無機フィラーが用いられてもよい。 In the present specification, the "thermosetting resin" includes not only a resin alone but also a resin containing an inclusion such as a filler. As the filler, for example, an inorganic filler such as chopped glass filler, milled glass filler, carbon black, chopped carbon filler, milled carbon filler, silica filler, hollow glass filler and the like may be used.
以下、繊維強化樹脂構造物１の製造方法の一例について説明する。 Hereinafter, an example of a method for manufacturing the fiber reinforced resin structure 1 will be described.
（第１の実施の形態）
図２は、硬化して本体部１０となる前の半硬化本体部２０を形成するプロセスを示す。先ず２種類の繊維強化樹脂、例えば第１の種類としてのＣＦＲＰ（炭素繊維強化樹脂）と第２の種類としてのＧＦＲＰ（ガラス繊維強化樹脂）のプリプレグ３０、３１が用意される（図２の（ａ））。各プリプレグ３０、３１には、硬化していない（未硬化（Ａステージ）或いは半硬化（Ｂステージ））の例えばエポキシ系樹脂などの熱硬化性樹脂が含浸されている。(First Embodiment)
FIG. 2 shows the process of forming the semi-cured main body 20 before it is hardened to become the main body 10. First, two types of fiber reinforced plastics, for example, CFRP (carbon fiber reinforced plastic) as the first type and GFRP (glass fiber reinforced resin) prepregs 30 and 31 as the second type are prepared ((FIG. 2). a)). Each of the prepregs 30 and 31 is impregnated with a uncured (uncured (A stage) or semi-cured (B stage)) thermosetting resin such as an epoxy resin.
次に、各プリプレグ３０、３１が切断機によりそれぞれ所定の形に切断され、それぞれのプリプレグ片が形成される（図２の（ｂ））。例えばＣＦＲＰのプリプレグ片３０は、所望の位置に開口部３０ａを有する方形状に形成され、ＧＦＲＰのプリプレグ片３１は、開口部３０ａに合致する大きさに切断される。 Next, each of the prepregs 30 and 31 is cut into a predetermined shape by a cutting machine to form each prepreg piece (FIG. 2 (b)). For example, the CFRP prepreg piece 30 is formed in a square shape having an opening 30a at a desired position, and the GFRP prepreg piece 31 is cut into a size that matches the opening 30a.
続いて各プリプレグ片３０、３１が平面上で組み合わされて方形状の板状体４０が形成される（図２の（ｃ））。このとき、ＣＦＲＰのプリプレグ片３０の開口部３０ａにＧＦＲＰのプリプレグ片３１がはめ込まれて、板状体４０が形成される。 Subsequently, the prepreg pieces 30 and 31 are combined on a plane to form a rectangular plate-shaped body 40 ((c) in FIG. 2). At this time, the prepreg piece 31 of the GFRP is fitted into the opening 30a of the prepreg piece 30 of the CFRP to form the plate-shaped body 40.
次に板状体４０の両面に、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート、例えばマイクロガラスのプリプレグシート４１が貼り付けられる（図２の（ｄ））。プリプレグシート４１は、図３に示すように板状体４０と同じ大きさの方形状を有し、板状体４０の両面全面を覆うように貼り付けられる。プリプレグシート４１は、例えば0.005ｍｍ〜0.5ｍｍ程度の厚みを有している。板状体４０及びプリプレグシート４１の熱硬化性樹脂は、半硬化（Ｂステージ）の状態で維持、制御される。こうして、熱硬化性樹脂が半硬化の状態の３層（板状体４０及びプリプレグシート４１）からなる半硬化本体部２０が形成される。かかる半硬化本体部２０の製造は、例えばプリプレグ３０、３１を供給し、その供給されたプリプレグ３０、３１を切断し、切断されてできたプリプレグ片３０、３１を組み合わせて板状体４０を形成し、さらに板状体４０にプリプレグシート４１を張り合わせる本体部形成装置Ａを用いて行われる。 Next, a fiber-reinforced resin prepreg sheet containing a thermosetting resin, for example, a microglass prepreg sheet 41, is attached to both sides of the plate-shaped body 40 (FIG. 2 (d)). As shown in FIG. 3, the prepreg sheet 41 has a square shape having the same size as the plate-shaped body 40, and is attached so as to cover the entire surfaces of both sides of the plate-shaped body 40. The prepreg sheet 41 has a thickness of, for example, about 0.005 mm to 0.5 mm. The thermosetting resin of the plate-shaped body 40 and the prepreg sheet 41 is maintained and controlled in a semi-cured state (B stage). In this way, the semi-cured main body portion 20 composed of three layers (plate-shaped body 40 and prepreg sheet 41) in which the thermosetting resin is semi-cured is formed. In the production of the semi-cured main body 20, for example, prepregs 30 and 31 are supplied, the supplied prepregs 30 and 31 are cut, and the cut prepreg pieces 30 and 31 are combined to form a plate-shaped body 40. Further, the prepreg sheet 41 is attached to the plate-shaped body 40 by using the main body forming device A.
次に、硬化して付加構造部１１となる前の半硬化付加構造部５０を形成するプロセスについて説明する。図４に示すように付加構造部１１の形状に対応する溝６１を有する金型６０が形成される。そして、金型６０の溝６１に、半硬化本体部２０と同じ、硬化していない例えばエポキシ系樹脂などの熱硬化性樹脂が充填される。かかる充填は、例えば図５に示すように樹脂タンク７０とノズル７１を有する樹脂充填装置７２により行われる。金型６０の溝６１が横に広い場合には、ノズル７１から液状の熱硬化性樹脂Ｂを吐出しながらノズル７１を横に移動させて、溝６１に熱硬化性樹脂を充填する。また、図６に示すように金型６０の溝６１が深い場合には、ノズル７１を溝６１の中に入れ込み、液状の熱硬化性樹脂Ｂを吐出しながらノズル７１を上昇させて溝６１に熱硬化性樹脂Ｂを充填する。なお、溝６１の形状に応じて、かかるノズル７１の横方向の移動と上下動を組み合わせて樹脂を充填してもよい。充填された熱硬化性樹脂は、半硬化（Ｂステージ）の状態で維持、制御される。こうして、金型６０に、熱硬化性樹脂が半硬化の状態の半硬化付加構造部５０が形成される。 Next, the process of forming the semi-cured additional structure portion 50 before being cured to become the additional structure portion 11 will be described. As shown in FIG. 4, a mold 60 having a groove 61 corresponding to the shape of the additional structure portion 11 is formed. Then, the groove 61 of the mold 60 is filled with the same thermosetting resin as the semi-cured main body 20, such as an uncured epoxy resin. Such filling is performed by, for example, a resin filling device 72 having a resin tank 70 and a nozzle 71 as shown in FIG. When the groove 61 of the mold 60 is wide in the lateral direction, the nozzle 71 is moved laterally while discharging the liquid thermosetting resin B from the nozzle 71, and the groove 61 is filled with the thermosetting resin. Further, as shown in FIG. 6, when the groove 61 of the mold 60 is deep, the nozzle 71 is inserted into the groove 61, and the nozzle 71 is raised into the groove 61 while discharging the liquid thermosetting resin B. It is filled with thermosetting resin B. Depending on the shape of the groove 61, the resin may be filled by combining the lateral movement and the vertical movement of the nozzle 71. The filled thermosetting resin is maintained and controlled in a semi-cured state (B stage). In this way, the semi-cured additional structure portion 50 in which the thermosetting resin is semi-cured is formed on the mold 60.
