JP6879198B2 - Resin molded body - Google Patents

Description

The present invention relates to a resin molded product.

Patent Document 1 below discloses a thermoplastic resin hollow molded body in which a substrate portion and a hollow structure portion are integrally connected by extrusion molding or the like. According to this thermoplastic resin hollow molded body, the substrate portion and the hollow structure portion are integrally connected without using a reinforcing material or the like, and a molded body having airtightness can be molded.

Japanese Unexamined Patent Publication No. H10-266889

However, with the method disclosed in Patent Document 1, for example, it is not easy to mold a plate-shaped resin body having a hollow structure such as a honeycomb structure inside. Further, it is also difficult to mold plate-shaped resin bodies having such a hollow structure into, for example, a resin molded body in which they are combined in a substantially T shape. Further, even when the resin molded body is heat-molded by an autoclave method or the like, the resin body having a hollow structure before heat molding has low rigidity against a compressive load acting in the axial direction of the hollow portion. Therefore, when a resin molded body is heat-molded by an autoclave method or the like, one resin body is heat-molded, and then the heat-molded one resin body is joined to the other resin body before heating for further heat molding. There is a need to. Therefore, there is room for improvement in molding the resin molded body by one heat molding in a state where the resin bodies having a hollow structure are integrally combined.

In consideration of the above facts, an object of the present invention is to obtain a resin molded body that can be molded by one heat molding in a state where resin bodies having a hollow structure are integrally combined.

The resin molded body according to claim 1 includes a core material whose surface is covered with a reinforcing fiber impregnated with a resin on one surface in the thickness direction of the first surface material on the support side, which is a surface material made of resin. One end face of the resin-made first hollow material having a hollow structure arranged on both sides of the core material in the thickness direction is joined to the core material and the other end face of the first hollow material in the thickness direction. , A first resin body in which one surface in the thickness direction of the support-side second surface material, which is a resin surface material, is joined, and both sides of the resin-made second hollow material having a hollow structure in the thickness direction. The end face is formed by joining one surface in the thickness direction of the first surface material on the supported side and the second surface material on the supported side, which are resin surface materials, to form the second surface material on the supported side. With the second resin body that is integrally heat-molded with the first resin body in a state where the side surface is joined to the other surface in the thickness direction of the support side second surface material at the position where the core material is joined. , Is included in the molding.

According to the resin molded body according to claim 1, a core material is provided inside the first resin body at a position where the side surface of the second resin body is joined to the support side second surface material of the first resin body. Therefore, the second resin body bonded to the first resin body is supported by the core material via the second surface material on the support side. Therefore, the load from the second resin body is not applied to the first hollow material of the first resin body, which has low rigidity with respect to the compressive load before heat molding, and the first resin body is not deformed. As a result, the resin molded body can be heat-molded in a state where the resin bodies having a hollow structure are integrally combined with each other.

Further, according to the resin molded body according to claim 1, since the second resin body is heat-molded in a state where the second resin body is bonded to the first resin body, one of the first resin body and the second resin body is used alone. It is not necessary to perform a plurality of heat moldings such as joining the other resin body and further heat molding after the heat molding with the above. As a result, it is possible to mold a resin molded body in which resin bodies having a hollow structure are integrally combined by one heat molding.

Further, the resin molded product according to claim 1 can be heat-molded in a state where the second resin body before heating is attached to the surface of the first resin body before heating. Therefore, in order to maintain the shape of the resin molded body before heating, for example, it is not necessary to provide a notch in the first resin body and insert the second resin body into the first resin body to combine them. Therefore, the first resin body and the second resin body can be integrally heat-molded without being cut or the like, and the bending strength of the first resin body and the second resin body is not lowered. As a result, it is possible to sufficiently secure the bending strength and the like of the resin molded body after molding.

As described above, the resin molded product according to the present invention has an excellent effect that it can be molded by one heat molding in a state where the resin bodies having a hollow structure are integrally combined.

It is the schematic perspective view which looked at the resin molded body which concerns on this embodiment from the diagonally upper side. It is the schematic cross-sectional view which cut the resin molded body along the line AA shown in FIG. It is the schematic perspective view which looked at the resin molded body which concerns on the prior art which is the 1st pair proportional, from the diagonally upper side. It is the schematic cross-sectional view which cut | cut the resin compact along the line BB shown in FIG. It is the schematic perspective view which looked at the resin molded body which concerns on the prior art which is the 2nd inverse proportional, from the diagonally upper side. It is the schematic cross-sectional view which cut | cut the resin compact along the CC line shown in FIG.

