JP7144253B2 - Method for producing fiber-reinforced composite material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a fiber-reinforced composite material and a fiber-reinforced composite material provided with a fastening member, and in particular, performs a resin impregnation step in a state in which a laminate of reinforcing fiber sheets is stretched in a mold. and relates to a method for producing a fiber-reinforced composite material that prevents twisting of fibers of a reinforcing fiber sheet and improves appearance quality, and a fiber-reinforced composite material provided with a fastening member.

In recent years, a resin transfer molding (RTM) method, a reaction injection molding (RIM) method, and the like have been used as methods for producing fiber-reinforced composite materials. In these methods, a laminate obtained by laminating a plurality of reinforcing fiber sheets is set in a mold, and after the molds are clamped, an uncured resin is injected, impregnated into the laminate, and cured. According to this method, since a laminate made of a dry base material not impregnated with a resin is shaped, it is possible to produce a molded article having a relatively complicated shape.

However, the reinforcing fiber sheets before being impregnated with a resin are poor in handleability, such as the laminated reinforcing fiber sheets falling apart during transportation. Therefore, a pre-shaping step is usually set before the main shaping step of impregnating the resin.

In the preshaping step, one reinforcing fiber sheet is set in a preshaping mold, a powder-like fixing material is sprinkled on its surface, and the next reinforcing fiber sheet is laminated thereon. These steps are sequentially repeated to form a laminate of reinforcing fiber sheets, and then the molds are clamped by a pre-shaping mold. As a result, the reinforcing fiber sheets are fixed to each other, and a preform preformed into a shape suitable for subsequent main forming is formed. In the main shaping step, by setting the preform body in the main shaping mold, positioning is facilitated and misalignment during the main shaping is prevented (see, for example, Patent Document 1). .

Moreover, the following manufacturing method is known as a method for manufacturing a fiber-reinforced composite material that omits the preforming step. A plurality of joints and a through-hole penetrating through the laminate are formed in a central portion of the joints in a laminate of a plurality of reinforcing fiber sheets, which is a dry base material.

Here, the joint portion is a portion where all the reinforcing fiber sheets of the laminate are partially joined by infiltrating an adhesive from the uppermost reinforcing fiber sheet to the lowermost reinforcing fiber sheet of the laminate. Then, when the laminate is placed in the mold for the main shaping, the laminate can be easily positioned by inserting pin-shaped members of the mold into the through holes formed in the joints. (For example, see Patent Document 2.).

Japanese Patent Application Laid-Open No. 2008-179130 JP 2017-213819 A

However, in the method for producing a fiber-reinforced composite material described in Patent Document 1, the pre-shaping step is performed before the main shaping step, which complicates the manufacturing process and increases the number of molds used for manufacturing. , there is a problem that the manufacturing cost increases.

On the other hand, in the method for producing a fiber-reinforced composite material described in Patent Document 2, although the preliminary shaping step can be omitted, during the main shaping step, the flow pressure of the resin and the pressure from the mold surface of the mold Due to the external pressure, the fibers are hardened in a twisted state, and there is a possibility that the appearance of the fiber-reinforced composite material after molding may be poor. In addition, since the defective appearance cannot be repaired after molding, the fiber-reinforced composite material with the defective appearance must be discarded, leading to a problem of deterioration in yield.

The above-mentioned poor appearance is caused by misalignment of the fibers, so it is not only a problem in terms of appearance, but also leads to variations in strength. In some cases, it was good, but there was a problem that it led to a deterioration in yield.

In addition, in the above-described laminate, by appropriately providing the joints and the through holes, the laminate can be easily positioned and the reinforcing fiber sheets can be prevented from being displaced during positioning. However, since the through-holes remain on the design surface of the fiber-reinforced composite material after molding, at least the region where the through-holes are formed must be cut when processing the fiber-reinforced composite material after molding into a product shape. However, there was a problem that it leads to a deterioration in the yield of the product and an increase in the processing cost.

In addition, in order to fasten the fiber reinforced composite material after molding to other parts, the fiber reinforced composite material after molding is subjected to post-processing such as drilling holes, rivets, bolts, nuts, etc. are arranged, mechanically There was a problem that it was necessary to form a fastening point, leading to an increase in processing costs.

The present invention has been made in view of the above circumstances. It is an object of the present invention to provide a method for producing a fiber-reinforced composite material and a fiber-reinforced composite material equipped with a fastening member, which prevent this and improve appearance quality.