次に、図７に示すように半硬化本体部２０と、金型６０の半硬化付加構造部５０が接合装置８０に設置される。接合装置８０は、例えば図７及び図８に示すように載置台９０と、その載置台９０に内蔵したヒータ９１と、載置台９０の周囲に配置されたサイドプレス機９２を有している。半硬化本体部２０は、図７に示すように載置台９０上に設置され保持される。半硬化付加構造部５０は、金型６０の溝６１を下に向けた状態で載置台９０の上方に設置される。次に図９に示すように金型６０が下降し、金型６０の半硬化付加構造部５０が、載置台９０上の半硬化本体部２０に押し付けられプレス成形により圧接される。この状態で例えば載置台９０に内蔵されたヒータ９１により半硬化本体部２０と半硬化構造部５０が例えば１５０℃程度に加熱され、それぞれの半硬化状態の熱硬化性樹脂が硬化（Ｃステージ状態に）する。こうして、半硬化本体部２０が硬化して本体部１０となり、半硬化付加構造部５０が硬化して付加構造部１１となり、このとき本体部１０と付加構造部１１が接着して一体化する。 Next, as shown in FIG. 7, the semi-cured main body portion 20 and the semi-cured additional structure portion 50 of the mold 60 are installed in the joining device 80. As shown in FIGS. 7 and 8, for example, the joining device 80 includes a mounting table 90, a heater 91 built in the mounting table 90, and a side press machine 92 arranged around the mounting table 90. The semi-cured main body 20 is installed and held on the mounting table 90 as shown in FIG. 7. The semi-cured additional structure portion 50 is installed above the mounting table 90 with the groove 61 of the mold 60 facing downward. Next, as shown in FIG. 9, the mold 60 is lowered, and the semi-cured additional structure portion 50 of the mold 60 is pressed against the semi-cured main body portion 20 on the mounting table 90 and pressed by press molding. In this state, for example, the semi-cured main body 20 and the semi-cured structure 50 are heated to about 150 ° C. by the heater 91 built in the mounting table 90, and the thermosetting resins in each semi-cured state are cured (C stage state). To). In this way, the semi-cured main body portion 20 is cured to become the main body portion 10, the semi-cured additional structure portion 50 is cured to become the additional structure portion 11, and at this time, the main body portion 10 and the additional structure portion 11 are adhered and integrated.
そして、この半硬化本体部２０と半硬化付加構造部５０の加熱接着時に図１０に示すようにサイドプレス機９２が内側に移動し、半硬化本体部２０の周囲がプレス成形される。 Then, when the semi-cured main body 20 and the semi-cured additional structure 50 are heat-bonded, the side press machine 92 moves inward as shown in FIG. 10, and the periphery of the semi-cured main body 20 is press-molded.
その後、図１１に示すよう金型６０が上昇し、一体化した付加構造部１１と本体部１０から離脱する。こうして、本体部１０と付加構造部１１を一体的に備えた繊維強化樹脂構造物１が成形される。すなわち、熱硬化性樹脂を含有する繊維強化樹脂からなる本体部１０と、本体部１０の表面に設けられた、熱硬化性樹脂からなる付加構造部１１と、を有し、本体部１０が、２種類の繊維強化樹脂片３０、３１を組み合わせた板状体４０と、板状体４０の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート４１とを有する繊維強化樹脂構造物１が製造される。その後、繊維強化樹脂構造物１は、バリを取り除く処理や塗装処理等が行われ、完成する。なお、本実施の形態では、本体部形成装置Ａ、樹脂充填装置７２及び接合装置８０により繊維強化樹脂構造物の製造システムが構成されている。 After that, as shown in FIG. 11, the mold 60 rises and separates from the integrated additional structure portion 11 and the main body portion 10. In this way, the fiber reinforced resin structure 1 integrally including the main body portion 10 and the additional structure portion 11 is formed. That is, it has a main body portion 10 made of a fiber reinforced resin containing a thermosetting resin, and an additional structure portion 11 made of a thermosetting resin provided on the surface of the main body portion 10. A fiber-reinforced resin having a plate-shaped body 40 in which two types of fiber-reinforced resin pieces 30 and 31 are combined, and a fiber-reinforced resin prepreg sheet 41 provided on both sides of the plate-shaped body 40 and containing a thermosetting resin. Structure 1 is manufactured. After that, the fiber-reinforced resin structure 1 is completed by performing a burr removal treatment, a painting treatment, and the like. In the present embodiment, the main body forming device A, the resin filling device 72, and the joining device 80 constitute a manufacturing system for the fiber reinforced resin structure.
本実施の形態によれば、半硬化の熱硬化性樹脂からなる半硬化付加構造部５０と、熱硬化性樹脂が半硬化の状態の半硬化本体部２０と圧接し硬化して、付加構造部５０と本体部１０を接着できるので、同種材料の接着が可能になり、本体部１０と付加構造部１１の接着強度を向上できる。また、本体部１０と付加構造部１１が類似組成であることから、インサート成形を用いず、低温、低圧下で本体部１０と付加構造部１１を接着できるので、従来のインサート成形のような熱収縮による変形や歪みの発生を低減できる。この結果、繊維強化樹脂構造物１の製品の歩留まりや品質が向上し、繊維強化樹脂構造物１の製品価格を下げることができる。 According to the present embodiment, the semi-cured additional structure portion 50 made of a semi-cured thermosetting resin and the semi-cured main body portion 20 in which the thermosetting resin is in a semi-cured state are pressed and cured to form the additional structure portion. Since the 50 and the main body 10 can be bonded, the same kind of material can be bonded, and the bonding strength between the main body 10 and the additional structure 11 can be improved. Further, since the main body portion 10 and the additional structure portion 11 have similar compositions, the main body portion 10 and the additional structure portion 11 can be adhered to each other at low temperature and low pressure without using insert molding, so that heat as in the conventional insert molding can be obtained. It is possible to reduce the occurrence of deformation and distortion due to shrinkage. As a result, the yield and quality of the product of the fiber reinforced resin structure 1 can be improved, and the product price of the fiber reinforced resin structure 1 can be lowered.
金型６０の溝６１に液状の熱硬化性樹脂を充填する工程において、ノズル７１から金型６０の溝６１に熱硬化性樹脂を吐出するようにしたので、熱硬化性樹脂の充填を簡単かつ適正に行うことができる。 In the step of filling the groove 61 of the mold 60 with the liquid thermosetting resin, the thermosetting resin is discharged from the nozzle 71 into the groove 61 of the mold 60, so that the filling of the thermosetting resin is easy. It can be done properly.
