JP7252021B2 - Resin injection molded product and its manufacturing method - Google Patents

Description

The present invention provides a resin injection molded product in which a fiber reinforced resin layer formed by impregnating a fiber sheet with a matrix resin is provided on a core material made of a resin foam, and the resin using the RTM (Resin Transfer Molding) method. The present invention relates to a method for manufacturing an injection-molded article.

In the method of manufacturing a resin injection molded product using the RTM method, a fiber sheet is set in a mold together with a core material, the mold is closed, and a cavity (molding) in which the fiber sheet and the core material are arranged is formed. space) is decompressed, and a liquid matrix resin is injected into the decompressed cavity under pressure to impregnate the fiber sheet with the matrix resin. Forming a reinforced resin layer is performed (see, for example, Patent Document 1).

Resin foam is used for the core material of the resin injection molded product manufactured using the RTM method in order to reduce the weight, and a relatively thick thick portion is provided to increase the rigidity. Sometimes. In such a resin injection molded article, the thick portion of the core material protrudes to one side in the thickness direction with respect to other relatively thin thin portions, for example, the back side of the resin injection molded article, and the matrix resin is applied to the fiber sheet. A fiber-reinforced resin layer impregnated with a material is provided so as to cover the protruding portion of the thick portion (see, for example, Patent Document 2).

JP 2005-169786 A JP-A-05-096567

In the production of a resin injection molded product in which the core material has a thick portion, the matrix resin injected into the cavity of the mold stagnates and becomes smooth as it flows through the portion corresponding to the protruding portion of the thick portion in the core material. hard to flow. For this reason, the matrix resin tends to accumulate in the cavity corresponding to the protruding portion of the core material, and the pressure of the matrix resin applied to the protruding portion of the core material at the thick portion increases, causing the core material to protrude. The part that has been pressed is likely to be crushed by the pressure of the matrix resin.

In that case, the temperature of the matrix resin rises due to the excessive filling of the matrix resin in the portion where the core material is crushed in the cavity. It deteriorates or turns brown. In addition, in the cavity, the portion where the core material is crushed is overfilled with the matrix resin, and the other portions are insufficiently filled with the matrix resin, resulting in non-impregnated portions in the fiber sheet. .

The present invention has been made in view of such a point, and an object of the present invention is to provide a resin injection-molded product having a core material having a thick portion, in which the portion protruding from the thick portion of the core material is a matrix resin. To suppress crushing due to the pressure of

In order to achieve the above object, in the present invention, the structure of the core material is devised so that the matrix resin injected into the cavity of the molding die smoothly flows through the portion corresponding to the thick-walled portion of the core material. bottom.

Specifically, the present invention comprises a plate-like core material made of a resin foam, and a fiber sheet-like material impregnated with a matrix resin provided on at least one side surface in the thickness direction of the core material. The object is a resin injection molded product having a fiber reinforced resin layer.

In the resin injection molded product according to the present invention, the core material has a relatively thin thin-walled portion and a relatively thick thick-walled portion protruding in the thickness direction of the core material with respect to the thin-walled portion. . A resin flow path extending from one side to the other side in the in-plane direction of the core material is provided in the protruding portion of the thick portion of the core material, and the resin flow path includes a matrix of the fiber-reinforced resin layer. Filled with resin. The term "in-plane direction" as used herein means any direction orthogonal to the thickness direction of the core material.

According to this configuration, since the resin flow path extending from one side to the other side in the in-plane direction of the core material is provided in the protruding portion of the thick portion of the core material, resin injection molding is performed using the RTM method. Goods can be suitably manufactured. That is, in the production of a resin injection molded product using the RTM method, the liquid matrix resin injected into the cavity of the mold smoothly flows through the resin channel at the protruding portion of the thick portion of the core material. flow. As a result, the matrix resin is less likely to accumulate in the cavity corresponding to the protruding portion of the core material thick portion, and the protruding portion of the core material can be suppressed from being crushed by the pressure of the matrix resin.

In the above-described resin injection-molded product, a groove-shaped concave portion formed from at least one side surface in the in-plane direction of the core material to an end surface on the protruding side of the protruding portion of the thick-walled portion of the core material is used as the resin flow path. may be provided.

According to this configuration, since the resin flow path is formed by the groove-shaped concave portion, in the production of a resin injection molded product using the RTM method, the liquid matrix resin injected into the cavity of the mold is spread out over the thickness of the core material. Smooth flow can be achieved by allowing the fluid to flow through the groove-shaped concave portion at the portion corresponding to the protruding portion of the meat portion. As a result, the above effects of the present invention can be specifically obtained.

In the above-described resin injection molded article, a through hole penetrating from one side to the other side in the in-plane direction of the core material may be provided as the resin flow path in the protruding portion of the thick portion of the core material.

According to this configuration, since the resin flow path is constituted by the through hole, in the production of the resin injection molded product using the RTM method, the liquid matrix resin injected into the cavity of the molding die is applied to the thickness of the core material. Smooth flow can be achieved by circulating through the through-holes at a location corresponding to the protruded portion. As a result, the above effects of the present invention can be specifically obtained.

