JP7030622B2 - Composite material structure and its formation method - Google Patents

Description

The present invention relates to a composite material structure including a core layer and fiber-reinforced resins provided on both sides of the core layer, and a method for forming the same.

The following Patent Document 1 discloses a composite material structure in which a core layer of a non-woven fabric is provided between a pair of carbon fiber reinforced resin (CFRP) plates. With such a structure, the excellent mechanical properties (strength, elastic modulus, etc.) of CFRP are maintained, and the carbon fiber layer is reduced while increasing the thickness by the core layer of the non-woven fabric, which makes it versatile. -Achieves a composite material structure with improved lightness and manufacturability.

Patent No. 4615398

When the product is finally molded using the composite material structure disclosed in Patent Document 1, the CFRP matrix resin impregnates the non-woven fabric (core layer having liquid infiltration) and the product surface becomes smooth. There is concern that it will not be. It is conceivable that the matrix resin is completely impregnated into the inside of the non-woven fabric (core layer having liquid infiltration), but in this case, the lightness is impaired.

Therefore, an object of the present invention is to provide a composite material structure which realizes a smooth surface after final molding and also realizes excellent light weight, and a method for forming the composite material structure.

In the composite material structure according to the present invention, fiber-reinforced resin layers are provided on both sides of the core layer. The core layer is formed of a material that is infiltrated with liquid, but at each contact portion of the core layer with the fiber reinforced resin layer, an infiltration suppressing layer having a higher density of the material than the other parts of the core layer is formed. The core layer is formed with a plurality of columnar portions in which the above-mentioned material does not exist, which are formed from one of the infiltration suppressing layers toward the other. Here, a shape-retaining layer having a higher density of the above-mentioned material than the other portions is also formed in each adjacent portion with the columnar portion inside the core layer .
Alternatively, in the composite material structure according to the present invention, fiber reinforced resin layers are provided on both sides of the core layer. The core layer is formed of a material that is infiltrated with liquid, but at each contact portion of the core layer with the fiber reinforced resin layer, an infiltration suppressing layer having a higher density of the material than the other parts of the core layer is formed. The above material is a non-woven fabric.

According to the method for forming a composite material structure according to the present invention, a composite material structure including a core layer formed from a material infiltrated with liquid and a fiber reinforced resin layer provided on both sides of the core layer, respectively. Is formed. The above-mentioned material is formed by containing a thermoplastic resin or a thermosetting resin, and by heating and compressing the sheet-shaped material from both sides using a pair of molds, the density of the material is increased in the vicinity of each of the two sides. An enhanced infiltration suppression layer is formed. A composite material structure is formed using the core layer in which the infiltration suppression layer is formed.

According to the composite material structure according to the present invention, a smooth surface can be realized after final molding, and excellent lightness can also be realized.

According to the method for forming a composite material structure according to the present invention, it is possible to form a composite material structure that can realize a smooth surface after final molding and also can realize excellent lightness.

FIG. 1 is a cross-sectional view of a nonwoven fabric used in the composite material structure according to the embodiment. FIG. 2 is a cross-sectional view showing heat compression processing by the mold of the nonwoven fabric. FIG. 3 is a cross-sectional view of the nonwoven fabric after heat compression processing. FIG. 4 is a cross-sectional view showing a first step of manufacturing a composite material structure using the nonwoven fabric. FIG. 5 is a cross-sectional view showing a second step of manufacturing the composite material structure. FIG. 6 is a cross-sectional view of the manufactured composite material structure. FIG. 7 is a cross-sectional view showing the heat compression processing of the nonwoven fabric in the modified example. FIG. 8 is a cross-sectional view of the nonwoven fabric after heat compression processing in the modified example. FIG. 9 is a cross-sectional view of the composite material structure in the modified example.

Hereinafter, embodiments will be described with reference to the drawings. The same or equivalent components are designated by the same reference numerals and detailed description thereof will be omitted. The drawings are schematic, and the dimensions and ratios may differ from the actual ones.