Hereinafter, the resin molded product according to the embodiment of the present invention will be described with reference to FIGS. 1 and 2. In the following figure, the arrow UP indicates the upper side of the molded body, the arrow L indicates the length direction of the molded body, and the arrow W indicates the width direction of the molded body.

As shown in FIG. 1, the resin molded body 10 according to the present embodiment extends along the length direction of the first resin body 20 provided on the lower side of the molded body, and the first resin body 20 is molded. The second resin body 40 to which the side surface portion 40A is joined to the upper side of the body is molded so that the outer shape of the molded body when viewed from the front is substantially inverted T-shaped. Further, on both outer sides of the second resin body 40 in the thickness direction (mold width direction), the first overlay 52 and the second overlay 54 straddle the first resin body 20 to the second resin body 40, and the first resin is formed. They are arranged so as to close the joint between the body 20 and the second resin body 40 from the outside.

The first resin body 20 extending in the length direction of the molded body and the width direction of the molded body is a support-side first surface material which is a surface material made of a thermosetting fiber reinforced resin in which a thermosetting resin is reinforced with carbon fibers. It is composed of 22 and a support side second surface material 24 which is a surface material made of thermosetting fiber reinforced resin, and a core material 30 and a first hollow material 26 arranged between them.

In front view, the surface on the upper side of the molded body, which is one surface in the thickness direction of the support-side first surface material 22 extending in the length direction of the molded body and the width direction of the molded body, is substantially at the center in the width direction of the molded body. A steel core material 30 formed in a substantially rectangular shape and extending in the length direction of the molded body is arranged. The surface of the core material 30 is covered on both sides in the width direction of the molded body and on both sides in the vertical direction of the molded body by reinforcing fibers 32 formed of carbon fibers (prepregs) impregnated with a thermosetting resin. Therefore, the lower side surface of the molded body, which is one end surface of the core material 30 in the thickness direction, is joined to the upper surface of the molded body of the support side first surface material 22 via the reinforcing fibers 32.

As shown in FIG. 2, a first hollow made of a thermosetting fiber reinforced resin having a hollow structure extending in the length direction of the molded body and the width direction of the molded body on both sides of the core material 30 in the width direction of the molded body. The material 26 is arranged. In the first hollow material 26, the end surface on the lower side of the molded body, which is one end surface of the first resin body 20 in the thickness direction, is joined to the upper surface of the molded body of the support side first surface material 22.

Inside the first hollow material 26, a hollow structure having a honeycomb structure is formed by continuously connecting the first wall portion 26A whose longitudinal direction is the thickness direction (vertical direction of the molded body) of the first hollow material 26. It is formed. Specifically, by continuously connecting the lateral end portions of the first wall portion 26A, the inside surrounded by the first wall portion 26A has an axis in the thickness direction of the first hollow member 26. The first hollow portion 26B, which is a space having a substantially hexagonal columnar direction, is formed.

On the upper side of the molded body of the core material 30 and the first hollow material 26, a support-side second surface material 24 extending in the length direction of the molded body and the width direction of the molded body is arranged. The lower surface of the molded body, which is one end surface of the support-side second surface material 24 in the thickness direction, is joined to the upper end faces of the core material 30 and the first hollow material 26.

The extending portion 24A of the end portion in the width direction of the molded body of the second surface material 24 on the support side extends downward to the lower side of the molded body toward the first surface material 22 on the support side, and the molded body of the first surface material 22 on the support side. It is joined to the upper surface. As a result, the cross section obtained by cutting the first resin body 20 in the vertical direction of the molded body and along the width direction of the molded body is formed into a closed cross section by the support side first surface material 22 and the support side second surface material 24. ..

Although the material of the core material 30 has been described here as being made of steel, the material is not limited to this, and may be formed of a material that is not deformed by heating when molding the resin molded body. Metals (eg, aluminum alloys, magnesium alloys, titanium alloys, etc.), preformed thermosetting resins (eg, vinyl ester resins, unsaturated polyester resins, phenolic resins, epoxy resins and urethane resins), thermosetting resins CFRP (carbon fiber reinforced resin), GFRP (glass fiber reinforced resin), or the like, which is preformed by heating using a resin as a base material, may be applied.