In the resin injection molded product, a plurality of resin flow paths may be provided at intervals.

According to this configuration, since a plurality of resin flow paths are provided at intervals from each other, in the production of a resin injection molded product using the RTM method, the liquid matrix resin injected into the cavity of the mold is divided into a plurality of resin flow paths. This is advantageous for allowing the matrix resin to flow smoothly through the passage and to the portion corresponding to the protruding portion of the thick portion of the core material in the cavity.

In the above-described resin injection molded product, the resin flow path may also be provided on the peripheral side surface of the protruding portion of the thick portion of the core material so as to extend along the circumferential direction of the thick portion.

According to this configuration, the resin flow path is also provided on the peripheral side surface of the projecting portion of the thick portion so as to extend along the peripheral direction. The matrix resin injected into the cavity flows along the resin channel and smoothly flows along the side portion of the protruding portion of the thick portion, so that the cavity can be quickly filled with the matrix resin. As a result, the above effects of the present invention can be suitably obtained, and the productivity of the resin injection-molded product can be improved.

In the resin injection-molded product, the protruding portion of the thick portion of the core material may form a convex portion extending in at least one in-plane direction of the core material.

According to this configuration, since the protruding portion of the thick portion of the core material constitutes a convex portion extending in at least one direction, the protruding portion of the thick portion functions as a reinforcing rib, thereby improving the strength of the resin injection molded product. Rigidity can be increased.

In the resin injection molded product, the protruding portion of the thick portion of the core material may be provided in an annular shape extending along the peripheral edge of the core material.

According to this configuration, since the protruding portion of the thick portion of the core member is provided in an annular shape extending along the peripheral edge of the core member, the thick portion can provide a reinforcing effect regardless of the bending direction of the core member. Therefore, providing such an annular protruding portion of the thick-walled portion is advantageous in increasing the rigidity of the resin injection-molded product.

In the resin injection molded product, the protruding portion of the thick portion of the core material may be provided on the back side of the core material. In this case, the protruding portion of the thick portion of the core material may not be provided on the front side of the core material.

According to this configuration, since the protruding portion of the thick portion is provided only on the back side of the core material, the design surface of the resin injection-molded product can be configured to be flat on the front side of the core material. Such a resin injection molded product is suitable for exterior panels (outer surface portions of body panels) for automobiles and the like.

The present invention is also directed to a method of manufacturing a resin injection molded article. The method for producing a resin injection-molded article according to the present invention comprises a preparation step of preparing a plate-shaped core material made of a resin foam and a fiber sheet; After the core material is placed on at least one surface in the thickness direction, the core material and the fiber sheet are arranged in the mold by closing the mold. and a setting step of forming a cavity.

The method for producing a resin injection-molded article according to the present invention further includes an impregnation step of impregnating the fiber sheet-like material with the matrix resin by injecting the matrix resin into the cavity, and curing the matrix resin impregnated in the fiber sheet-like material. Thus, a curing step of molding a fiber reinforced resin layer in which the fiber sheet-like material is solidified with the matrix resin, and a resin injection molded product in which the fiber reinforced resin layer is molded on the core material are opened by opening the mold. and a demolding step of removing from the mold.

In the method for manufacturing a resin injection-molded product according to the present invention, in the preparation step, a relatively thin-walled portion as a core material and a relatively A core member is prepared, which has a thick wall portion and a resin flow path extending from one side to the other side in the in-plane direction of the core member at a projecting portion of the thick wall portion. Then, in the impregnation step, the matrix resin is circulated and filled in the resin flow channel at the portion corresponding to the protruding portion of the thick portion of the core material with respect to the cavity.

According to this configuration, a core material having a resin flow path extending from one side to the other side in the in-plane direction is used as the core material. In the above, the liquid matrix resin injected into the cavity of the molding die flows smoothly by flowing through the resin channel at the protruding portion of the thick portion of the core material. As a result, the matrix resin is less likely to accumulate in the cavity corresponding to the protruding portion of the core material thick portion, and the protruding portion of the core material can be suppressed from being crushed by the pressure of the matrix resin.

In the method for manufacturing a resin injection-molded product, in the preparation step, the groove-shaped concave portion, which is the resin flow path, protrudes from at least one side surface of the core material in the in-plane direction of the projecting portion of the thick-walled portion as the core material. You may prepare the core material formed over the end surface of the side.

According to this configuration, the groove-shaped concave portion, which is the resin flow path, is formed as the core material from at least one side surface in the in-plane direction of the core material to the end surface of the projecting side in the protruding portion of the thick portion. In the impregnation step, the liquid matrix resin injected into the cavity of the molding die is circulated in the groove-shaped concave portion at the portion corresponding to the protruding portion of the thick portion of the core material. It can flow smoothly. As a result, the above effects of the present invention can be specifically obtained.