An embodiment of a method for forming the composite material structure 1 (see FIG. 6) will be described. By explaining the forming method, the structure of the formed composite material structure 1 can be easily understood. First, the material 2X for forming the core layer 2 will be described. As shown in FIG. 1, the material 2X in this embodiment is a non-woven fabric 2X. The fibers of the nonwoven fabric 2X are made of a thermoplastic resin. The nonwoven fabric 2X has a high porosity and has a structure in which a liquid infiltrates. Therefore, the nonwoven fabric 2X is lightweight, but the thickness can be secured.

First, the core layer 2 is formed from the nonwoven fabric 2X. As shown in FIG. 2, the sheet-shaped nonwoven fabric 2X is heat-compressed from both sides by a first mold 100 (a mold for forming the core layer 2). The first mold 100 is provided with a heating mechanism, and heats the nonwoven fabric 2X to a temperature at which the thermoplastic resin is softened. The first mold 100 is preheated, and the nonwoven fabric 2X is compressed from that state. Since heat is transferred from the surface of the nonwoven fabric 2X to the inside, the thermoplastic resin softens from the surface. Since the non-woven fabric 2X is compressed at the same time as heating, the vicinity of the surface of the nonwoven fabric 2X is crushed with the softening of the thermoplastic resin, and the infiltration suppressing layer 20 having a high density, that is, a low gap ratio is formed in the vicinity of the surface. The infiltration suppression layer 20 has a higher density than the other parts of the core layer 2, and therefore has a lower porosity than the other parts of the core layer 2.

The infiltration suppression layer 20 is a region having a low porosity and suppresses the infiltration of liquid. Further, the core layer 2 on which the infiltration suppressing layer 20 is formed is cured after the softened thermoplastic resin is deformed along the inner surface of the first mold 100, so that the inner surface of the first mold 100 is transferred smoothly. It has a nice surface. The inside of the core layer 2 is maintained as a region having a high porosity.

Next, the fiber reinforced resin layer 3 is formed on both sides of the core layer 2 shown in FIG. 3 formed as described above. In this embodiment, carbon fiber is used as the reinforcing fiber. Further, a bidirectional carbon fiber sheet in which carbon fibers are woven into a sheet is laminated and used. Further, in the present embodiment, the fiber reinforced resin layer 3 is formed by the RTM (Resin Transfer Molding) method, and the composite material structure 1 shown in FIG. 6 is in a state after final molding (after that, painting, drilling, and so on. Processing such as cutting may be performed).

In the formation of the fiber reinforced resin layer 3 by the RTM method, as shown in FIG. 4, the core layer 2 and the carbon fiber sheet 3X are contained in the second mold 200 (the mold for forming the fiber reinforced resin layer 3). To set. The carbon fiber sheet 3X in FIG. 4 is schematically shown, and the number of carbon fiber sheets 3X is not accurately represented. The carbon fiber sheet 3X in the present embodiment is a so-called preform used by the RTM method. In the state of FIG. 4, the matrix resin is filled into the mold from each second mold 200.

As shown in FIG. 5, the matrix resin is filled between the infiltration suppressing layer 20 and the second mold 200, but since the infiltration suppressing layer 20 is formed, the matrix resin is inside the core layer 2. Does not infiltrate. Although a small amount of the matrix resin may infiltrate the infiltration suppressing layer 20, it does not infiltrate deep inside the core layer 2. The filling pressure of the matrix resin is set to a pressure that does not crush the core layer 2 and does not allow the matrix resin to infiltrate into the core layer 2.

In the present embodiment, the matrix resin of the fiber reinforced resin layer 3 is a thermosetting resin. However, in the case of the RTM method, it is also possible to use a thermoplastic resin as the matrix resin of the fiber reinforced resin layer 3. Depending on the resin used, the second mold 200 is provided with a heating mechanism (for curing the thermosetting resin) and a cooling mechanism (for early cooling of the thermoplastic resin). Since the infiltration suppressing layer 20 is formed on both sides of the core layer 2, the matrix resin is filled from each of the pair of second molds 200. If the matrix resin is filled only from one second mold 200, the carbon fiber sheet 3X on the other second mold 200 side is not filled with the matrix resin. The matrix resin is cured and the fiber reinforced resin layer 3 is formed on both sides of the core layer 2, whereby the composite material structure 1 shown in FIG. 6 is formed.