In the method for producing a fiber-reinforced composite material of the present invention, a fiber-reinforced composite material is formed by arranging a laminate of reinforcing fiber sheets in a molding die, impregnating the laminate with a resin and curing the fiber-reinforced composite material. In a method for producing a composite material, a step of fixing at least the vicinities of opposite end portions of the laminate with sandwiching plates sandwiching the laminate therebetween; are folded inward, and the laminate is placed in the cavity of the molding die such that at least a part of the clamping plate is fitted into the recess of the mold surface of the lower die of the molding die. and a step of injecting the resin into the cavity while the laminate is stretched, and molding the fiber-reinforced composite material by impregnating the laminate with the resin and curing it. , is characterized by having

Further, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body having a plurality of locking portions formed on one main surface thereof for restraining the laminate, and the locking plate-like body. and a second plate-like body formed with a plurality of locking holes into which the parts are inserted, wherein the laminated body is sandwiched between the one plate-like body and the other plate-like body. Then, the one plate-like body and the other plate-like body are connected to each other by processing the locking portion protruding from the locking hole on one main surface side of the other plate-shaped body. characterized by

Further, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body formed with a projection locking portion projecting toward one main surface thereof, and the other plate-like body projecting toward the other side and formed with a protrusion engaging portion into which the protrusion locking portion is inserted; By inserting the projection engaging portion and at least a part of the laminated body into the projection engaging portion with the laminated body sandwiched therebetween, the one plate-like body and the other plate It is characterized in that the two bodies are in a connected state.

Further, in the method for producing a fiber-reinforced composite material of the present invention, a metal member is fixed to the one main surface of the other plate-shaped body, and in the step of arranging the laminate in the cavity of the mold, , wherein the both ends of the laminate are folded inward so as to wrap the one plate-like body inside the laminate, and the metal member is fitted into the recess of the lower mold. and

Further, in the method for producing a fiber-reinforced composite material of the present invention, a metal member is fixed to the one main surface of the one plate-like body, and the other plate-like body has an insertion hole through which the metal member is inserted. In the step of arranging the laminated body in the cavity of the molding die, after projecting the metal member toward the one main surface side of the other plate-shaped body, the one plate-shaped body are folded inwardly so as to wrap the inside of the laminate, and the metal member is fitted into the concave portion of the lower mold.

Moreover, in the method for producing a fiber-reinforced composite material of the present invention, the metal member is a fastening member or a welding member.

Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of impregnating and curing the resin in the laminate, the metal member and at least part of the clamping plate are fitted into the recess of the lower mold. The recessed portion of the lower mold is moved in the closed state to extend the laminate.

In the method for producing a fiber-reinforced composite material of the present invention, the step of fixing the vicinity of both ends of a laminate of reinforcing fiber sheets with clamping plates, respectively, and fixing both ends of the laminate so that the clamping plates are vertically inverted. arranging the laminate in the cavity of the molding die so that at least a part of the clamping plate is fitted in the concave portion of the mold surface of the lower mold of the molding die while folding the laminate inward; and stretching the laminate. a step of injecting a resin into the cavity in a state where the laminated body is placed, impregnating the resin into the laminate and curing the resin to form a fiber-reinforced composite material. According to this manufacturing method, the sandwiching plate is used to extend the laminate, and the cavity is filled with resin, so that the flow pressure of the resin makes it difficult for the fiber bundles of the reinforcing fiber sheet to twist, and the fibers after molding are not easily twisted. The appearance defects of the reinforced composite material can be greatly reduced.

Further, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body formed with a plurality of locking portions for restraining the laminate on one principal surface side thereof, and the locking portions inserted into the plate-like body. and the other plate-like body in which a plurality of locking holes are formed. Then, in a state in which the laminated body is sandwiched between one plate-like body and the other plate-like body, a locking portion protruding from the locking hole is processed on one main surface side of the other plate-like body. Thus, one plate-like body and the other plate-like body are brought into a connected state. According to this manufacturing method, a laminate in which a plurality of reinforcing fiber sheets are accurately aligned is formed, and the laminate is placed in a cavity of a molding die with high positional accuracy without performing a pre-shaping step. can be done.

In addition, in the method for producing a fiber-reinforced composite material of the present invention, the clamping plate includes one plate-like body in which a protrusion locking portion that protrudes toward one main surface side is formed, and and the other plate-shaped body projecting toward and formed with a projection engaging portion into which the projection locking portion is inserted. By inserting the projection engaging portion and at least a part of the laminated body into the projection engaging portion while the laminated body is sandwiched between one plate-shaped body and the other plate-shaped body, One plate-like body and the other plate-like body are brought into a connected state. According to this manufacturing method, a laminate in which a plurality of reinforcing fiber sheets are accurately aligned is formed, and the laminate is placed in a cavity of a molding die with high positional accuracy without performing a pre-shaping step. can be done.

Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of placing the laminate in the cavity of the molding die, both ends of the laminate are wrapped so that one plate-like body is wrapped inside the laminate. Each is folded inward, and the metal member is fitted into the concave portion of the lower mold. According to this manufacturing method, the plate-like body and the metal member can be used as alignment members when arranging them in the cavity, and the laminate can be uniformly stretched in the cavity using the plate-like body.

Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of arranging the laminate in the cavity of the molding die, the metal member is protruded toward one main surface of the other plate-like body, Both ends of the laminated body are folded inward so as to wrap the plate-like bodies of (1) inside the laminated body, and the metal members are fitted into the concave portions of the lower mold. According to this manufacturing method, the plate-like body and the metal member are used as an alignment member when the plate-like body and the metal member are arranged in the cavity. The laminate can be stretched uniformly by

Further, in the method for producing a fiber-reinforced composite material of the present invention, the metal member arranged on the clamping plate is a fastening member or a welding member, and the metal member is also arranged in the cavity of the molding die. According to this manufacturing method, the fiber-reinforced composite material can be assembled to the vehicle body frame without attaching a fastening member or the like in post-processing after releasing the fiber-reinforced composite material from the molding die. In addition, it is possible to suppress an increase in processing costs and improve the yield of materials.

Further, in the method for producing a fiber-reinforced composite material of the present invention, in the step of impregnating the laminate with a resin and curing it, the metal member and at least part of the clamping plate are fitted in the recess of the lower mold. Move the recess of the mold. With this manufacturing method, the laminate can be impregnated with the resin while the laminate is uniformly stretched in the cavity, and the flow pressure of the resin makes it difficult for the fiber bundles of the reinforcing fiber sheet to twist, and the molding is performed. Poor appearance of the subsequent fiber-reinforced composite material can be greatly reduced.

In the fiber-reinforced composite material provided with the fastening member of the present invention, a sandwiching plate is fixed to at least both ends of the laminated body in which the laminated reinforcing fiber sheets are impregnated with a resin and hardened. A fastening member is fixed to the upper surface of the plate. The clamping plate has one main surface formed with a plurality of engaging portions for restraining the laminated body, and the other plate-like member formed with a plurality of engaging holes into which the engaging portions are inserted. and a plate-like body of With this structure, in a state in which the laminated body is sandwiched between one plate-like body and the other plate-like body, the locking portion protruding from the locking hole is formed on one main surface side of the other plate-like body. By processing, one plate-like body and the other plate-like body can be brought into a connected state.

In addition, in the fiber-reinforced composite material equipped with the fastening member of the present invention, clamping plates are fixed to at least both ends of the laminated body in which the laminated reinforcing fiber sheets are impregnated with a resin and hardened. A fastening member is fixed to the upper surface of the clamping plate. The clamping plate includes one plate-like body formed with a protrusion locking portion projecting toward one main surface side, and a plate-like body formed with a protrusion locking portion projecting toward the one main surface side, into which the projection locking portion is inserted. and a plate-like body on which a protrusion engaging portion is formed. With this structure, the protrusion engaging portion and at least a part of the laminate can be inserted into the protrusion engaging portion while the laminate is sandwiched between one plate-like member and the other plate-like member. Then, one plate-like body and the other plate-like body can be brought into a connected state.

Moreover, in the fiber-reinforced composite material provided with the fastening member of the present invention, the fastening member is a member that is mechanically fastened to the body frame of the vehicle. With this structure, the fiber-reinforced composite material can be assembled to the vehicle body frame without attaching the fastening member to the fiber-reinforced composite material by post-processing. In addition, it is possible to suppress an increase in processing costs and improve the yield of materials.

BRIEF DESCRIPTION OF THE DRAWINGS It is (A) perspective view, (B) perspective view, (C) perspective view explaining the fiber reinforced composite material manufactured with the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is (A) perspective view and (B) perspective view explaining the fiber reinforced composite material manufactured with the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention. BRIEF DESCRIPTION OF THE DRAWINGS It is (A) sectional drawing and (B) top view explaining the molding die used with the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention. It is (A) sectional drawing explaining the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention, and (B) sectional drawing. It is (A) sectional drawing explaining the manufacturing method of the fiber reinforced composite material which concerns on one Embodiment of this invention, and (B) sectional drawing.