In the method for manufacturing a resin injection-molded product, in the preparation step, the through hole, which is the resin flow path, penetrates from one side to the other side in the in-plane direction of the core material in the projecting portion of the thick portion as the core material. You may prepare a core material that is

According to this configuration, as the core material, the through hole, which is the resin flow path, penetrates from one side to the other side in the in-plane direction of the core material in the projecting portion of the thick portion. Therefore, in the impregnation step, the matrix resin injected into the cavity of the mold can flow smoothly through the through holes at the locations corresponding to the thick portions of the core material. As a result, the above effects of the present invention can be specifically obtained.

In the method for manufacturing a resin injection molded product, in the preparing step, a core material having a plurality of resin flow paths spaced apart from each other may be prepared as the core material.

According to this configuration, since a core material in which a plurality of resin flow paths are provided at intervals is used as the core material, in the impregnation step, the liquid matrix resin injected into the cavity of the mold is This is advantageous in that the matrix resin flows through each of the plurality of resin channels and smoothly flows through the portions corresponding to the protruding portions of the thick portion of the core material.

In the method for manufacturing a resin injection-molded product, in the preparation step, a resin flow path is provided as a core material so as to extend along the circumferential direction of the thick portion on the side peripheral surface of the protruding portion of the thick portion. You may prepare a core material that is

According to this configuration, since the core material is provided so as to extend along the circumferential direction of the side peripheral surface of the portion where the thick-walled portion protrudes, the resin flow path is used as the core material. In the step, the matrix resin injected into the cavity of the molding die smoothly flows along the resin channel along the side portion of the protruding portion of the thick portion, so that the cavity can be quickly filled with the matrix resin. As a result, the above effects of the present invention can be suitably obtained, and the productivity of the resin injection-molded product can be improved.

In the method for manufacturing a resin injection-molded product, in the preparation step, a core material is prepared as the core material, the protruding portion of the thick portion of which forms a convex portion extending in at least one in-plane direction of the core material. may

According to this configuration, the protruding portion of the thick portion forms a convex portion extending in at least one direction as the core material. Therefore, the protruding portion of the thick portion functions as a reinforcing rib. It is possible to increase the rigidity of the resin injection molded product.

In the method for manufacturing a resin injection-molded product, in the preparing step, a core member having a ring shape in which the protruding portion of the thick portion extends along the peripheral edge of the core member may be prepared as the core member.

According to this configuration, since the core member is provided in an annular shape in which the protruding portion of the thick portion extends along the peripheral edge of the core member, the thickness of the core member is increased regardless of the bending direction of the core member. Reinforcement action by the part is obtained. Therefore, the use of a core member having such an annular protruding thick-walled portion is advantageous in increasing the rigidity of the resin injection molded product.

In the method for manufacturing a resin injection molded product, in the preparation step, a core material having a protruding portion of the thick portion provided on the back side of the core material may be prepared as the core material. In this case, as the core material, a core material in which the protruding portion of the thick portion is not provided on the front side of the core material may be prepared.

According to this configuration, since the core material in which the protruding portion of the thick portion is provided only on the back side of the core material is used as the core material, the design surface of the resin injection molded product is flattened on the front side of the core material. can be configured to Such a resin injection molded product is suitable for exterior panels (outer surface portions of body panels) for automobiles and the like.

According to the resin injection molded article and the method for producing the same according to the present invention, in a resin injection molded article having a thick portion of the core material, the portion protruding from the thick portion of the core material is suppressed from being crushed by the pressure of the matrix resin. can do. As a result, in the resin injection-molded article, deterioration and discoloration of the matrix resin of the fiber-reinforced resin layer can be suppressed, and the occurrence of portions not impregnated with the matrix resin in the fiber sheet can be suppressed.

FIG. 1 is a schematic perspective view of a resin injection molded product according to the first embodiment. FIG. 2 is a schematic plan view of a core material that constitutes the resin injection molded product according to the first embodiment. FIG. 3 is a cross-sectional view of a resin injection molded product taken along line III--III in FIG. FIG. 4 is a cross-sectional view of the resin injection molded product taken along line IV-IV of FIG. 5A and 5B are diagrams showing components of a molding apparatus and a resin injection molded part used in the method for manufacturing a resin injection molded product according to the first embodiment. FIG. 6 is a diagram showing a setting step in the method of manufacturing a resin injection molded product according to the first embodiment. FIG. 7 is a diagram showing the state of the impregnation step in the method of manufacturing the resin injection molded product according to the first embodiment. FIG. 8 is a view showing the thick portion of the resin-injected molded article in the molding die and the surrounding molding locations, which are surrounded by VIII in FIG. 7 . FIG. 9 is a diagram showing a demolding step in the method of manufacturing a resin injection molded product according to the first embodiment. FIG. 10 is a schematic perspective view of a resin injection molded product according to the second embodiment. FIG. 11 is a schematic plan view of a core material that constitutes a resin injection molded product according to the second embodiment. FIG. 12 is a cross-sectional view of the resin injection molded product taken along line XII-XII in FIG. FIG. 13 is a diagram showing the state of the impregnation step in the method of manufacturing the resin injection molded product according to the second embodiment. FIG. 14 is a view showing the thick portion of the resin injection-molded product in the molding die and the surrounding molding locations, which are surrounded by XIV in FIG. 13 . FIG. 15 is a schematic plan view of a resin injection molded product according to a modification. FIG. 16 is a cross-sectional view of the resin injection molded product taken along line XVI--XVI of FIG.