Since the infiltration of the matrix resin of the fiber reinforced resin layer 3 into the core layer 2 at the time of forming the fiber reinforced resin layer 3 is suppressed by the infiltration suppressing layer 20, the formed composite material structure 1 has a uniform thickness. The fiber reinforced resin layer 3 of the above can be provided. Therefore, the resin shrinkage during cooling of the matrix resin becomes uniform. Further, the surface of the infiltration suppressing layer 20 is also smooth as described above. Therefore, due to these factors, the composite material structure 1 can realize a very beautiful appearance.

Further, the composite material structure 1 has a fiber-reinforced resin layer 3 (CFRP layer) on both sides thereof, and has a composite structure having a lightweight core layer 2 between them. Therefore, the composite material structure 1 has excellent mechanical properties even though it is lightweight. Since the fiber reinforced resin layer 3 and the core layer 2 are integrally and directly bonded to each other, peeling between the two is unlikely to occur.

In the composite material structure 1 described above, the fiber reinforced resin layer 3 is formed by the RTM method, but the fiber reinforced resin layer 3 may be formed by another method. For example, by forming a structure similar to that of a normal prepreg as a fiber reinforced resin layer 3 on both sides of the core layer 2 shown in FIG. 3 formed in the above-mentioned step, the composite material structure 1 shown in FIG. 6 is formed. May be constructed. In this case, the formed composite material structure 1 is used as a prepreg, and the fiber reinforced resin layer 3 is cured by final molding by an autoclave molding method. It should be noted that not only the composite material structure 1 before the final molding but also the composite material structure 1 after the final molding can be regarded as the composite material structure 1 of the present invention.

In order to form a fiber-reinforced resin layer 3 similar to a prepreg on the surface of the core layer 2, a carbon fiber sheet (or a carbon fiber bundle) is set on the surface of the core layer 2, and a thermosetting resin is applied thereto. It may be impregnated. Alternatively, a carbon fiber sheet (or carbon fiber bundle) impregnated with a thermosetting resin in advance may be provided on the surface of the core layer 2. Since the composite material structure 1 shown in FIG. 6 is used as a prepreg, the thermosetting resin of the fiber reinforced resin layer 3 is in a semi-cured state.

Normally, when creating a prepreg, a prepreg is constructed on a base sheet (release sheet) and rolled to use the base sheet as a protective sheet, or a protective sheet is attached on the constructed prepreg. In this example, the core layer 2 functions similarly to this base sheet. However, since the fiber reinforced resin layer 3 is formed on both sides of the core layer 2, it cannot be rolled. Therefore, protective sheets are attached to both sides of the formed composite material structure 1 as a prepreg, and the composite material structure 1 is stored in a refrigerator. The protective sheet is peeled off when the composite material structure 1 is used for final molding.

Also in this example, when the fiber reinforced resin layer 3 is formed, the infiltration of the matrix resin (thermosetting resin) into the core layer 2 is suppressed by the infiltration suppressing layer 20, so that the formed composite material structure is also formed. 1 includes a fiber reinforced resin layer 3 having a uniform thickness. Further, when the composite material structure 1 as the formed prepreg is finally molded, the infiltration of the matrix resin (thermosetting resin) into the core layer 2 is suppressed by the infiltration suppressing layer 20. Further, the surface of the infiltration suppressing layer 20 is also smooth as described above. Therefore, due to these factors, the composite material structure 1 (after final molding) can achieve a very beautiful appearance.

Further, the composite material structure 1 (after final molding) has a fiber reinforced resin layer 3 (CFRP layer) on both sides thereof, and has a composite structure having a lightweight core layer 2 between them. For this reason, the composite structure 1 (after final molding) can have excellent mechanical properties despite being lightweight. Since the fiber-reinforced resin layer 3 and the core layer 2 are integrally and directly bonded in the process of the autoclave molding method, peeling between the two is unlikely to occur.

The nonwoven fabric 2X of the present embodiment was formed of thermoplastic resin fibers. However, the nonwoven fabric 2X may be a nonwoven fabric formed of some kind of fiber mixed with a thermoplastic resin powder or granules. If the nonwoven fabric (material) 2X contains the thermoplastic resin in this way, the core layer 2 having the infiltration suppressing layer 20 described above can be formed.