半硬化本体部２０を形成する工程では、２種類の繊維強化樹脂のプリプレグ片３０、３１を組み合わせて板状体４０を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート４１で挟むようにした。これにより、繊維強化樹脂構造物１において部分的に種類の異なる繊維強化樹脂を用いることができ、繊維強化樹脂構造物１の用途を広げることができる。例えば図１に示したように本体部１０を主に強度の高いＣＦＲＰ片３０で構成し、本体部１０の一部に電波を通しやすい誘電体からなるＧＦＲＰ片３１を用いることにより、通信機能の付いたモバイル機器の筐体として用いることができる。この場合、軽量で薄型のモバイル機器の筐体を低価格で実現できる。なお、誘電体からなる繊維強化樹脂としては、ＧＦＲＰに限られず、ポリエステルなどのその他の有機繊維、無機繊維等を用いてもよい。 In the step of forming the semi-cured main body portion 20, two types of fiber-reinforced resin prepreg pieces 30 and 31 are combined to form a plate-shaped body 40, and both sides thereof are made of fiber-reinforced resin prepreg containing a thermosetting resin. It was sandwiched between sheets 41. As a result, different types of fiber-reinforced resins can be used in the fiber-reinforced resin structure 1, and the applications of the fiber-reinforced resin structure 1 can be expanded. For example, as shown in FIG. 1, the main body 10 is mainly composed of a high-strength CFRP piece 30, and a GFRP piece 31 made of a dielectric that easily transmits radio waves is used as a part of the main body 10 to provide a communication function. It can be used as a housing for attached mobile devices. In this case, a lightweight and thin mobile device housing can be realized at a low price. The fiber reinforced resin made of a dielectric is not limited to GFRP, and other organic fibers such as polyester, inorganic fibers and the like may be used.
また、半硬化本体部２０を形成する工程において、第１の種類の繊維強化樹脂（ＣＦＲＰ）のプリプレグ片３０の開口部３１ａに、第２の種類の繊維強化樹脂（ＧＦＲＰ）のプリプレグ片３１を入れ込むことで板状体４０を形成した。これにより、複数種類の繊維強化樹脂からなる本体部１０を簡単に製造できる。 Further, in the step of forming the semi-cured main body portion 20, the prepreg piece 31 of the second type fiber reinforced resin (GFRP) is inserted into the opening 31a of the prepreg piece 30 of the first type fiber reinforced resin (CFRP). The plate-like body 40 was formed by inserting it. As a result, the main body 10 made of a plurality of types of fiber reinforced resins can be easily manufactured.
付加構造部１１と本体部１０を接着する工程において、半硬化本体部２０を所望の形状にプレス成形しているので、別途半硬化本体部２０の全体形状を成形する工程を行う必要がなく、繊維強化樹脂構造物１の製造時間を短縮できる。 In the step of adhering the additional structure portion 11 and the main body portion 10, since the semi-cured main body portion 20 is press-molded into a desired shape, there is no need to separately perform a step of molding the entire shape of the semi-cured main body portion 20. The production time of the fiber reinforced resin structure 1 can be shortened.
（第２の実施の形態）
第１の実施の形態で記載した半硬化本体部２０を形成する工程では、２種類の繊維強化樹脂のプリプレグ片３０、３１を組み合わせて板状体４０を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート４１で挟むようにしていたが、図１２に示すように発泡樹脂を含有する板状体１００を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート４１で挟むようにしてもよい。すなわち、半硬化本体部２０が硬化されてできる本体部１０は、発泡樹脂を含有する板状体１００と、板状体１００の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシート４１とを有するものであってもよい。ここで発泡樹脂とは、樹脂内に多数の発泡体が混在するものをいう。発泡体には、例えば加熱により発泡するアクリルなどの球状体が用いられ、発泡体を含有する樹脂には、例えばエポキシ樹脂などの熱硬化性樹脂が用いられる。(Second Embodiment)
In the step of forming the semi-cured main body portion 20 described in the first embodiment, the prepreg pieces 30 and 31 of two types of fiber reinforced resins are combined to form a plate-shaped body 40, and both surfaces thereof are thermosetting. Although it was sandwiched between prepreg sheets 41 of fiber-reinforced resin containing resin, as shown in FIG. 12, a plate-like body 100 containing foamed resin was formed, and both sides thereof were fiber-reinforced resin containing thermosetting resin. It may be sandwiched between the prepreg sheets 41 of. That is, the main body 10 formed by curing the semi-cured main body 20 is made of a plate-shaped body 100 containing a foamed resin and a fiber-reinforced resin containing a thermosetting resin provided on both sides of the plate-shaped body 100. It may have a sheet 41 and the like. Here, the foamed resin refers to a resin in which a large number of foams are mixed. As the foam, for example, a spherical body such as acrylic that foams by heating is used, and as the resin containing the foam, a thermosetting resin such as an epoxy resin is used.
半硬化本体部２０を形成するプロセスでは、例えば図１３に示すように加熱により発泡樹脂が発泡して板状体１００が形成され、その後板状体１００の両面にプリプレグシート４１が接着される。 In the process of forming the semi-cured main body portion 20, for example, as shown in FIG. 13, the foamed resin is foamed by heating to form the plate-shaped body 100, and then the prepreg sheet 41 is adhered to both sides of the plate-shaped body 100.
別の半硬化本体部２０を形成するプロセスでは、図１４に示すように未発泡の発泡樹脂シート１０１が２枚のプリプレグシート４１で挟まれ、その後加熱により発泡樹脂が発泡し樹脂が硬化して板状体１００が形成される。この場合、発泡樹脂の発泡の際にプリプレグシート４１と板状体１００が接着される。 In the process of forming another semi-cured main body 20, the unfoamed foamed resin sheet 101 is sandwiched between two prepreg sheets 41 as shown in FIG. 14, and then the foamed resin is foamed by heating and the resin is cured. The plate-shaped body 100 is formed. In this case, the prepreg sheet 41 and the plate-shaped body 100 are adhered to each other when the foamed resin is foamed.