Exemplary embodiments are described in detail below on the basis of the drawings.

<<1st Embodiment>>
FIG. 1 is a schematic perspective view of a resin injection molded product 1 according to the first embodiment. FIG. 2 is a schematic plan view of the core material 3 that constitutes the resin injection molded product 1. As shown in FIG. FIG. 3 is a cross-sectional view of the resin injection molded product 1 taken along line III--III in FIG. FIG. 4 is a cross-sectional view of the resin injection molding 1 taken along line IV--IV of FIG. A resin injection molded product 1 shown in FIG. 1 is used, for example, as a roof panel that constitutes the outer surface of the vehicle body roof of an automobile.

- Composition of resin injection molding -
As shown in FIGS. 1, 3 and 4, this resin injection molded product 1 comprises a plate-shaped core material 3 made of resin foam and a fiber-reinforced resin layer 5 provided outside the core material 3. I have.

As shown in FIGS. 1 and 2, the core material 3 is rectangular in plan view. The core material 3 has a relatively thin thin portion 7 and a relatively thick thick portion 9 . A thickness t1 of the thin portion 7 is, for example, 3 mm or more and 10 mm or less. A thickness t2 of the thick portion 9 is, for example, 10 mm or more and 40 mm or less. The thick portion 9 is provided at the peripheral portion of the core material 3 and protrudes to one side of the thin portion 7 in the thickness direction of the core material 3 , specifically, to the back side of the core material 3 .

A protruding portion of the thick portion 9 is provided in a rectangular annular shape extending along the peripheral edge of the core material 3 and constitutes a thick convex portion 11 surrounding the thin portion 7 . The thick-walled protrusions 11 extend in two directions in the in-plane direction of the core material 3 , function as reinforcing ribs, and play a role in increasing the rigidity of the resin injection molded product 1 . An outer peripheral side surface 13 facing the outer peripheral side of the thick convex portion 11 is formed substantially parallel to the thickness direction of the core material 3 . On the other hand, the inner peripheral side surface 15 facing the inner peripheral side of the thick convex portion 11 has a thickness of the thick convex portion 11 as it goes inward (center side) of the core material 3 with respect to the thickness direction of the core material 3 . is inclined so that

The thick convex portion 11 is provided with a resin flow path 17 for circulating a liquid matrix resin 29 with which the fiber reinforced resin layer 5 is impregnated in the production of the resin injection molded product 1 . The resin flow path 17 includes a first groove-shaped concave portion 19 for circulating the matrix resin 29 from the outer peripheral side to the inner peripheral side of the thick convex portion 11 , and the matrix resin 29 on the outer peripheral side of the thick convex portion 11 . A second groove-like concave portion 21 is provided for circulating.

A plurality (13 in the example shown in FIGS. 1 and 2) of the first groove-shaped concave portions 19 are provided at intervals in the circumferential direction of the thick convex portion 11 . Each of these first groove-shaped concave portions 19 is formed on one side surface of the thick convex portion 11 in the in-plane direction of the core material 3 , specifically, the end surface 22 on the protruding side from the outer peripheral side surface 13 of the thick convex portion 11 . (that is, the back surface of the thick convex portion 11) and is open to the inner peripheral side of the thick convex portion 11. As shown in FIG. A depth d1 of the first groove-shaped concave portion 19 is, for example, 1 mm or more and 5 mm or less.

The second groove-shaped concave portion 21 is provided at the base end portion of the outer peripheral side surface 13 of the thick convex portion 11 along the entire circumference of the thick portion 9 along the circumferential direction. The second groove-shaped concave portion 21 allows the plurality of first groove-shaped concave portions 19 to communicate with each other on the outer peripheral side surface 13 of the thick convex portion 11 . The depth d2 of the second groove-shaped concave portion 21 is, for example, 1 mm or more and 5 mm or less. Both the first groove-shaped recesses 19 and the second groove-shaped recesses 21 are filled with the matrix resin 29 of the fiber-reinforced resin layer 5 .

The core material 3, as shown in FIGS. and a rectangular ring-shaped second core material component 25 . The first core material component 23 constitutes the entire thin portion 7 and the portion on the front side of the thick portion 9 in the core material 3 . The second core material component 25 constitutes the portion behind the thick portion 9 of the core material 3 , that is, the thick convex portion 11 .