A fiber-reinforced composite material 10 and a method for producing the same according to an embodiment of the present invention will be described in detail below with reference to the drawings. In the following description, in principle, the same reference numerals are used for the same members, and repeated descriptions are omitted.

First, a fiber-reinforced composite material 10 produced by the method for producing a fiber-reinforced composite material 10 of the present embodiment will be described with reference to FIGS. 1 and 2. FIG.

FIG. 1(A) is a perspective view illustrating a fiber-reinforced composite material 10 of this embodiment. FIGS. 1(B) and 1(C) are perspective views illustrating clamping plates 11 and 12 fixed to the fiber-reinforced composite material 10 of this embodiment. FIGS. 2(A) and 2(B) are perspective views illustrating a modification of the clamping plates 11 and 12 shown in FIG. 1, and the clamping plate 21 fixed to the fiber-reinforced composite material 10 of the present embodiment. be.

As shown in FIG. 1A, the fiber-reinforced composite material 10 is CFRP (Carbon Fiber Reinforced Plastics), for example. The fiber-reinforced composite material 10 is produced by impregnating a laminate 18 (see FIG. 1(C)) in which a plurality of reinforcing fiber sheets 41 (see FIG. 4(A)) are laminated as a dry base material and curing the resin. formed by The fiber-reinforced composite material 10 can be used in aircraft, automobiles, and the like, and is used as a material that is highly effective in reducing weight.

As the reinforcing fibers forming the reinforcing fiber sheet 41, for example, carbon fibers, glass fibers, aramid fibers, or the like can be used. As a form of the reinforcing fiber sheet 41, a fabric material such as a woven fabric or a knitted fabric, or a UD material (unidirectional material) can be adopted.

As the resin 52 (see FIG. 5B), thermosetting resin such as epoxy resin, or thermoplastic resin such as polyamide (PA) or polypropylene (PP) can be used. The resin 52 is hardened while impregnating the laminate 18 of the reinforcing fiber sheets 41 , that is, entering the laminate 18 of the reinforcing fiber sheets 41 .

The fiber-reinforced composite material 10 is molded, for example, as a roof panel of a vehicle (not shown), and FIG. 1(A) shows the roof panel viewed from the rear side. The fiber-reinforced composite material 10 is molded into a gently curved shape, and its surface 10A is used as the design surface of the roof panel. Sandwiching plates 11 and 12 are disposed in the vicinity of both ends of the fiber-reinforced composite material 10 so as to fold back toward the back surface 10B. A plurality of fastening members 13 are fixed to the clamping plates 11 and 12 for mechanical fastening to the body frame of the vehicle.

Note that the clamping plates 11 and 12 are not limited to being arranged near both ends in one direction (the width direction of the vehicle). For example, when the roof panel is mechanically fastened to a roof cross member (not shown) in order to increase the rigidity of the roof, it is also possible to apply A new clamping plate may be provided and a plurality of fastening members 13 may be fixed to the clamping plate.

As shown in FIG. 1B, the clamping plate 11 mainly includes long plate-like bodies 14 and 15, a plurality of locking portions 16 formed on one main surface 14A side of the plate-like body 14, It has a plurality of locking holes 17 formed through the plate-like body 15 and a fastening member 13 fixed to the one main surface 15A side of the plate-like body 15 .

The plate-like bodies 14 and 15 are made of sheet metal or resin, for example, and although they are thin films, they have a thickness that can withstand press molding. The plate-like bodies 14 and 15 have the same shape, and are arranged so as to sandwich a laminate 18 (see FIG. 1(C)) in which a plurality of reinforcing fiber sheets 41 are laminated from the upper and lower surfaces thereof. As illustrated, a plurality of engaging portions 16 are arranged at regular intervals along the longitudinal direction of the plate-like body 14 on one main surface 14A of the plate-like body 14 . As the engaging portion 16, for example, a needle, a pin, or the like is used, and is adhesively fixed to the upper surface of one main surface 14A of the plate-like body 14. As shown in FIG.

On the other hand, one main surface 15A of the plate-like body 15 is formed with a plurality of locking holes 17 along the longitudinal direction of the plate-like body 15 at regular intervals. The locking hole 17 is a hole for inserting the locking portion 16 when the plate-like bodies 14 and 15 are superimposed, and is formed at the same interval as the locking portion 16 . Rivets, bolts, and nuts as fastening members 13 are appropriately adhered and fixed to one main surface 15A of the plate-like body 15 near both ends in the longitudinal direction.