発泡樹脂を含有する板状体１００は、発泡体が圧縮変形するため加工性に優れている。そこで、例えば板状体１００及びプリプレグシート４１からなる三層構造の半硬化本体部２０（本体部１０）の厚みを調整してもよい。このとき半硬化本体部２０の厚みを１ｍｍ以下に調整してもよい。かかる厚みの調整は、例えば上述の図９で示した半硬化本体部２０と半硬化付加構造部５０とを接合する際に、金型６０の半硬化付加構造部５０と載置台９０の半硬化本体部２０との間の圧縮力を調整することにより行うことができる。また、かかる厚みの調整は、図１５に示すように未発泡の発泡樹脂シート１０１をプリプレグシート４１で挟み、当該発泡樹脂シート１０１及びプリプレグシート４１を所望の間隔（最終的な半硬化本体部２０の厚みに合わせた間隔）の狭持体１１０の間に配置し、その状態で加熱により発泡樹脂を発泡させることにより行うこともできる。このとき発泡樹脂の発泡（膨張）が狭持体１１０により規制され、半硬化本体部２０の厚みが２つの狭持体１１０の間隔と等しくなる。さらに、発泡後の板状体１００を所定の厚みにプレス加工し、その後プリプレグシート４１で挟むことにより行うこともできる。かかる例によれば、１ｍｍ以下の極めて薄くて軽い半硬化本体部２０（本体部１０）を形成できるので、軽くて強度のある繊維強化樹脂構造物１を実現できる。 The plate-shaped body 100 containing the foamed resin is excellent in workability because the foamed material is compressionally deformed. Therefore, for example, the thickness of the semi-cured main body portion 20 (main body portion 10) having a three-layer structure composed of the plate-shaped body 100 and the prepreg sheet 41 may be adjusted. At this time, the thickness of the semi-cured main body 20 may be adjusted to 1 mm or less. Such thickness adjustment is performed, for example, when the semi-cured main body portion 20 and the semi-cured additional structure portion 50 shown in FIG. 9 are joined, the semi-cured additional structure portion 50 of the mold 60 and the mounting table 90 are semi-cured. This can be done by adjusting the compressive force with the main body 20. Further, in the adjustment of the thickness, as shown in FIG. 15, the unfoamed foamed resin sheet 101 is sandwiched between the prepreg sheets 41, and the foamed resin sheet 101 and the prepreg sheet 41 are placed at a desired interval (final semi-cured main body portion 20). It can also be carried out by arranging it between the narrow holding bodies 110 (intervals according to the thickness of the above) and foaming the foamed resin by heating in that state. At this time, the foaming (expansion) of the foamed resin is regulated by the narrow holding body 110, and the thickness of the semi-cured main body 20 becomes equal to the distance between the two narrow holding bodies 110. Further, the foamed plate-shaped body 100 can be press-processed to a predetermined thickness and then sandwiched between the prepreg sheets 41. According to such an example, since an extremely thin and light semi-cured main body portion 20 (main body portion 10) of 1 mm or less can be formed, a light and strong fiber-reinforced resin structure 1 can be realized.
また、板状体１００が加工性に優れていることを利用して、半硬化本体部２０（本体部１０）に段差を形成してもよい。かかる段差１３０の形成は、例えば図１６に示すように発泡時に板状体１００に所望の形状、例えば凹状の段差１２０を形成し、その板状体１００とプリプレグシート４１を併せてプレス加工することにより行うことができる。また、かかる段差１３０の形成は、図１７に示すように発泡後の平板状の板状体１００とプリプレグシート４１を併せて凸部のあるプレス機によりプレス加工することにより行うこともできる。さらに、図１８に示すように未発泡の発泡樹脂シート１０１をプリプレグシート４１で挟み、当該発泡樹脂シート１０１及びプリプレグシート４１を所望の間隔（最終的な半硬化本体部２０の厚みに合わせた間隔）の凸部のある狭持体１１０の間に配置し、その状態で加熱により発泡樹脂を発泡させることにより行うこともできる。さらに、図１９に示すように１枚のプリプレグシート４１に予め凹状の段差１４０を形成しておき、その段差１４０のあるプリプレグシート４１と平板状の他のプリプレグシート４１と板状体１００を所望の間隔（最終的な半硬化本体部２０の厚みに合わせた間隔）の狭持体１１０の間に配置し、その状態で加熱により発泡樹脂を発泡させることにより行うこともできる。かかる例によれば、１ｍｍ以下の薄い半硬化本体部２０であっても、例えば電池の収容部等に利用可能な所望の段差を有する半硬化本体部２０を形成できる。また、１ｍｍ以下の薄い半硬化本体部２０であっても、厚み変化率が５０％以上の段差を形成できる。よって、軽くて強度がありなおかつ多様な形状の繊維強化樹脂構造物１を実現できる。 Further, by utilizing the fact that the plate-shaped body 100 is excellent in workability, a step may be formed in the semi-cured main body portion 20 (main body portion 10). To form such a step 130, for example, as shown in FIG. 16, a desired shape, for example, a concave step 120 is formed on the plate-shaped body 100 at the time of foaming, and the plate-shaped body 100 and the prepreg sheet 41 are pressed together. Can be done by. Further, as shown in FIG. 17, the step 130 can be formed by pressing the foamed flat plate-shaped body 100 and the prepreg sheet 41 together with a press machine having a convex portion. Further, as shown in FIG. 18, the unfoamed foamed resin sheet 101 is sandwiched between the prepreg sheets 41, and the foamed resin sheet 101 and the prepreg sheet 41 are spaced apart from each other at a desired interval (interval according to the thickness of the final semi-cured main body 20). ) Can be placed between the narrow holding bodies 110 having a convex portion, and the foamed resin can be foamed by heating in that state. Further, as shown in FIG. 19, a concave step 140 is formed in advance on one prepreg sheet 41, and a prepreg sheet 41 having the step 140, another flat plate-shaped prepreg sheet 41, and a plate-like body 100 are desired. (The interval according to the thickness of the final semi-cured main body 20) is arranged between the narrow holding bodies 110, and the foamed resin is foamed by heating in that state. According to such an example, even a thin semi-cured main body 20 of 1 mm or less can form a semi-cured main body 20 having a desired step that can be used, for example, in a battery accommodating portion. Further, even with a thin semi-cured main body portion 20 of 1 mm or less, a step with a thickness change rate of 50% or more can be formed. Therefore, it is possible to realize the fiber reinforced resin structure 1 which is light and strong and has various shapes.
なお、上記例で調整される半硬化本体部２０の厚みや、半硬化本体部２０の段差の形状は、上記例に限定されるものではない。また、第２の実施の形態において特に言及していない繊維強化樹脂構造物１の構造や製造工程は、例えば第１の実施の形態と同様である。 The thickness of the semi-cured main body 20 and the shape of the step of the semi-cured main body 20 adjusted in the above example are not limited to the above example. Further, the structure and manufacturing process of the fiber reinforced resin structure 1 not particularly mentioned in the second embodiment are the same as those in the first embodiment, for example.
（第３の実施の形態）
上記第２の実施の形態では、半硬化付加構造部と半硬化本体部を加熱し硬化させることにより接着していたが、半硬化付加構造部を予め硬化させておき、その硬化した付加構造部と半硬化本体部を加熱し半硬化本体部を硬化させることにより接着させてもよい。かかる場合、例えば図２０に示すように付加構造部１１の形状に対応して形成された金型６０の溝６１に熱硬化性樹脂が充填され、加熱により熱硬化性樹脂が硬化されて付加構造部１１が形成される。また、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部２０が形成される。この半硬化本体部２０は、例えば第２の実施の形態のように発泡樹脂を含有する板状体１００を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート４１で挟むことにより形成される。なお、半硬化本体部２０は、第１の実施の形態のように複数種類の繊維強化樹脂のプリプレグ片を組み合わせて板状体４０を形成し、その両面を、熱硬化性樹脂を含有する繊維強化樹脂のプリプレグシート４１で挟むことにより形成することもできる。その後半硬化本体部２０は、例えば接合装置８０の載置台９０に載置される。(Third Embodiment)
In the second embodiment, the semi-cured additional structure portion and the semi-cured main body portion are bonded by heating and curing, but the semi-cured additional structure portion is previously cured and the cured additional structure portion is bonded. And the semi-cured main body may be heated and the semi-cured main body may be cured to adhere them. In such a case, for example, as shown in FIG. 20, the groove 61 of the mold 60 formed corresponding to the shape of the additional structure portion 11 is filled with the thermosetting resin, and the thermosetting resin is cured by heating to form the additional structure. The part 11 is formed. Further, a semi-cured main body 20 is formed in which the thermosetting resin of the fiber reinforced resin is semi-cured. The semi-cured main body 20 forms a plate-like body 100 containing a foamed resin as in the second embodiment, and both sides thereof are made of a fiber-reinforced resin prepreg sheet 41 containing a thermosetting resin. It is formed by sandwiching. The semi-cured main body 20 forms a plate-like body 40 by combining a plurality of types of fiber-reinforced resin prepreg pieces as in the first embodiment, and fibers containing a thermosetting resin on both sides thereof. It can also be formed by sandwiching it between prepreg sheets 41 of reinforced resin. After that, the semi-cured main body 20 is placed on the mounting table 90 of the joining device 80, for example.