Each of the first core material composition 23 and the second core material composition 25 is composed of a large number of foamed particles and a shell covering the large number of foamed particles. It is a resin foam that is bound and integrated with a shell. The expanded particles have a shape such as a sphere, an ellipsoid, or a cylinder, and are made of a thermoplastic resin. Examples of thermoplastic resins used for expanded beads include polyester resins and polyamide resins.

The shell is made of thermoplastic resin containing reinforcing fibers and inorganic particles. As the reinforcing fibers, for example, one or more short fibers selected from organic fibers such as carbon fibers, glass fibers, and cellulose may be employed. The inorganic particles are made of talc or calcium carbonate, for example. Examples of thermosetting resins used for the shell include vinyl ester resins, phenolic resins, urethane resins, unsaturated polyester resins, and epoxy resins.

The fiber reinforced resin layer 5 is composed of a fiber sheet 27 and a matrix resin 29 containing the fiber sheet 27, and the fiber sheet 27 is impregnated with the matrix resin 29. As shown in FIG. The reinforcing fibers forming the fiber sheet-like material 27 are bound and integrated by a matrix resin 29 . The fiber-reinforced resin layer 5 covers the entire core material 3, and the fiber sheet-like material 27 consists of a first fiber sheet-like material 31 covering the surface of the core material 3, and a rear surface and both side surfaces of the core material 3. and a second fibrous sheet 33 covering the

Both the first fibrous sheet-like material 31 and the second fibrous sheet-like material 33 are aggregates of reinforcing fibers, and can take forms such as woven fabrics and non-woven fabrics. For example, the first fiber sheet 31 and the second fiber sheet 33 employ a configuration in which a plurality of UD (Uni-Direction) materials in which a large number of reinforcing fibers are aligned in one direction are laminated. Alternatively, a configuration in which a single layer or multiple layers of NCF (Non-Crimp Fabric) in which fiber bundles laminated in multiple directions are stitched with auxiliary yarns may be employed.

Examples of reinforcing fibers include inorganic fibers such as carbon fibers, glass fibers and ceramic fibers, metal fibers such as stainless steel fibers and steel fibers, and organic fibers such as aramid fibers and polyethylene fibers. Among them, carbon fiber has excellent mechanical properties in spite of its light weight. For the first fiber sheet-like material 31 and the second fiber sheet-like material 33, one type of reinforcing fiber may be used alone, or two or more types of reinforcing fiber may be used in combination.

The matrix resin 29 is cured in a state in which the first fiber sheet 31 and the second fiber sheet 33 are evenly impregnated. The matrix resin 29 hardens the first fiber sheet 31 and the second fiber sheet 33 and covers the outer surfaces of both the fiber sheets 31 and 33 to form the surface layer of the resin injection molded product 1 . forming That is, the outer shell of the resin injection molded product 1 is made of the matrix resin 29 . A thermosetting resin is used as the matrix resin 29 .

Thermosetting resins used for the matrix resin 29 include, for example, epoxy resins, phenolic resins, unsaturated polyester resins, urethane resins, silicones, vinyl ester resins, and cyanate ester resins. Among them, epoxy resins and vinyl ester resins are excellent in heat resistance, impact absorption, and chemical resistance. The thermosetting resin may contain additives such as curing agents, curing accelerators, and flame retardants. Further, the matrix resin 29 may be a single type of thermosetting resin, or two or more types of thermosetting resins may be used in combination.

- Manufacturing method of resin injection molding -
The resin injection molded product 1 having the above configuration is manufactured using the RTM method. FIG. 5 shows a molding apparatus 101 used for manufacturing the resin injection molded product 1 and the constituent members of the resin injection molded product 1 (core material 3, first fiber sheet 31 and second fiber sheet 33). It is a figure which shows . The resin injection molding product 1 is manufactured using a molding apparatus 101 shown in FIG.

The molding apparatus 101 includes a molding die 103 for molding the fiber reinforced resin layer 5 on the core material 3, a vacuum suction device 105 for decompressing the cavity 119 in the molding die 103, and a matrix resin in the cavity 119 in the molding die 103. 29 and a heating device (not shown) for controlling the temperature of the molding die 103 .

The mold 103 is composed of a cavity mold 111 and a core mold 113 which are arranged to face each other. The cavity mold 111 is a fixed mold and has a first molding surface 115 on which the first fiber sheet 31 is placed together with the core material 3 . The first molding surface 115 is a surface for molding the surface of the resin injection molded product 1, and although it is shown in a flat shape in FIG. there is The core mold 113 is a movable mold and has a concave second molding surface 117 for molding the back and both side surfaces of the resin injection molded product 1 . This second molding surface 117 also has a shape corresponding to the roof panel formed by the resin injection molding product 1 .

The cavity mold 111 and the core mold 113 are closed together to form a cavity (molding space) 119 between the first molding surface 115 and the second molding surface 117 . The core mold 113 is provided with a vacuum suction port 121 and a resin injection port 123 .