Further, here, it has been described that the heat-curable fiber-reinforced resin of the support-side first surface material 22, the support-side second surface material 24, and the first hollow material 26 is reinforced by using carbon fibers. It is not limited to the above, and may be reinforced by using other fibers depending on the purpose. For example, glass fiber, metal fiber and aramid fiber, cellulose fiber, nylon fiber, vinylon fiber, polyester fiber, polyolefin fiber and rayon fiber. Examples include resin fibers.

As shown in FIG. 1, the second resin body 40 extending in the longitudinal direction of the molded body with the length direction of the molded body as the longitudinal direction has the width direction of the molded body as the thickness direction and one end in the thickness direction. The first surface material 42 on the supported side, which is a surface material made of thermosetting fiber reinforced resin arranged in the portion, and the surface material made of thermosetting fiber reinforced resin arranged at the other end portion in the thickness direction. It is configured to include a second surface material 44 on the supported side and a second hollow material 46 arranged between them.

As shown in FIG. 2, the second hollow material 46 extending in the longitudinal direction of the molded body with the length direction of the molded body as the longitudinal direction is the end face in the thickness direction of the second resin body 40 in the width direction of the molded body. The end faces on both sides are joined to the first surface material 42 on the supported side and the second surface material 44 on the supported side, respectively.

Inside the second hollow material 46, a hollow structure having a honeycomb structure is formed by continuously connecting a second wall portion 46A whose longitudinal direction is the thickness direction (mold width direction) of the second hollow material 46. It is formed. Specifically, by continuously connecting the lateral end portions of the second wall portion 46A, the inside surrounded by the second wall portion 46A has an axis in the thickness direction of the second hollow member 46. A second hollow portion 46B, which is a substantially hexagonal columnar space in the direction, is formed.

The second resin body 40 is formed on the upper surface of the molded body, which is the other surface in the thickness direction of the second surface material 24 on the support side at the position where the second surface material 24 on the support side is joined to the core material 30. The lower side surface of the molded body of the second resin body 40 is joined.

Further, the first overlay 52 and the second overlay 52 and the second overlay 52 formed of the prepreg impregnated with the thermosetting resin straddle the supported side first surface material 42 and the supported side second surface material 44 to the supported side second surface material 24. The overlay 54 is arranged so as to close both outer sides of the joint portion between the first resin body 20 and the second resin body 40 in the width direction of the molded body. With these configurations, the resin molded body 10 in which the first resin body 20 and the second resin body 40 are combined is molded so that the outer shape of the molded body 10 when viewed from the front of the molded body has an inverted T shape.

Although it has been described here that the heat-curable fiber-reinforced resin of the first surface material 42 on the supported side, the second surface material 44 on the supported side, and the second hollow material 46 is reinforced by using carbon fibers. , Not limited to this, may be reinforced with other fibers depending on the purpose, for example, glass fiber, metal fiber and aramid fiber, cellulose fiber, nylon fiber, vinylon fiber, polyester fiber, polyolefin fiber and rayon. Examples thereof include resin fibers of fibers.

Next, the operation and effect of this embodiment will be described.

(1st pair proportional)
First, the action and effect of the resin molded product according to the present embodiment will be described through comparison with the first pair proportionality shown in FIGS. 3 and 4 and the second pair proportionality shown in FIGS. 5 and 6 described later. To do. The same components as those in the present embodiment described above will be assigned the same number and the description thereof will be omitted.

As shown in FIGS. 3 and 4, the resin molded body 70 according to the first inverse proportion is the first resin body 72 and the first resin body 72 provided on the lower side of the molded body, as in the present embodiment. The side surface portion 40A is formed by the second resin body 40 in which the side surface portion 40A is joined to the upper side of the molded body of the first resin body 72 along the longitudinal direction so that the outer shape of the molded body when viewed from the front is substantially inverted T-shaped. ..

Here, in the resin molded body 70 according to the first pair proportionality, the core material is not provided in the first resin body 72, and the support side first surface material 22 and the support side second surface material 24 are separated from each other. Only 1 hollow material 26 is arranged. Therefore, at the position where the second resin body 40 is joined to the surface on the upper side of the molded body of the second surface material 24 on the support side, the first hollow is formed on the lower surface of the molded body of the second surface material 24 on the support side. The material 26 is joined.

The first hollow material 26 having a hollow structure has low rigidity against a compressive load from the thickness direction (vertical direction of the molded body) before heat molding. Therefore, when the second resin body 40 is joined to the first resin body 72 before heat molding, the first hollow material 26 to which the compressive load due to the gravity of the second resin body 40 is applied is buckled and deformed. The shape of the first resin body 72 cannot be maintained. As a result, pressure molding and heat molding cannot be performed integrally with the first resin body 72 in contact with the second resin body.