次に、金型６０の溝６１の付加構造部１１と半硬化本体部２０とが圧接され加熱され、半硬化本体部２０のプリプレグシート４１の熱硬化性樹脂が硬化して、付加構造部１１と本体部１０が接着される。このとき、金型６０と載置台９０との距離を調整して本体部１０の厚みを調整してもよい。その後、金型６０が付加構造部１１から外され、繊維強化樹脂構造物１ができる。 Next, the additional structure portion 11 of the groove 61 of the mold 60 and the semi-cured main body portion 20 are pressure-welded and heated, and the thermosetting resin of the prepreg sheet 41 of the semi-cured main body portion 20 is cured to cure the additional structure portion 11. And the main body 10 are adhered. At this time, the thickness of the main body 10 may be adjusted by adjusting the distance between the mold 60 and the mounting table 90. After that, the mold 60 is removed from the additional structure portion 11, and the fiber reinforced resin structure 1 is formed.
上記例において、図２１に示すように未発泡の発泡樹脂シート１０１と、その両面の２枚のプリプレグシート４１からなる三層構造を、載置台９０に載置しておき、その三層構造を加熱し発泡樹脂を発泡させることで、三層構造からなる本体部１０と付加構造部１１を接着するようにしてもよい。この場合、例えば金型６０と載置台９０の間隔は、所望の間隔（最終的な本体部１０の厚みに合わせた間隔）に調整され、その状態で加熱により発泡樹脂を発泡させる。こうすることにより、発泡樹脂シート１０１が発泡して膨張し、上側のプリプレグシート４１が付加構造部１１に接触し、さらにプリプレグシート４１の熱硬化性樹脂が硬化して、本体部１０と付加構造部１１が接着する。 In the above example, as shown in FIG. 21, a three-layer structure composed of an unfoamed foamed resin sheet 101 and two prepreg sheets 41 on both sides thereof is placed on a mounting table 90, and the three-layer structure is formed. By heating and foaming the foamed resin, the main body portion 10 having a three-layer structure and the additional structure portion 11 may be adhered to each other. In this case, for example, the distance between the mold 60 and the mounting table 90 is adjusted to a desired distance (a distance matching the final thickness of the main body 10), and the foamed resin is foamed by heating in that state. By doing so, the foamed resin sheet 101 foams and expands, the upper prepreg sheet 41 comes into contact with the additional structure portion 11, and the thermosetting resin of the prepreg sheet 41 is further cured to form the main body 10 and the additional structure. The part 11 adheres.
（第４の実施の形態）
第３の実施の形態では、三層構造の本体部１０が一体的に形成されていたが、本体部１０の三層構造を分離し、付加構造部１１と第１のプリプレグシート４１ａを予め接着してもよい。かかる場合、例えば図２２に示すように付加構造部１１の形状に対応して形成された金型６０の溝６１に熱硬化性樹脂が充填され、加熱により熱硬化性樹脂が硬化されて付加構造部１１が形成される。次に、熱硬化性樹脂を含有する繊維強化樹脂の第１のプリプレグシート４１ａを付加構造部１１に接触させ、その状態で加熱し、第１のプリプレグシート４１ａの熱硬化性樹脂が硬化されて、第１のプリプレグシート４１ａが付加構造部１１に接着する。一方で、熱硬化性樹脂を含有する繊維強化樹脂の第２のプリプレグシート４１ｂと、未発泡の発泡樹脂を含有する発泡樹脂シート１０１が重ねられて接着された状態（二層構造）で載置台９０に載置される。次に加熱により発泡樹脂シート１０１の発泡樹脂が発泡されて板状体１００が形成される。このとき、例えば金型６０と載置台９０の間隔が所望の間隔（最終的な本体部１０の厚みに合わせた間隔）に調整されており、板状体１００が膨張し上方の第１のプリプレグシート４１ａに接着される。こうして、板状体１００とその両面に接着された第１のプリプレグシート４１ａ及び第２のプリプレグシート４１ｂからなる本体部１０と付加構造部１１とが接着した状態になる。最後に金型６０が付加構造部１１から外され、繊維強化樹脂構造物１ができる。(Fourth Embodiment)
In the third embodiment, the main body portion 10 having a three-layer structure was integrally formed, but the three-layer structure of the main body portion 10 is separated, and the additional structure portion 11 and the first prepreg sheet 41a are bonded in advance. You may. In such a case, for example, as shown in FIG. 22, the groove 61 of the mold 60 formed corresponding to the shape of the additional structure portion 11 is filled with the thermosetting resin, and the thermosetting resin is cured by heating to form the additional structure. The part 11 is formed. Next, the first prepreg sheet 41a of the fiber-reinforced resin containing the thermosetting resin is brought into contact with the additional structure portion 11 and heated in that state to cure the thermosetting resin of the first prepreg sheet 41a. , The first prepreg sheet 41a adheres to the additional structure portion 11. On the other hand, a mounting table in a state (two-layer structure) in which a second prepreg sheet 41b of a fiber-reinforced resin containing a thermosetting resin and a foamed resin sheet 101 containing an unfoamed foamed resin are laminated and adhered to each other. Placed on 90. Next, the foamed resin of the foamed resin sheet 101 is foamed by heating to form the plate-shaped body 100. At this time, for example, the distance between the mold 60 and the mounting table 90 is adjusted to a desired distance (distance according to the thickness of the final main body 10), and the plate-shaped body 100 expands and the upper first prepreg It is adhered to the sheet 41a. In this way, the main body portion 10 composed of the plate-shaped body 100 and the first prepreg sheet 41a and the second prepreg sheet 41b bonded to both sides thereof and the additional structure portion 11 are adhered to each other. Finally, the mold 60 is removed from the additional structure portion 11, and the fiber reinforced resin structure 1 is formed.