Further, the core layer 2 may contain a thermosetting resin instead of the thermoplastic resin. In this case, the fibers of the nonwoven fabric 2X may be formed of a thermosetting resin, or the powder or granules of the thermosetting resin may be mixed with the nonwoven fabric 2X. Even in this way, the core layer 2 having the infiltration suppressing layer 20 described above can be formed. When a thermosetting resin is used, the thermosetting resin is heated by the first mold 100 to soften, and then the curing proceeds at the curing reaction (crosslinking reaction) temperature. At this time, the nonwoven fabric 2X is compressed with heating to form the infiltration suppressing layer 20.

Further, in the present embodiment, the material 2X is a non-woven fabric, but any material may be used as long as it is a material that infiltrates a liquid (has a high porosity). For example, the material 2X may be a foam or a porous body (for example, a sponge). Even with such a material 2X, the infiltration suppressing layer 20 is also formed by being heat-compressed by containing a thermoplastic resin (or a thermosetting resin). However, the foam in which the bubbles are closed cells is a material in which the liquid does not infiltrate into the inside.

In this embodiment, a bidirectional (multidirectional) carbon fiber sheet is used, but even if a unidirectional carbon fiber sheet is used to form the fiber reinforced resin layer 3. good. Further, the isotropic fiber reinforced resin layer 3 may be formed instead of the anisotropic fiber reinforced resin layer 3 such as unidirectional or multidirectional. For example, without using a carbon fiber sheet, a short cut carbon fiber (chopped strand) impregnated with a matrix resin or a matrix resin kneaded with a short cut carbon fiber (chopped strand) is used and isotropic. The sex fiber reinforced resin layer 3 may be formed. In this case, the fiber reinforced resin layer 3 can be formed on both sides of the core layer 2 by the SMC (Sheet Molding Compound) molding method or the BMC (Bulk Molding Compound) molding method.

Further, a quasi-isotropic fiber reinforced resin layer 3 may be formed by using a plurality of anisotropic carbon fiber sheets. In this embodiment, the fiber reinforced resin layer 3 is formed by using carbon fiber, but the fiber reinforced resin layer 3 may be formed by using other fibers such as glass fiber. The direction of the fiber when the glass fiber is used is the same as that of the carbon fiber described above. The above-mentioned SMC molding method and BMC molding method are often used as a molding method for glass fiber reinforced plastic (GFRP).

In this embodiment, the matrix resin of the fiber reinforced resin layer 3 constituting the composite material structure 1 is a thermosetting resin. As described above, in the RTM method, a thermoplastic resin can also be used as the matrix resin of the fiber reinforced resin layer 3. However, although it depends on the molding method, a thermoplastic resin may be used as the matrix resin when the fiber reinforced resin layer 3 is formed by a molding method other than the RTM method (the fiber reinforced resin layer 3 is formed by CFRTP). Further, it is also possible to use a PCM (Prepreg Compression Molding) method instead of the above-mentioned autoclave molding method.

In the above embodiment, the material 2X of the core layer 2 contains a thermoplastic resin, but it is also possible to use a thermosetting resin instead of the thermoplastic resin. In this case, the thermoplastic resin may be completely cured or the thermosetting resin may not be completely cured in the state of FIG. 3 after the core layer 2 is formed. For example, when the core layer 2 is formed, the thermosetting resin is only softened without heating to the curing reaction temperature to form the infiltration suppressing layer 20. After that, the fiber reinforced resin layer 3 is formed on both sides of the core layer 2. When the fiber reinforced resin layer 3 is formed, the thermosetting resin of the core layer 2 is cured by heating to the curing reaction temperature. In this case, the state shown in FIG. 6 after the formation of the fiber reinforced resin layer 3 is the state after the final molding. Even in this way, since the infiltration suppressing layer 20 is formed in advance, the infiltration of the matrix resin of the fiber reinforced resin layer 3 into the core layer 2 can be suppressed.