As shown in FIG. 1C, the laminate 18 is arranged on the upper surface of one main surface 14A of the plate-like body 14. As shown in FIG. Then, the locking portion 16 pierces the fiber bundle (not shown) of the warp yarns of each reinforcing fiber sheet 41 (see FIG. 4A), which constitutes the laminate 18, for example, so that the laminate 18 is It is fixed on one main surface 14A of the plate-like body 14 . After that, the plate-like body 15 is arranged on the upper surface of the laminate 18 so that the locking portion 16 is inserted into the locking hole 17 of the plate-like body 15 . By bending the locking portions 16 protruding from the locking holes 17 of the plate-like body 15 , the plate-like bodies 14 and 15 are connected to each other, and the laminated body 18 is sandwiched between the sandwiching plates 11 . is realized. It should be noted that the plate-like members 14 and 15 may be connected to each other by crimping the region protruding from the locking hole 17 of the locking portion 16 .

In addition, the fastening member 13 is not limited to the case where it is fixed to the one main surface 15A of the plate-like body 15. For example, the fastening member 13 is fixed to the one main surface 14A of the plate-like body 14, Since an insertion hole through which the fastening member 13 is inserted is formed in the body 15, even when the fastening member 13 protrudes from one main surface 15A of the plate-like body 15 when the laminated body 18 is sandwiched, good. The clamping plate 12 also has the same shape as the clamping plate 11, and the same reference numerals are used for the same members.

As shown in FIG. 2(A), the clamping plate 21 mainly includes elongated plate-like bodies 22 and 23, a projection engaging portion 24 that protrudes toward one main surface 22A of the plate-like body 22, and a plate-like body. It has a protrusion engaging portion 25 that protrudes toward one main surface 23A side of the body 23 and engages with the protrusion locking portion 24, and a fastening member 13 that is fixed to the one main surface 23A side of the plate-like body 23. ing.

The plate-like bodies 22 and 23 are made of sheet metal or resin, for example. The plate-like bodies 22 and 23 are arranged so as to sandwich a layered body 18 (see FIG. 2(B)) in which a plurality of reinforcing fiber sheets 41 (see FIG. 4(A)) are laminated from the upper and lower surfaces thereof. As shown in the figure, on the main surface 22A side of the plate-like body 22, a projection engaging portion 24 is formed along the longitudinal direction of the plate-like body 22, from which a part of the plate-like body 22 projects. The protrusion engaging portion 24 is formed by press-molding the plate-like body 22, for example.

On the other hand, on one main surface 23A of the plate-like body 23, a protrusion engaging portion 25 is formed along the longitudinal direction of the plate-like body 23, from which a part of the plate-like body 23 protrudes. The projection engaging portion 25 is formed, for example, by press-molding the plate-like body 23 . Since the projection engaging portion 24 and a part of the laminate 18 are inserted into the projection engaging portion 25, the engaging space 26 of the projection engaging portion 25 becomes wider than the projection engaging portion 24. In addition, the space on the far side of the entrance is widened so that the protrusion locking portion 24 and the laminate 18 are difficult to come off.

It should be noted that the projection engaging portion 24 and the projection engaging portion 25 are not limited to the case where one is formed in the straight line shape. For example, the projection locking portion 24 and the projection engaging portion 25 are engaged with each other, and the laminate 18 may be supported therebetween. A case where the engaging portion 25 is formed may be used.

As shown in FIG. 2B, the laminated body 18 is arranged on the upper surface of one main surface 22A of the plate-like body 22, and after the plate-shaped body 23 is positioned and arranged on the upper surface of the laminated body 18, , the plate-shaped bodies 22 and 23 are connected to each other by pushing the projection locking portion 24 of the plate-shaped body 22 and the laminate 18 into the engagement space 26 of the projection engagement portion 25, and the laminated body 18 is sandwiched. A state of being sandwiched by the plates 21 is realized.

Next, with reference to FIG. 3, the molding die 31 used in the method for manufacturing the fiber-reinforced composite material 10 of this embodiment will be described.

FIG. 3(A) is a cross-sectional view illustrating a molding die 31 used in the method for producing the fiber-reinforced composite material 10 of this embodiment. FIG. 3(B) is a top view for explaining a mold surface 33A of the lower mold 33 of the molding mold 31 shown in FIG. 3(A).

As shown in FIG. 3A, the molding die 31 is composed of an upper die 32 and a lower die 33 . A cavity 34 is formed as a gap formed between the upper mold 32 and the lower mold 33 when they are closed. The cavity 34 has the same shape as the fiber-reinforced composite material 10 (see FIG. 1(A)) manufactured in this embodiment.