以上、添付図面を参照しながら本発明の好適な実施の形態について説明したが、本発明はかかる例に限定されない。当業者であれば、特許請求の範囲に記載された思想の範疇内において、各種の変更例または修正例に想到し得ることは明らかであり、それらについても当然に本発明の技術的範囲に属するものと了解される。 Although preferred embodiments of the present invention have been described above with reference to the accompanying drawings, the present invention is not limited to such examples. It is clear that a person skilled in the art can come up with various modifications or modifications within the scope of the ideas described in the claims, and these also naturally belong to the technical scope of the present invention. It is understood as a thing.
例えば上記実施の形態において、本体部１０が２種類の繊維強化樹脂から構成されていたが、２種類に限られず、１種類或いは３種類以上の繊維強化樹脂から構成されている場合にも本発明は適用できる。また、繊維強化樹脂の種類も、ＣＦＲＰ、ＧＦＲＰに限られず、クオーツ、ポリエステル、ボロン、アラミド、ケブラー、ポリエチレン、ザイロン、ポリイミドなどの有機、無機繊維を用いた他の繊維強化樹脂を使用してもよい。 For example, in the above embodiment, the main body 10 is composed of two types of fiber reinforced resins, but the present invention is not limited to two types, and the present invention may also be composed of one type or three or more types of fiber reinforced resins. Is applicable. The type of fiber reinforced resin is not limited to CFRP and GFRP, and other fiber reinforced resins using organic and inorganic fibers such as quartz, polyester, boron, aramid, Kevlar, polyethylene, zylon, and polyimide may be used. Good.
上記実施の形態では、付加構造部１１と本体部１０を接着する工程において、半硬化本体部２０を所望の形状にプレス成形していたが、このプレス成形は、付加構造部１１と本体部１０を接着させる工程の前或いは後に行ってもよい。 In the above embodiment, in the step of adhering the additional structure portion 11 and the main body portion 10, the semi-cured main body portion 20 is press-molded into a desired shape, but in this press molding, the additional structure portion 11 and the main body portion 10 are pressed. May be performed before or after the step of adhering.
上述の半硬化本体部２０を形成する工程では、２種類の繊維強化樹脂のプリプレグ片３０、３１を組み合わせて板状体４０を形成し、その両面をプリプレグシート４１で挟むようにしていたが、他の方法で、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部２０を形成するようにしてもよい。また、半硬化が必要ない場合は、半硬化を行わなくてもよい。 In the step of forming the semi-cured main body portion 20 described above, the plate-shaped body 40 was formed by combining the prepreg pieces 30 and 31 of the two types of fiber reinforced resins, and both sides thereof were sandwiched between the prepreg sheets 41. By the method, the thermosetting resin of the fiber reinforced resin may form the semi-cured main body 20 in a semi-cured state. If semi-curing is not required, semi-curing may not be performed.
また、本体部１０の繊維強化樹脂に含有される熱硬化性樹脂と、付加構造部１１の熱硬化性樹脂には、同じ樹脂を用いていたが、熱硬化性樹脂であれば異なる樹脂を用いてもよい。また、本体部１０と付加構造部１１の熱硬化性樹脂の種類は、特に限定されることなく、フェノール樹脂、尿素樹脂、メラミン樹脂、不飽和ホ■リエステル樹脂、ケイ素樹脂、ホ■リウレタン樹脂、ヒ■スマレイミト■樹脂等の樹脂を用いてもよい。 Further, the same resin was used for the thermosetting resin contained in the fiber reinforced resin of the main body 10 and the thermosetting resin of the additional structure portion 11, but different resins were used if they were thermosetting resins. You may. The types of the thermosetting resin of the main body 10 and the additional structure 11 are not particularly limited, and are phenol resin, urea resin, melamine resin, unsaturated e-reester resin, silicon resin, e-reurethane resin, etc. A resin such as a resin may be used.
上記実施の形態において、金型６０の溝６１に液状の熱硬化性樹脂を充填する工程は、ノズル７１から金型６０の溝６１に熱硬化性樹脂を吐出することにより行っていたが、他の方法を用いて行ってもよい。例えば真空注型、レジンインジェクション、ＲＴＭ、ＶａＲＴＭ等の方法を用いてもよい。 In the above embodiment, the step of filling the groove 61 of the mold 60 with the liquid thermosetting resin is performed by discharging the thermosetting resin from the nozzle 71 into the groove 61 of the mold 60. It may be carried out by using the method of. For example, a method such as vacuum casting, resin injection, RTM, VaRTM or the like may be used.
上記実施の形態では、付加構造部１１と本体部１０を接着する工程は、金型６０の半硬化付加構造部５０を半硬化本体部２０に押し付けて圧接するプレス成形を用いて行われていたが、プレス成形以外の方法で接着を行う場合も本発明に含まれる。例えば一般的な、金型６０の半硬化付加構造部５０と半硬化本体部２０を真空バック内で真空引きして圧接するオートクレーブ成形、真空バック成形を用いる場合も本発明に含まれる。 In the above embodiment, the step of adhering the additional structure portion 11 and the main body portion 10 is performed by using press molding in which the semi-cured additional structure portion 50 of the mold 60 is pressed against the semi-cured main body portion 20 and pressure-welded. However, the present invention also includes a case where bonding is performed by a method other than press molding. For example, the present invention also includes a general case of using autoclave molding or vacuum back molding in which the semi-cured additional structure portion 50 and the semi-cured main body portion 20 of the mold 60 are evacuated and pressure-welded in a vacuum back.
さらに、本発明における、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部２０を形成する工程と、金型６０の溝６１の半硬化付加構造部５０と半硬化本体部２０とを圧接して加熱し、半硬化付加構造部５０及び半硬化本体部２０の熱硬化性樹脂を硬化して、付加構造部１１と本体部１０を接着する工程には、これらの工程を同時に行うＲＴＭ成形、ＶａＲＴＭ成形等を用いる場合も含まれる。すなわち、ＲＴＭ成形においては、金型６０の半硬化付加構造部５０に、強化繊維（樹脂なし）を重ねその強化繊維に熱硬化性樹脂を圧力をかけて流し込むことで、半硬化の状態の半硬化本体部２０を形成しつつ、それと同時に金型６０の半硬化付加構造部５０と半硬化本体部２０を互いに圧接して、付加構造部１１と本体部１０を接着する。また、ＶａＲＴＭ成形においては、金型６０の半硬化付加構造部５０に、強化繊維（樹脂なし）を重ねその強化繊維に熱硬化性樹脂を真空引きして流し込んで、半硬化の状態の半硬化本体部２０を形成しつつ、それと同時に金型６０の半硬化付加構造部５０と半硬化本体部２０を互いに圧接して、付加構造部１１と本体部１０を接着する。 Further, in the present invention, the step of forming the semi-cured main body 20 in which the thermosetting resin of the fiber reinforced resin is semi-cured, and the semi-cured additional structure 50 and the semi-cured main body 20 of the groove 61 of the mold 60. In the step of pressing and heating the thermosetting resin of the semi-cured additional structure portion 50 and the semi-cured main body portion 20 to bond the additional structure portion 11 and the main body portion 10, these steps are simultaneously performed. It also includes the case of using RTM molding, VaRTM molding, etc. to be performed. That is, in RTM molding, reinforcing fibers (without resin) are superposed on the semi-cured additional structure portion 50 of the mold 60, and a thermosetting resin is poured into the reinforcing fibers by applying pressure to the semi-cured state. While forming the cured main body portion 20, at the same time, the semi-cured additional structure portion 50 and the semi-cured main body portion 20 of the mold 60 are pressed against each other to bond the additional structure portion 11 and the main body portion 10. Further, in VaRTM molding, reinforcing fibers (without resin) are superposed on the semi-cured additional structure portion 50 of the mold 60, and a thermosetting resin is vacuum-drawn and poured into the reinforcing fibers to semi-cure the semi-cured state. While forming the main body portion 20, at the same time, the semi-cured additional structure portion 50 and the semi-cured main body portion 20 of the mold 60 are pressed against each other to bond the additional structure portion 11 and the main body portion 10.