The opening of vacuum suction port 121 is positioned in the center of cavity 119 . On the other hand, the opening of the resin injection port 123 is positioned on the outer peripheral side of the cavity 119 . A downstream portion of the resin injection port 123 constitutes a gate 125 for injecting the matrix resin 29 into the cavity 119 . In this embodiment, only one gate 125 is provided in the core mold 113 and opens on one side of the cavity 119 .

The vacuum suction device 105 is connected to the vacuum suction port 121 of the core mold 113 via a vacuum suction path 127 . The vacuum suction device 105 decompresses the cavity 119 from the vacuum suction port 121 through the vacuum suction path 127 . An on-off valve 129 is provided in the middle of the vacuum suction path 127 .

The resin injection device 107 is connected to the resin injection port 123 of the core mold 113 through the resin injection path 131 . The resin injection device 107 pressurizes and injects the liquid matrix resin 29 into the cavity 119 from the gate 125 downstream of the resin injection port 123 through the resin injection path 131 . An on-off valve 133 is provided in the middle of the resin injection path 131 .

A method for manufacturing the resin injection molded article 1 using such a molding apparatus 101 includes a preparation step, a setting step, an impregnation step, a curing step, and a demolding step. A method of manufacturing the resin injection molded product 1 will be described below with reference to FIGS. 6 to 9. FIG.

FIG. 6 is a diagram showing a setting step in the method of manufacturing the resin injection molded product 1. As shown in FIG. FIG. 7 is a diagram showing the state of the impregnation step in the method of manufacturing the resin injection molded product 1. As shown in FIG. FIG. 8 is a diagram showing the thick portion 9 of the resin injection molded product 1 in the molding die 103 and the surrounding molding locations, which are surrounded by VIII in FIG. FIG. 9 is a diagram showing the demolding step in the method of manufacturing the resin injection molded product 1. As shown in FIG.

In the preparation step, the plate-shaped core material 3 made of the resin foam described above, the first fiber sheet-like material 31 and the second fiber sheet-like material 33 are prepared. At this time, as described above, the core material 3 includes the relatively thin thin portion 7 and the relatively thick thick portion 9 protruding to the back side of the core material 3 with respect to the thin portion 7. A core material in which a plurality of first groove-shaped recesses 19 and second groove-shaped recesses 21 are provided as resin flow paths 17 in the thick-walled protrusion 11 formed by the protruding portion of the thick-walled part 9 Prepare 3.

The core material 3 may be produced by molding the first core material constituent 23 and the second core material constituent 25 separately, and then laminating both of the core material constituents 23 and 25 together. . In addition, the core material 3 is formed by molding one of the first core material construction 23 and the second core material construction 25 first, and molding one of the previously molded core material constructions into the other core material construction. may be set in a mold for molding the core material structures, and one core material structure may be directly molded with the other core material structure.

In the next setting step, the first fiber sheet 31, the core material 3 and the second fiber sheet 33 are laminated in this order on the first molding surface 115 of the cavity mold 111 (see FIG. 5). , the first fiber sheet 31 is on one side of the core material 3 in the thickness direction (the first molding surface 115 side of the cavity mold 111), and the second fiber sheet 33 is on the thickness of the core material 3. They are set in a state in which they are arranged on the other side (the side facing the first molding surface 115) in the direction.

Then, as shown in FIG. 6, by closing the mold 103, the core material 3, the first fiber sheet 31 and the second fiber sheet 33 are arranged in the mold 103. a cavity 119 is formed. At this time, pass media and flow between the molding surface 105 of the cavity mold 111 and the first fiber sheet 31, and between the molding surface 107 of the core mold 113 and the second fiber sheet 33. A resin diffusion medium called media may be arranged.

In the subsequent impregnation step, first, the opening/closing valve 129 of the vacuum suction device 105 is opened and the vacuum suction device 105 is operated to reduce the pressure in the cavity 119 by vacuum suction through the vacuum suction port 121 . While reducing the pressure in the cavity 119, the opening/closing valve 133 of the resin injection device 107 is opened as shown in FIG. A liquid matrix resin 29 is pressurized and injected into every corner. The pressure reduction of the cavity 119 by the vacuum suction device 105 may be stopped at the timing of injecting the matrix resin 29 into the cavity 119 .

Here, when the matrix resin 29 is injected in the height direction of the cavity 119 (the direction corresponding to the thickness direction of the core material 3 placed in the cavity 119) from the gate opening in the middle of the cavity 119, the matrix resin The injection pressure of 29 presses the first fiber sheet 31, the core material 3 and the second fiber sheet 33 toward the cavity mold 111, so that the first fiber sheet 31 is The amount of the matrix resin 29 to be impregnated becomes smaller than the amount of the matrix resin 29 to be impregnated into the second fiber sheet 33, and the thickness of the fiber reinforced resin layer 5 on the front side of the core material 3 is adjusted. Hateful.