Therefore, in the resin molded body 70 according to the first pair proportion, after the first resin body 72 is heat-molded independently, the second resin body 40 is arranged on the upper side of the molded body of the first resin body 72 and heat-molded again. It is necessary to perform heat molding multiple times. As a result, the work man-hours increase and the manufacturing cost increases as compared with the resin molded body 10 according to the present embodiment.

(2nd proportional)
Further, the second pair proportionality shown in FIGS. 5 and 6 will be described. The same components as those in the present embodiment described above will be assigned the same number and the description thereof will be omitted.

As shown in FIGS. 5 and 6, the resin molded body 80 according to the second inverse proportion also has the first resin body 82 and the first resin body 82 provided on the lower side of the molded body, similarly to the present embodiment. The side surface portion 40A is formed by the second resin body 40 in which the side surface portion 40A is joined to the first resin body 82 along the longitudinal direction so that the outer shape of the molded body when viewed from the front is an inverted T shape.

In the resin molded body 80 according to the second pair proportion, the side surface portion 40A of the second resin body 40 is joined to the surface on the upper side of the molded body of the support side first surface material 22. The second resin body 40 is formed of a prepreg impregnated with a thermosetting resin so as to extend from the first surface material 42 on the supported side and the second surface material 44 on the supported side to the first surface material 22 on the supported side. The 3 overlay 84 is arranged so as to close both outer sides of the joint portion between the support side first surface material 22 and the second resin body 40 in the width direction of the molded body.

In the resin molded body 80 according to the second pair proportion in which the third overlay 84 is arranged, it is necessary to first heat-mold only the support-side first surface material 22 and the second resin body 40 in which the third overlay 84 is arranged. is there. After the first heat molding, the first hollow material 26 is arranged on the upper surface of the support side first surface material 22 on the outer side in the width direction of the molded body of the heat-molded third overlay 84, and the first hollow material 26 is arranged. The lower end surface of the upper side of the molded body is joined to the lower end surface of the support side second surface material 86 divided at the substantially central portion in the width direction of the molded body in the thickness direction of the second surface material 86. The extending portion 86A on the outer side of the support-side second surface material 86 in the width direction of the molded body is joined to the surface of the support-side first surface material 22 on the upper side of the molded body.

Therefore, the resin molded body 80 according to the second inverse proportion needs to be heat-molded a plurality of times because the first hollow material 26 and the support-side second surface material 86 are heat-molded again in a state of being arranged. .. As a result, the work man-hours increase and the manufacturing cost increases as compared with the resin molded body 10 according to the present embodiment.

Further, since the support-side second surface material 86 is divided at a substantially central portion in the width direction of the molded body, the bending strength of the first resin body 82 and the like are lowered as compared with the case where the second surface material 86 is not divided. As a result, the bending strength and the like of the resin molded body 80 according to the second inverse proportion, which is formed by using the divided support-side second surface material 86, is lower than that of the resin molded body 10 of the present embodiment.

On the other hand, the resin molded body 10 according to the present embodiment in which the second resin body 40 is bonded to the upper side of the molded body 20 of the first resin body 20 on which the core material 30 is arranged is the first resin body 20 and the first resin body 20. 2 The resin body 40 is heat-molded by the autoclave method in a state of being integrally combined.

According to the resin molded body 10 of the present embodiment, in the second resin body 40, the lower surface of the molded body, which is one surface in the thickness direction of the support side second surface material 24, is joined to the core material 30. At this position, the second surface material 24 on the support side is joined to the upper surface of the molded body, which is the other surface in the thickness direction. Therefore, since the gravity of the second resin body 40 acts on the core material 30 via the second surface material 24 on the support side, no load acting on the first hollow material 26 is generated. As a result, the resin molded body 10 can be molded in a state where the resin bodies having a hollow structure are integrally combined with each other.

According to the resin molded body 10 of the present embodiment, the resin molded body 10 can be heat-molded once with the second resin body 40 integrally combined on the upper side of the molded body of the first resin body 20. A resin molded body in which resin bodies having a hollow structure are combined can be molded by heat molding.