Alternatively, the infiltration suppressing layer 20 may be formed without heating to the curing reaction temperature at the time of forming the core layer 2, and then the fiber reinforced resin layer 3 as a prepreg may be formed on both sides of the core layer 2 as described above. .. In this case, when the fiber reinforced resin layer 3 is formed, the infiltration of the matrix resin of the fiber reinforced resin layer 3 into the core layer 2 can be suppressed. The composite material structure 1 in the state shown in FIG. 6 after the formation of the fiber reinforced resin layer 3 is finally molded by an autoclave molding method (or PCM method) as a prepreg. Also at this time, since the infiltration suppressing layer 20 is formed in advance, the infiltration of the matrix resin of the fiber reinforced resin layer 3 into the core layer 2 can be suppressed.

In the composite material structure 1, the matrix resin of the fiber reinforced resin layer 3 is in direct contact with the infiltration suppressing layer 20 of the core layer 2. In other words, the fiber reinforced resin layer 3 is directly provided on both sides of the core layer 2. A layer of another material such as an adhesive layer is not provided between the core layer 2 (infiltration suppression layer 20) and the fiber reinforced resin layer 3.

The composite material structure 1 according to the present embodiment includes a core layer 2 and a fiber reinforced resin layer 3 provided on both sides of the core layer 2, respectively. The core layer 2 is formed of the material 2X in which the liquid infiltrates, and each contact portion of the core layer 2 with the fiber reinforced resin layer 3 forms an infiltration suppression layer 20 in which the density of the material 2X is increased. There is.

Therefore, since the infiltration of the matrix resin into the core layer 2 at the time of forming the fiber reinforced resin layer 3 is suppressed by the infiltration suppressing layer 20, the fiber reinforced resin layer 3 having a uniform thickness can be provided. Therefore, the composite material structure 1 can realize a smooth and beautiful appearance without unevenness.

Even when the composite material structure 1 is in the state before the final molding (for example, prepreg), the infiltration of the matrix resin into the core layer 2 at the time of the final molding is also suppressed by the infiltration suppressing layer 20. Therefore, it is possible to give the composite material structure 1 after the final molding a smooth and beautiful appearance without unevenness.

Further, the composite material structure 1 has a fiber-reinforced resin layer 3 on both sides thereof, and has a composite structure having a core layer 2 between them. Therefore, the volume of the fiber reinforced resin layer 3 can be reduced by the core layer 2. As a result, it is possible to realize the excellent mechanical properties of the composite material structure 1 while reducing the weight of the composite material structure 1.

Further, in the forming method according to the present embodiment, a composite material structure including a core layer 2 formed from a material 2X infiltrated with a liquid and a fiber reinforced resin layer 3 provided on both sides of the core layer 2 respectively. Form 1. The material 2X forming the core layer 2 is formed by containing a thermoplastic resin or a thermosetting resin. Then, by heating and compressing the sheet-shaped material 2X from both sides using a pair of molds (first mold 100), an infiltration suppression layer 20 having an increased density of the material 2X is formed in the vicinity of the surface. The core layer 2 is formed. Next, the fiber reinforced resin layer 3 is formed on both sides of the formed core layer 2.

Therefore, the infiltration of the matrix resin into the core layer 2 at the time of forming the fiber reinforced resin layer 3 is suppressed by the infiltration suppressing layer 20. Therefore, according to this forming method, the fiber reinforced resin layer 3 having a uniform thickness can be obtained. The composite material structure 1 to be provided can be formed. Therefore, it is possible to give the composite material structure 1 a smooth and beautiful appearance without unevenness.

Even when the composite material structure 1 is in a state before final molding (for example, prepreg), the core layer of the matrix resin when the composite material structure 1 is finally molded (for example, autoclave molding) by this forming method. 2 Infiltration into the inside can also be suppressed by the infiltration suppression layer 20. Therefore, it is possible to give the composite material structure 1 after the final molding a beautiful appearance without unevenness.

Further, according to this forming method, a composite material structure 1 having a composite structure having a fiber reinforced resin layer 3 on both sides and a core layer 2 between them is formed. Therefore, the volume of the fiber reinforced resin layer 3 can be reduced by the core layer 2. As a result, it is possible to impart excellent mechanical properties to the composite material structure 1 while reducing the weight of the formed composite material structure 1.