On the other hand, in the method of manufacturing the resin injection molded product 1 according to the first embodiment, the matrix resin 29 is injected inward from the outer peripheral side of the cavity 119, so that the first fiber sheet 31 and the core material 3 and the second fiber sheet-like material 33 is not pressed toward the cavity mold 111 by the injection pressure of the matrix resin 29, making it easy to adjust the thickness of the fiber reinforced resin layer 5 on the front side of the core material 3. is.

In the impregnation step, when a predetermined amount of the matrix resin 29 has been injected into the cavity 119, the pressure reduction of the cavity 119 by the vacuum suction device 105 is stopped and the on-off valve 129 is closed. is stopped and the on-off valve 133 is closed. The pressure reduction of the cavity 119 by the vacuum suction device 105 may be stopped at the timing when the matrix resin 29 is started to be injected into the cavity 119 or during the injection of the matrix resin 29 .

In this impregnation step, the matrix resin 29 injected into the cavity 119 of the molding die 103 flows into the second groove-shaped concave portion 21 and travels along the second groove-shaped concave portion 21 to form the thick-walled convex portion 11 of the core material 3 . As shown by the arrow in FIG. flow smoothly towards As a result, the entire cavity 119 is quickly filled with the matrix resin 29, and the matrix resin 29 is less likely to accumulate in the cavity 119 at locations corresponding to the thick protrusions 11 of the core material 3. An increase in the pressure of the matrix resin 29 can be suppressed.

In the subsequent curing step, the heating device heats the molding die 103 to a predetermined temperature at which the liquid matrix resin 29 is cured, thereby forming the first fiber sheet 31 and the second fiber sheet. Matrix resin 29 impregnated in 33 is cured. Thereby, the fiber reinforced resin layer 5 in which the first fiber sheet 31 and the second fiber sheet 33 are solidified with the matrix resin 29 is formed outside the core material 3 .

In the subsequent demolding step, as shown in FIG. 9, the mold 103 is opened, and the resin-injected product 1 in which the fiber-reinforced resin layer 5 is formed on the core material 3 is taken out from the mold 103 . After that, terminal processing is performed to remove the gate residue 201 attached to the resin injection molded product 1 and other unnecessary pieces 203 . Thus, the resin injection molded product 1 can be manufactured.

According to the resin injection molded product 1 according to the first embodiment, the thick convex portion 11 of the core material 3 is provided with the first groove-shaped concave portion 19 extending from the outer peripheral side toward the inner peripheral side. , and the second groove-like recesses 21 extending along the circumferential direction are provided on the outer peripheral side surface 13 of the thick-walled protrusion 11 of the core material 3 over the entire circumference. , the resin injection molded product 1 can be suitably produced by the method for producing the resin injection molded product 1 using the RTM method as described above.

According to the method of manufacturing the resin injection-molded product 1 according to the first embodiment, the core material 3 has the first groove-shaped concave portion 19 extending from the outer peripheral side toward the inner peripheral side of the thick convex portion 11 as the core material 3 . Since a plurality of core members 3 are provided at intervals in the circumferential direction of the convex portion 11, in the impregnation step, the liquid matrix resin 29 injected into the cavity 119 of the molding die 103 is absorbed into the cavity 119. is less likely to accumulate at locations corresponding to the thick protrusions 11 of the core material 3 , and crushing of the thick protrusions 11 of the core material 3 by the pressure of the matrix resin 29 can be suppressed. As a result, deterioration and discoloration of the matrix resin 29 of the fiber reinforced resin layer 5 are suppressed, and portions not impregnated with the matrix resin 29 are generated in the first fiber sheet 31 and the second fiber sheet 33. can be suppressed.

Further, according to the method of manufacturing the resin injection molded product 1 according to the first embodiment, the core material 3 has the second groove-shaped concave portion 21 formed on the outer peripheral side surface 13 of the thick convex portion 11 of the core material 3 . Since the core material 3 provided extending along the direction is used, in the impregnation step, the liquid matrix resin 29 injected into the cavity 119 of the mold 103 fills the second groove-shaped recess 21. The matrix resin 29 can smoothly flow along the outer periphery of the thick convex portion 11 of the core material, and the entire cavity 119 can be quickly filled with the matrix resin 29 . As a result, it is possible to suitably obtain the above effects such as crushing of the thick protrusions 11 of the core material 3, deterioration and discoloration of the matrix resin 29, and occurrence of non-impregnated portions in the fiber sheet 27. In addition, the productivity of the resin injection molded product 1 can be improved.

<<Second embodiment>>
The resin injection molded product 1 according to the second embodiment differs from that of the first embodiment in the configuration of the resin flow path 17 . In addition, in the second embodiment, the resin injection molding product 1 is configured in the same manner as in the first embodiment, except that the configuration of the resin flow path 17 is different from that in the first embodiment. Only the different resin flow passages 17 and their related items will be described, and the same components will be left to the description of the first embodiment based on FIGS. 1 to 9, and detailed description thereof will be omitted.