Further, according to the resin molded body 10 of the present embodiment, the first resin body 20 and the second resin body 40 can be integrally heat-molded without being cut or the like, and the first resin body 20 and the second resin body can be integrally heat-molded. It does not reduce the bending strength of 40 or the like. As a result, it is possible to sufficiently secure the bending strength and the like of the resin molded body 10 after molding.

Further, the resin molded body 10 of the present embodiment extends from the first surface material 42 on the supported side and the second surface material 44 on the supported side to the second surface material 24 on the supported side, and has the first overlay 52 formed of the prepreg and the first overlay 52. The second overlay 54 is arranged so as to close both outer sides of the joint between the first resin body 20 and the second resin body 40 in the width direction of the molded body. As a result, the resin molded body 10 can be heat-molded in a state in which the combined state of the first resin body 20 and the second resin body 40 is further stabilized.

As described above, the resin molded product of the present embodiment can be molded by one heat molding in a state where the resin bodies having a hollow structure are integrally combined.

Further, in the resin molded body 10 of the present embodiment, the extending portion 24A of the support side second surface material 24 and the support side first surface material 22 are joined to form the first resin body 20. As a result, the strength of the first resin body 20 can be improved as compared with the case where the extending portion 24A and the support side first surface material 22 are not joined.

Further, in the resin molded body 10 of the present embodiment, since the other resin body may be joined to the position where the core material 30 of one resin body is arranged, the combination of parts is performed even before heat molding. Can be easily performed. In the resin molded body 10 of the present embodiment, the core material 30 is arranged at substantially the center of the surface of the support-side first surface material 22 on the upper side of the molded body in the width direction of the molded body, but the present invention is limited to this. Instead, the core material may be arranged at a position other than the substantially central portion in the width direction of the molded body of the support-side first surface material 22. As a result, according to the resin molded body 10 of the present embodiment, it is possible to form a resin molded body by combining various resin bodies having a hollow structure.

In the resin molded body 10 of the present embodiment, the first overlay 52 and the second overlay 54 are used to stabilize the joint portion between the first resin body 20 and the second resin body 40. Not limited to this, an adhesive may be provided between the side surface portion 20A of the first resin body 20 and the second surface material 24 on the support side of the second resin body 40 to be fixed.

Further, here, it has been described that the hollow structures of the first hollow material 26 and the second hollow material 46 are formed by a honeycomb structure, but the present invention is not limited to this, and the wall portion is formed in a corrugated shape and the space portion is axially oriented. A space portion is formed by combining a corrugated structure arranged so that is in the thickness direction of the core material and a wall portion formed in a corrugated or substantially hat shape when viewed from the side of the molded body, and the axial direction of the space portion is the core. A hollow structure may be formed by a monolithic structure formed so as to be in the longitudinal direction or the lateral direction of the material.

Further, here, the support side first surface material 22, the support side second surface material 24, the supported side first surface material 42, and the supported side second surface material 44 are molded using a thermosetting fiber reinforced resin. However, the present invention is not limited to this, and may be molded using a thermoplastic fiber reinforced resin. Examples of the thermoplastic resin that can be used in the present embodiment include polycarbonate resin, polyamide (PA) resin, polyurethane (PU) resin, polyvinyl chloride resin, acrylonitrile-butadiene-styrene copolymer (ABS) resin, and polypropylene. (PP) resin can be mentioned.

10 Resin molded body 20 1st resin body 22 Supporting side 1st surface material 24 Supporting side 2nd surface material 26 1st hollow material 30 Core material 32 Reinforcing fiber 40 2nd resin body 42 Supported side 1st surface material 44 Supported Side second surface material 46 Second hollow material 52 First overlay 54 Second overlay

Claims (1)

A core material whose surface is covered with resin-impregnated reinforcing fibers on one surface in the thickness direction of the support-side first surface material, which is a resin surface material, and a hollow structure arranged on both sides of the core material. One end face of the resin-made first hollow material in the thickness direction is joined to each other, and the core material and the other end face of the first hollow material in the thickness direction are joined to the support side first, which is a resin surface material. 2 The first resin body to which one surface of the surface material in the thickness direction is joined,
One surface in the thickness direction of the first surface material on the supported side and the second surface material on the supported side, which are resin surface materials, on both end faces in the thickness direction of the second hollow material made of resin having a hollow structure. Are formed by joining the two, and the side surface is joined to the other surface in the thickness direction of the support side second surface material at the position where the support side second surface material is joined to the core material. The second resin body, which is integrally heat-molded with the first resin body,
A resin molded body molded including.

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