また、上記ＲＴＭ成形及びＶａＲＴＭ成形を用いる例において、複数種類の繊維強化樹脂、例えばＣＦＲＰとＧＦＲＰの２種類の繊維強化樹脂からなる半硬化本体部２０を形成する場合には、例えばＣＦＲＰとＧＦＲＰのドライクロス（樹脂未含浸の強化繊維）をそれぞれ任意の形状に切断し、それらのドライクロス片を同一平面上で互いに組み合わせて平面状にし、その両面を別の平面状のドライクロスで挟み込む。そして、３層になったドライクロス上に金型６０の半硬化付加構造部５０を設置し、加圧或いは真空吸引しながらドライクロスに熱硬化性樹脂を流し込む。 Further, in the example using the above RTM molding and VaRTM molding, when the semi-cured main body portion 20 made of a plurality of types of fiber reinforced resins, for example, two types of fiber reinforced resins, CFRP and GFRP, is formed, for example, CFRP and GFRP Dry cloths (reinforced fibers not impregnated with resin) are cut into arbitrary shapes, and these dry cloth pieces are combined with each other on the same plane to form a flat surface, and both sides thereof are sandwiched between different flat dry cloths. Then, the semi-curable additional structure portion 50 of the mold 60 is installed on the three-layered dry cloth, and the thermosetting resin is poured into the dry cloth while applying pressure or vacuum suction.
上記実施の形態では、繊維強化樹脂構造物１として、コンピュータや携帯電話等の電子機器の筐体に用いる例を示したが、本発明は、車や日用品、家電製品、産業機器などのあらゆる繊維強化樹脂構造物に適用できる。本体部１０はトレイ状のものに限られず、付加構造部１１は、リブやボスの突起状物に限られない。 In the above embodiment, an example of using the fiber reinforced resin structure 1 as a housing of an electronic device such as a computer or a mobile phone has been shown, but the present invention shows all fibers such as cars, daily necessities, home appliances, and industrial devices. Applicable to reinforced resin structures. The main body portion 10 is not limited to the tray shape, and the additional structure portion 11 is not limited to the rib or boss protrusion.
繊維強化樹脂構造物の製造システムも上記実施の形態の構成に限定されるものではない。 The manufacturing system for the fiber-reinforced resin structure is not limited to the configuration of the above embodiment.
参考までに、発泡樹脂を含有する熱硬化性樹脂を有する板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有する、三層構造の繊維強化樹脂構造物を提案できる。かかる技術によれば、極めて薄くて軽い強度のある繊維強化樹脂構造物が実現できる。繊維強化樹脂構造物は、段差を有していてもよい。また、繊維強化樹脂構造物は、厚みが１ｍｍ以下であってもよい。 For reference, a three-layer structure having a plate-shaped body having a thermosetting resin containing a foamed resin and a fiber-reinforced resin sheet containing a thermosetting resin provided on both sides of the plate-shaped body. We can propose a fiber reinforced resin structure. According to such a technique, a fiber reinforced resin structure having extremely thin and light strength can be realized. The fiber reinforced resin structure may have a step. Further, the fiber reinforced resin structure may have a thickness of 1 mm or less.
本発明は、繊維強化樹脂構造物における繊維強化樹脂を有する本体部と、その本体部に付加する付加構造部との接着強度を向上し、なおかつ従来のインサート成形のような熱収縮による変形や歪みの発生を低減する際に有用である。 The present invention improves the adhesive strength between the main body of the fiber reinforced resin structure having the fiber reinforced resin and the additional structure added to the main body, and is deformed or distorted due to heat shrinkage as in conventional insert molding. It is useful in reducing the occurrence of.
１ 繊維強化樹脂構造物
１０ 本体部
１１ 付加構造部
２０ 半硬化本体部
３０、３１ プリプレグ片
４０ 板状体
４１ プリプレグシート
５０ 半硬化付加構造部
６０ 金型
６１ 溝
７１ ノズル
Ｂ 熱硬化性樹脂
1 Fiber reinforced resin structure 10 Main body part 11 Additional structure part 20 Semi-curing main body part 30, 31 Prepreg piece 40 Plate-shaped body 41 Prepreg sheet 50 Semi-curing additional structure part 60 Mold 61 Groove 71 Nozzle B Thermosetting resin
Claims (26)
付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し、当該熱硬化性樹脂が半硬化の状態の半硬化付加構造部を形成する工程と、
繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成する工程と、
前記金型の溝の前記半硬化付加構造部と前記半硬化本体部とを圧接して加熱し、前記半硬化付加構造部及び前記半硬化本体部の熱硬化性樹脂を硬化して、付加構造部と本体部を接着する工程と、
前記金型を前記付加構造部から離脱させる工程と、を有する、繊維強化樹脂構造物の製造方法。 A method for manufacturing a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion.
A step of filling a groove of a mold formed corresponding to the shape of the additional structure portion with a thermosetting resin to form a semi-curable additional structure portion in a semi-cured state of the thermosetting resin.
The process of forming a semi-cured main body of the thermosetting resin of fiber reinforced resin in a semi-cured state,
The semi-cured additional structure portion of the groove of the mold and the semi-cured main body portion are pressed against each other and heated to cure the thermosetting resin of the semi-cured additional structure portion and the semi-cured main body portion to cure the additional structure. The process of adhering the part and the main body,
A method for producing a fiber-reinforced resin structure, comprising a step of separating the mold from the additional structure portion.
前記第２の種類の繊維強化樹脂は、誘電体からなる繊維強化樹脂である、請求項４に記載の繊維強化樹脂構造物の製造方法。 The first type of fiber reinforced resin is CFRP.
The method for producing a fiber-reinforced resin structure according to claim 4, wherein the second type of fiber-reinforced resin is a fiber-reinforced resin made of a dielectric.
付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し、当該熱硬化性樹脂を硬化させて付加構造部を形成する工程と、
繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成する工程と、
前記金型の溝の前記付加構造部と前記半硬化本体部とを圧接して加熱し、前記半硬化本体部の熱硬化性樹脂を硬化して、付加構造部と本体部を接着する工程と、
前記金型を前記付加構造部から離脱させる工程と、を有する、繊維強化樹脂構造物の製造方法。 A method for manufacturing a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion.