An injection hole 35 is formed through the upper mold 32 . Liquid or low-viscosity resin is supplied to the molding die 31 from the outside through the injection hole 35 . Here, one injection hole 35 is formed in the central portion of the upper mold 32, but the injection hole 35 may be formed in the peripheral portion of the upper mold 32, or a plurality of injection holes 35 may be formed. can be Furthermore, the injection hole 35 may be formed in the lower mold 33 .

As shown in FIG. 3B, two concave portions 36 and 37 are formed in the mold surface 33A of the lower mold 33 near both ends of the cavity 34 so as to extend in the vertical direction of the drawing. Clamping plates 11 and 12 (see FIG. 1A) provided near both ends of the laminate 18 (see FIG. 1C) are fitted into the recesses 36 and 37, so that the laminate 18 forms a cavity. It is also an area for arranging within 34 with good positional accuracy. As described above, the fastening members 13 are fixed to the upper surface of the main surface 15A of the plate-like body 15 in the vicinity of both ends of the holding plates 11 and 12 in the longitudinal direction. Therefore, in the recesses 36 and 37, recesses 38 in which the fastening members 13 are fitted are further formed in communication near both ends in the up-down direction of the paper surface.

The lower mold 33 is composed of a known split mold, and the forming regions of the recesses 36, 37, 38 of the lower mold 33 are formed as indicated by an arrow 39 after the laminate 18 is arranged in the cavity 34. In addition, it can be slid in the horizontal direction of the paper surface. Although the details will be described later, the forming regions of the recesses 36, 37, and 38 of the lower mold 33 are slid, so that the cavity 34 is formed in the step of impregnating the laminate 18 with the resin 52 (see FIG. 5B). The inner laminations 18 can be maintained in a stretched state.

Next, a method for manufacturing the fiber-reinforced composite material 10 of the present embodiment will be described with reference to FIGS. 4 and 5. FIG. 1 to 3 and the description thereof will be referred to as needed in the description of the above manufacturing method, and in principle the same reference numerals will be used for the same members, and repeated description will be omitted.

4(A) and 4(B) are cross-sectional views illustrating the process of attaching the clamping plates 11 and 12 to the laminate 18 described above. 5(A) and 5(B) are cross-sectional views illustrating the process of impregnating the above-described laminate 18 with a resin to form the fiber-reinforced composite material 10. As shown in FIG.

As shown in FIG. 4(A), a plurality of reinforcing fiber sheets 41 having the same shape are prepared and laminated while being aligned with each other to form a laminate 18 . In this embodiment, the reinforcing fiber sheet 41 is, for example, a fabric woven using fiber bundles in which 3000 carbon fibers are bundled together as warp and weft.

As illustrated, the reinforcing fiber sheet 41 is a dry base material, and by sandwiching the vicinity of both ends of the laminate 18 between the sandwiching plates 11 and 12, the reinforcing fiber sheets 41 are aligned with each other and the laminate 18 is held. can be fixed as

In this embodiment, as shown in FIG. 1(B), each reinforcing fiber sheet 41 is attached to an engaging portion 16 consisting of needles or pins arranged on one main surface 14A of the plate-like body 14 at regular intervals. The laminated body 18 is fixed on one main surface 14A of the plate-like body 14 by pricking the warp fiber bundle (not shown). It should be noted that the reinforcing fiber sheets 41 may be pierced into the locking portion 16 one by one, or may be pierced into the locking portion 16 from the laminated body 18 state.

Thereafter, as shown in FIG. 1(C), the engaging portion 16 protruding from the reinforcing fiber sheet 41 on the uppermost surface is inserted into the engaging hole 17 of the plate-like body 15, and the plate-like body is attached to the upper surface of the laminate 18. 15 are placed. Then, the locking portions 16 protruding from the locking holes 17 of the plate-like body 15 are bent, the plate-like bodies 14 and 15 are connected to each other, and the laminated body 18 is sandwiched between the sandwiching plates 11 and 12. and

As shown in FIG. 4B, both ends of the laminate 18 are folded inward along the clamping plates 11 and 12 . Specifically, the vertical positions of the plates 14 and 15 are reversed, and both ends of the laminate 18 are rotated approximately 180 degrees so that the plate 14 is hidden inside the laminate 18 .