Here, the material 2X of the core layer 2 is preferably a non-woven fabric. The non-woven fabric has a large porosity and effectively contributes to weight reduction of the composite material structure 1. Further, the non-woven fabric tends to form the infiltration suppressing layer 20 even though the porosity is large. Further, since elastic restoration is hardly performed after heating and compression, it is easy to control the thickness of the composite material structure 1 (core layer 2) when forming the composite material structure 1. Further, the nonwoven fabric can easily change its shape and improves the formability of the composite material structure 1. In particular, when the composite material structure 1 is used as a prepreg, it is easy to attach it to a molding die for final molding.

Next, a modified example of the core layer 2 described above will be described with reference to FIGS. 7 to 9. Instead of the core layer 2 shown in FIG. 3, the core layer 2A shown in FIG. 9 is used to form the composite material structure 1A. The formation of the fiber reinforced resin layer 3 is the same as that of the above-described embodiment.

The core layer 2A shown in FIG. 9 is also formed from the nonwoven fabric 2X shown in FIG. However, of the pair of first molds 100 and 101 for heating and compressing the nonwoven fabric 2X, one of the first molds 101 has a plurality of contact surfaces with the nonwoven fabric (material) 2X as shown in FIG. Columnar protrusions 100a are formed. The columnar protrusion 100a of this modification is a weight-shaped protrusion, and has a conical shape or a polygonal pyramid shape (triangular pyramid shape, quadrangular pyramid shape, or the like). The plurality of columnar protrusions 100a are uniformly arranged on the contact surface. The tip of the columnar protrusion 100a does not reach the other first mold 100, but reaches the region where the infiltration suppression layer 20 near the other first mold 100 is formed.

When the nonwoven fabric 2X is heated and compressed using the pair of first molds 100 and 101 described above, the columnar protrusions 100a pierce the nonwoven fabric 2X and the thermoplastic resin (or heat) around the columnar protrusions 100a is inserted. The shape-retaining layer 21 is formed by the curable resin). The shape-retaining layer 21 also has a higher density than the other parts of the core layer 2 (parts other than the infiltration-suppressing layer 20) like the infiltration-suppressing layer 20, and therefore has a lower porosity than the other parts of the core layer 2. .. When the pair of first molds 100 and 101 is removed, the columnar portion 22 in which the material 2X does not exist is formed inside the shape-retaining layer 21 by the columnar protrusions 100a. That is, a shape-retaining layer 21 is formed in an adjacent portion of each columnar portion 22. The shape-retaining layer 21 is formed from one of the infiltration suppressing layers 20 toward the other. Since the shape-retaining layer 21 is also formed in the same manner as the infiltration suppressing layer 20, the density of the material 2X is increased and the rigidity is also increased. Therefore, the shape-retaining layer 21 suppresses the collapse of the core layer 2A in the thickness direction and retains the shape of the core layer 2 (that is, the composite material structure 1A).

FIG. 9 shows a composite material structure 1A formed by using the core layer 2A shown in FIG. 8 and forming the fiber reinforced resin layer 3 by the above-mentioned RTM method. Since the fiber reinforced resin layer 3 is formed by the RTM method, the matrix resin of the fiber reinforced resin layer 3 is also filled inside the columnar portion 22. In the composite material structure 1A thus created, a large number of shape-retaining layers 21 are formed so as to connect the pair of infiltration suppressing layers 20, and crushing in the thickness direction is suppressed. Further, since the fiber reinforced resin layer 3 is formed on both surfaces of the core layer 2A, bending of the core layer 2A is also suppressed, so that the surface rigidity of the composite material structure 1A is improved. In particular, in the example shown in FIG. 9, since the matrix resin of the fiber reinforced resin layer 3 is also filled inside the columnar portion 22, the surface rigidity of the composite material structure 1A is particularly excellent.

Further, since the shape-retaining layer 21 having a high density is formed around the columnar portion 22, the matrix resin hardly infiltrates from the columnar portion 22 into the core layer 2A when the fiber reinforced resin layer 3 is formed. Therefore, the advantages provided by the above-described embodiments are also provided by this modification. It is preferable that the columnar portion 22 is arranged so that the tip thereof is located on the side that finally becomes the appearance. That is, in the case shown in FIG. 9, the upper surface is the surface to be the appearance. Since the opening of the columnar portion 22 is formed at the base end of the columnar portion 22, the surface of the upper fiber-reinforced resin layer 3 is surely more beautiful without being affected by the opening of the columnar portion 22.