A step of filling a groove of a mold formed corresponding to the shape of the additional structure portion with a thermosetting resin and curing the thermosetting resin to form an additional structure portion.
The process of forming a semi-cured main body of the thermosetting resin of fiber reinforced resin in a semi-cured state,
A step of pressing and heating the additional structure portion of the groove of the mold and the semi-curing main body portion to cure the thermosetting resin of the semi-curing main body portion and adhering the additional structure portion and the main body portion. ,
A method for producing a fiber-reinforced resin structure, comprising a step of separating the mold from the additional structure portion.
付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し、当該熱硬化性樹脂を硬化させて付加構造部を形成する工程と、
熱硬化性樹脂を含有する繊維強化樹脂の第１のプリプレグシートを前記付加構造部に接触させた状態で加熱し、前記第１のプリプレグシートの熱硬化性樹脂を硬化して、前記第１のプリプレグシートを前記付加構造部に接着させる工程と、
熱硬化性樹脂を含有する繊維強化樹脂の第２のプリプレグシートと、未発泡の発泡樹脂を含有するシートを重ねて接着させる工程と、
加熱により前記シートの発泡樹脂を発泡させて板状体を形成しつつ、当該板状体を前記第１のプリプレグシートに接着させて、前記板状体とその両面に接着された第１のプリプレグシート及び第２のプリプレグシートからなる本体部と前記付加構造部とを接着した状態にする工程と、
前記金型を前記付加構造部から離脱させる工程と、を有する、繊維強化樹脂構造物の製造方法。 A method for manufacturing a fiber-reinforced resin structure having a main body portion having a fiber-reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion.
A step of filling a groove of a mold formed corresponding to the shape of the additional structure portion with a thermosetting resin and curing the thermosetting resin to form an additional structure portion.
The first prepreg sheet of the fiber-reinforced resin containing the thermosetting resin is heated in a state of being in contact with the additional structure portion, and the thermosetting resin of the first prepreg sheet is cured to cure the first prepreg sheet. The process of adhering the prepreg sheet to the additional structure and
A step of stacking and adhering a second prepreg sheet of a fiber-reinforced resin containing a thermosetting resin and a sheet containing an unexpanded foamed resin.
The foamed resin of the sheet is foamed by heating to form a plate-like body, and the plate-like body is adhered to the first prepreg sheet, and the plate-like body and the first prepreg adhered to both sides thereof. A step of adhering the main body portion composed of the sheet and the second prepreg sheet and the additional structure portion, and
A method for producing a fiber-reinforced resin structure, comprising a step of separating the mold from the additional structure portion.
付加構造部の形状に対応して形成された金型の溝に熱硬化性樹脂を充填し当該熱硬化性樹脂が半硬化の状態の半硬化付加構造部を形成し、繊維強化樹脂の熱硬化性樹脂が半硬化の状態の半硬化本体部を形成し、前記金型の溝の前記半硬化付加構造部と前記半硬化本体部とを圧接して加熱し前記半硬化付加構造部及び前記半硬化本体部の熱硬化性樹脂を硬化して付加構造部と本体部を接着し、前記金型を前記付加構造部から離脱させる、繊維強化樹脂構造物の製造システム。 A system for manufacturing a fiber-reinforced resin structure having a main body having a fiber-reinforced resin containing a thermosetting resin and an additional structure formed on the surface of the main body.
A thermosetting resin is filled in a groove of a mold formed corresponding to the shape of the additional structure portion to form a semi-curable additional structure portion in a semi-cured state of the thermosetting resin, and the fiber-reinforced resin is thermoset. The semi-cured main body is formed of the semi-cured resin, and the semi-cured additional structure and the semi-cured main body of the groove of the mold are pressed and heated to heat the semi-cured additional structure and the semi-cured. A manufacturing system for a fiber-reinforced resin structure in which a thermosetting resin of a cured main body is cured to bond the additional structure and the main body, and the mold is separated from the additional structure.
熱硬化性樹脂を含有する繊維強化樹脂からなる本体部と、
前記本体部の表面に設けられた、熱硬化性樹脂からなる付加構造部と、を有し、
前記本体部は、複数種類の繊維強化樹脂片を組み合わせた板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有する、繊維強化樹脂構造物。 It is a fiber reinforced resin structure
The main body made of fiber reinforced resin containing thermosetting resin,
It has an additional structure portion made of a thermosetting resin provided on the surface of the main body portion.
The main body is a fiber-reinforced resin having a plate-like body obtained by combining a plurality of types of fiber-reinforced resin pieces and fiber-reinforced resin sheets containing a thermosetting resin provided on both sides of the plate-like body. Structure.
前記第２の種類の繊維強化樹脂片は、誘電体からなる繊維強化樹脂である、請求項２１に記載の繊維強化樹脂構造物。 The first type of fiber reinforced resin piece is CFRP.
The fiber-reinforced resin structure according to claim 21, wherein the fiber-reinforced resin piece of the second type is a fiber-reinforced resin made of a dielectric.
熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、
前記本体部の表面に設けられ、突状物を有し、熱硬化性樹脂からなる付加構造部と、を有し、
前記本体部は、発泡樹脂を含有する板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有する、繊維強化樹脂構造物。 It is a fiber reinforced resin structure
The main body having a fiber reinforced resin containing a thermosetting resin,
It is provided on the surface of the main body portion, has a projecting shape, and has an additional structural portion made of a thermosetting resin.
The main body is a fiber-reinforced resin structure having a plate-shaped body containing a foamed resin and a fiber-reinforced resin sheet containing a thermosetting resin provided on both sides of the plate-shaped body.
熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、
前記本体部の表面に設けられた、熱硬化性樹脂からなる付加構造部と、を有し、
前記本体部は、発泡樹脂を含有する板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有し、
前記本体部は、段差を有する、繊維強化樹脂構造物。 It is a fiber reinforced resin structure
The main body having a fiber reinforced resin containing a thermosetting resin,
It has an additional structure portion made of a thermosetting resin provided on the surface of the main body portion.
It said body portion, possess a plate-shaped body containing a foamed resin, provided on both surfaces of the plate-like body, a fiber-reinforced resin containing a thermosetting resin and a sheet,
The main body is a fiber-reinforced resin structure having a step .
熱硬化性樹脂を含有する繊維強化樹脂を有する本体部と、
前記本体部の表面に設けられた、熱硬化性樹脂からなる付加構造部と、を有し、
前記本体部は、発泡樹脂を含有する板状体と、前記板状体の両面に設けられた、熱硬化性樹脂を含有する繊維強化樹脂のシートとを有し、
前記本体部の厚みが、１ｍｍ以下である、繊維強化樹脂構造物。 It is a fiber reinforced resin structure
The main body having a fiber reinforced resin containing a thermosetting resin,
It has an additional structure portion made of a thermosetting resin provided on the surface of the main body portion.
It said body portion, possess a plate-shaped body containing a foamed resin, provided on both surfaces of the plate-like body, a fiber-reinforced resin containing a thermosetting resin and a sheet,
A fiber reinforced resin structure having a main body having a thickness of 1 mm or less .
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