As shown in FIG. 5A, the laminate 18 in the state shown in FIG. Here, as shown in FIG. 3(B), two recesses 36, 37, 38 are formed in the mold surface 33A of the lower mold 33. 12 (see FIG. 1A) and the fastening member 13 are fitted, the laminate 18 is arranged in a state of being aligned with the cavity 34 . Note that the laminate 18 is not a preform that is preformed in advance.

After that, the forming regions of the recesses 36 , 37 , 38 of the lower mold 33 are slid in the direction indicated by the arrow 51 , that is, toward the outside of the cavity 34 , so that the laminate 18 is elongated within the cavity 34 . state. It should be noted that the distance between the concave portions 36 and 37 may be set wider, and the laminate 18 may be in an extended state when the laminate 18 is installed in the lower mold 33. In this case, the lower mold The sliding mechanism of 33 is omitted.

At this time, at least a portion of the clamping plates 11 and 12 and the fastening member 13 are fitted into the concave portions 36 , 37 , and 38 of the lower mold 33 , so that the stack 18 is aligned with the clamping plates 11 and 12 . contact and the entire laminate 18 can be stretched uniformly. In particular, when both ends of the laminate 18 are folded back along the clamping plates 11 and 12, the laminate 18 is pulled, and compared with the case where the fiber bundle is simply stabbed by the locking portion 16 and pulled. As a result, it becomes difficult for the laminate 18 to come off from the clamping plates 11 and 12 .

As shown in FIG. 5(B), as indicated by arrow 51, the forming regions of the recesses 36, 37, 38 of the lower mold 33 are slid to extend the laminate 18, and the injection hole 35 is opened. By injecting the resin 52 into the cavity 34 via the cavity 34 , the laminate 18 is impregnated with the resin 52 inside the cavity 34 . It should be noted that, in the step of impregnating the resin 52, the clamping plates 11 and 12 may be press-molded by the mold surface of the molding die 31. FIG. In this case, the flexibility of the product shape of the fiber-reinforced composite material 10 after molding can be increased.

After the step of injecting the resin 52 described above is completed, the resin 52 is cured inside the cavity 34 . When the resin 52 is a thermosetting resin such as an epoxy resin, the resin 52 is heated to about 100° C. or higher to cause a curing reaction. On the other hand, when the resin 52 is a thermoplastic resin such as polypropylene, the resin 52 is hardened by cooling to 20° C. to 60° C. or less (preferably, for example, about 40° C.).

After the resin 52 has sufficiently hardened inside the cavity 34, the upper mold 32 and the lower mold 33 are separated, and then the fiber-reinforced composite material 10 shown in FIG. 1(A) is taken out. In this embodiment, the surface 10A of the fiber-reinforced composite material 10 is used, for example, as the design surface of the roof panel. A plurality of fastening members 13 for mechanical fastening to the body frame of the vehicle are fixed to the clamping plates 11 and 12 arranged near both ends of the fiber-reinforced composite material 10 .

With this structure, after releasing the fiber reinforced composite material 10 from the molding die 31, the fiber reinforced composite material 10 can be attached to the vehicle body frame as a roof panel without attaching the fastening member 13 or the like in post-processing. . As a result, an increase in processing costs after molding the fiber-reinforced composite material 10 can be suppressed.

Furthermore, by the above-described manufacturing method, the sandwiching plates 11 and 12 and the fastening members 13 are used to extend the laminate 18, and the resin is filled in the cavity 34, whereby the reinforcing fiber sheet 41 is formed by the flow pressure of the resin. The fiber bundles are less likely to be twisted, and poor appearance of the molded fiber-reinforced composite material 10 can be greatly reduced. In addition, by using the areas where the clamping plates 11 and 12 are provided as attachment areas to the vehicle body frame without cutting them off, the yield of materials can be improved.

In this embodiment, a method for manufacturing the fiber-reinforced composite material 10 by a resin transfer molding (RTM) method in which resin is filled into the cavity 34 of the molding die 31 has been described, but the present invention is not limited to this case. For example, the fiber-reinforced composite material 10 is molded by a PCM (Prepreg Compression Molding) method in which a prepreg obtained by impregnating a reinforcing fiber sheet with a resin is placed in a cavity of a molding die and high temperature and high pressure are applied to the reinforcing fiber sheet of the prepreg. Even if you do. In this case as well, the laminate composed of a plurality of reinforcing fiber sheets is stretched in the cavity in the same manner as in the above-described manufacturing method, so that even if high temperature and high pressure are applied, the reinforcing fiber sheet will not be formed. The fiber bundles are less likely to be twisted, and poor appearance of the molded fiber-reinforced composite material 10 can be greatly reduced.