Even if the carbon fiber sheet (or carbon fiber bundle) set on the surface of the core layer 2A is impregnated with the thermosetting resin to form the fiber reinforced resin layer 3, the composite material structure 1A is formed as a prepreg. good. When the composite material structure 1A is used as a prepreg, the thermosetting resin can infiltrate the inside of the columnar portion 22 at the time of final molding (for example, autoclave molding or PMC molding), but the thermosetting resin is formed from the columnar portion 22 to the core layer. It hardly invades the inside of 2A (outside of the columnar portion 22).

In FIGS. 7 to 9, the outer diameter of the base end of the columnar protrusion 100a and the inner diameter of the base end of the columnar portion 22 are shown large for easy understanding. However, the columnar protrusion 100a may be thick enough to transfer heat, and the internal volume of the columnar portion 22 is not large. Therefore, even if the matrix resin of the fiber reinforced resin layer 3 infiltrates the inside of the columnar portion 22, the amount thereof is not large.

Further, in this case as well, it is preferable that the tip of the columnar portion 22 is arranged on the molding mold side (that is, the side that finally becomes the appearance). The surface of the fiber reinforced resin layer 3 on the tip side of the columnar portion 22 is surely more beautiful without being affected by the opening formed at the base end of the columnar portion 22 and the infiltration of the matrix resin into the inside of the columnar portion 22. Become.

The present invention is not limited to the above embodiments and modifications. For example, the columnar protrusion 100a of the above-mentioned modified example was formed as a weight-shaped protrusion. However, the columnar protrusion 100a may be formed as a columnar protrusion having a constant outer diameter with only the tip pointed.

The composite material structure of the present invention can be applied to various panel materials such as automobile panel materials. Further, the molding method can be applied when forming such a composite material structure.

1,1A Composite material structure 2,2A Core layer 2X Non-woven fabric (material)
3 Fiber-reinforced resin layer 20 Infiltration-suppressing layer 21 Shape-retaining layer 22 Columnar portions 100, 101 (for forming the core layer) 1st mold 100a Columnar protrusions 200 (for forming the fiber-reinforced resin layer) 2nd mold

Claims (5)

In a composite material structure provided with a core layer and fiber-reinforced resin layers provided on both sides of the core layer, respectively.
The core layer is made of a material that is infiltrated with liquid.
An infiltration suppressing layer having a higher density of the material than the other parts of the core layer is formed at each contact portion of the core layer with the fiber reinforced resin layer.
The core layer is formed with a plurality of columnar portions in which the material does not exist, which are formed from one of the infiltration suppressing layers toward the other.
A composite material structure in which a shape-retaining layer having a higher density of the material than other portions is formed in each adjacent portion of the inside of the core layer with the columnar portion . In a composite material structure provided with a core layer and fiber-reinforced resin layers provided on both sides of the core layer, respectively.
The core layer is made of a material that is infiltrated with liquid.
An infiltration suppressing layer having a higher density of the material than the other parts of the core layer is formed at each contact portion of the core layer with the fiber reinforced resin layer.
A composite material structure in which the material is a non-woven fabric. A method for forming a composite material structure including a core layer formed of a material infiltrated with a liquid and a fiber reinforced resin layer provided on both sides of the core layer.
The material forming the core layer is formed by containing a thermoplastic resin or a thermosetting resin.
By heating and compressing the sheet-shaped material from both sides using a pair of molds, an infiltration suppression layer having an increased density of the material is formed in the vicinity of both sides to form the core layer.
A method for forming a composite material structure, wherein the fiber-reinforced resin layer is formed on both sides of the formed core layer. One of the pair of molds has a plurality of columnar protrusions on the contact surface with the material.
When the material is heated and compressed using the pair of molds, the material is present from one of the infiltration suppressing layers toward the other by the plurality of columnar protrusions piercing the inside of the core layer. The method for forming a composite material structure according to claim 3 , wherein a plurality of non-columnar portions are formed and a shape-retaining layer having an increased density of the material is formed around the columnar portions. The method for forming a composite material structure according to claim 3 or 4 , wherein the material is a non-woven fabric.

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