Moreover, although the case where the fastening member 13 is used as the metal member fixed to the clamping plates 11 and 12 has been described, the present invention is not limited to this case. For example, welding members may be used as the metal members fixed to the clamping plates 11 and 12 . In this case, too, the welded member can be used as a welding point, and the molded fiber-reinforced composite material 10 can be assembled to a vehicle frame or the like without post-processing, and the same effect as described above can be obtained.

Moreover, although the case where the laminate 18 uses the reinforcing fiber sheet 41 made entirely of carbon fibers has been described, the present invention is not limited to this case. For example, a reinforcing fiber sheet 41 made of glass fiber may be disposed on at least the top surface and the bottom surface of the laminate 18 to insulate the laminate 18 . Alternatively, the metal member such as the fastening member 13 fixed to the clamping plates 11 and 12 may be insulated by painting or coating with the resin 52 . In this case, the risk of corrosion due to electrolytic corrosion of the laminate 18 can be more reliably prevented. In addition, various modifications are possible without departing from the gist of the present invention.

REFERENCE SIGNS LIST 10 Fiber-reinforced composite material 11, 12, 21 Clamping plate 13 Fastening member 14, 15, 22, 23 Plate-like body 16 Locking portion 17 Locking hole 18 Laminate 24 Projection locking portion 25 Projection engaging portion 26 Engaging space 31 molding die 32 upper die 33 lower die 34 cavity 36, 37, 38 concave portion 41 reinforcing fiber sheet 52 resin

Claims (7)

In a method for producing a fiber-reinforced composite material, a fiber-reinforced composite material is formed by arranging a laminate of reinforcing fiber sheets in a molding die, impregnating the laminate with a resin and curing the laminate,
a step of fixing at least the vicinities of opposite end portions of the laminate with clamping plates that sandwich the laminate between them;
Both ends of the laminate are folded inward so that the holding plate is vertically reversed, and at least a part of the holding plate is fitted into a concave portion of the mold surface of the lower mold of the molding die. placing the laminate in a cavity of the mold, such that
and forming the fiber-reinforced composite material by injecting the resin into the cavity while the laminated body is stretched, impregnating the laminated body with the resin and curing the resin. A method for producing a fiber-reinforced composite material. The clamping plate has one plate-like body formed with a plurality of locking portions for restraining the laminated body on one main surface thereof, and a plurality of locking holes into which the locking portions are inserted. and the other plate-shaped body,
In a state in which the laminated body is sandwiched between the one plate-shaped body and the other plate-shaped body, the locking protrudes from the locking hole on one main surface side of the other plate-shaped body. 2. The method for producing a fiber-reinforced composite material according to claim 1, wherein the one plate-like body and the other plate-like body are brought into a connected state by processing the portion. The clamping plate includes one plate-like body formed with a protrusion engaging portion protruding toward one main surface thereof, and a plate-like member protruding toward the one main surface thereof into which the protrusion engaging portion is inserted. and the other plate-shaped body formed with the projection engaging portion formed thereon,
With the laminated body sandwiched between the one plate-shaped body and the other plate-shaped body, the projection engaging portion and at least a part of the laminated body are inserted into the projection engaging portion. 2. The method for producing a fiber-reinforced composite material according to claim 1, wherein the one plate-like body and the other plate-like body are brought into a connected state. A metal member is fixed to the one main surface of the other plate-shaped body,
In the step of placing the laminate in the cavity of the molding die, the both ends of the laminate are folded inward so that the one plate-like body is wrapped inside the laminate, and 4. The method for producing a fiber-reinforced composite material according to claim 2, wherein the metal member is fitted into the recess of the lower mold. A metal member is fixed to the one main surface of the one plate-shaped body, and an insertion hole through which the metal member is inserted is formed in the other plate-shaped body,
In the step of arranging the laminate in the cavity of the molding die, the metal member is protruded toward the one main surface of the other plate-like body, and then the one plate-like body is placed in the laminate. 4. The method according to claim 2 or 3, wherein the both ends of the laminate are folded inward so as to wrap the laminated body inside the body, and the metal member is fitted into the recess of the lower mold. A method for producing the described fiber-reinforced composite material. 6. The method for producing a fiber-reinforced composite material according to claim 4, wherein the metal member is a fastening member or a welding member. In the step of impregnating and curing the resin in the laminate, the recess of the lower mold is movable while the metal member and at least a part of the clamping plate are fitted in the recess of the lower mold. 7. The method for producing a fiber-reinforced composite material according to any one of claims 4 to 6, wherein the laminate is stretched.

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