FIG. 10 is a schematic perspective view of a resin injection molded product 1 according to the second embodiment. FIG. 11 is a schematic plan view of the core material 3 that constitutes the resin injection molded product 1 according to the second embodiment. FIG. 12 is a cross-sectional view of the resin injection molding 1 taken along line XII-XII in FIG. In the resin injection molded product 1 of the second embodiment, as shown in FIGS. A through hole 35 is provided as the resin flow path 17 .

A plurality of through-holes 35 (13 in the example shown in the figure) are provided at intervals in the circumferential direction of the thick convex portion 11 of the core material 3 . Each of these through holes 35 is opened to the outer peripheral side surface 13 and the inner peripheral side surface 15 of the thick convex portion 11 of the core material 3, and is formed in a linearly extending cylindrical shape. The diameter Φ of the through hole 35 is, for example, 1 mm or more and 5 mm or less.

The resin injection molded product 1 having the above configuration is manufactured using the RTM method in the molding apparatus 101 described in the first embodiment. A method of manufacturing the resin injection molded product 1 will be described below with reference to FIGS. 13 and 14. FIG. FIG. 13 is a diagram showing the impregnation step in the method of manufacturing the resin injection molded product 1 according to the second embodiment. FIG. 14 is a diagram showing the thick portion 9 of the resin injection molded product 1 in the molding die 103 and the surrounding molding locations, which are surrounded by XIV in FIG. 12 .

The method of manufacturing the resin injection molded product 1 includes a preparation step, a setting step, an impregnation step, a curing step, and a demolding step. In the method for manufacturing the resin injection molded product 1 according to the second embodiment, the setting step, the curing step, and the demolding step are the same as in the method for manufacturing the resin injection molded product 1 according to the first embodiment. Therefore, detailed description thereof is omitted.

In the preparation step, the plate-shaped core material 3 made of the resin foam described above, the first fiber sheet-like material 31 and the second fiber sheet-like material 33 are prepared. At this time, as described above, the core material 3 includes the relatively thin thin portion 7 and the relatively thick thick portion 9 protruding to the back side of the core material 3 with respect to the thin portion 7. , and a plurality of through-holes 35 as resin flow paths 17 are provided in the thick convex portion 11 formed by the protruded portion of the thick portion 9 .

Each through-hole 35 of the core material 3 is formed by forming a plurality of through-holes 35 in the joined body of the first core material constituent 23 and the second core material constituent 25 by the above-described method. may be formed by perforating to form a Further, each through-hole 35 of the core material 3 is formed by inserting a tubular or rod-shaped punching member into the mold for molding the second core material structure 25 when molding the second core material structure 25 . , and after molding the second core material structure 25 , the punching member may be pulled out from the second core material structure 25 .

In the next setting step, the first fiber sheet 31, the core material 3 and the second fiber sheet 33 are placed into a cavity mold in the same manner as in the method of manufacturing the resin injection molded product 1 in the first embodiment. 111, and the mold 103 is closed to form a cavity 119 in which the core material 3 and the first fiber sheet 31 and the second fiber sheet 33 are arranged in the mold 103. do.

In the impregnation step performed next, as in the method of manufacturing the resin injection molded product 1 in the first embodiment, after depressurizing the cavity 119 of the mold 103, as shown in FIG. The matrix resin 29 is pressurized and injected to spread all over. At this time, the matrix resin 29 injected into the cavity 119 of the molding die 103 flows through the through-holes 35 in the thick projections 11 of the core material 3 as indicated by arrows in FIG. It flows smoothly from the outer peripheral side to the inner peripheral side of the thick convex portion 11 . As a result, the matrix resin 29 is less likely to accumulate in the cavities 119 corresponding to the thick projections 11 of the core material 3 , and the increase in the pressure of the matrix resin 29 applied to the thick projections 11 can be suppressed.

Thereafter, the curing step, demolding step and terminal treatment are performed in the same manner as in the method for manufacturing the resin injection molded product 1 in the first embodiment. Thus, the resin injection molded product 1 can be manufactured.

According to the resin injection molded product 1 according to the second embodiment, the through holes 35 extending from the outer peripheral side to the inner peripheral side are formed in the thick convex portion 11 of the core material 3 in the circumferential direction of the thick convex portion 11 . Since a plurality of them are provided at intervals, the resin injection molded product 1 can be suitably manufactured by the method for manufacturing the resin injection molded product 1 using the RTM method as described above.

According to the method of manufacturing the resin injection molded product 1 according to the second embodiment, the through holes 35 extending from the outer peripheral side to the inner peripheral side of the thick convex portion 11 are formed in the thick convex portion 11 as the core material 3 . Since a plurality of core materials 3 are provided at intervals in the circumferential direction, in the impregnation step, the liquid matrix resin 29 pressurized and injected into the cavity 119 of the molding die 103 is applied to the core material in the cavity 119. As a result, it is possible to prevent the thick protrusions 11 of the core material 3 from collapsing due to the pressure of the matrix resin 29 . As a result, deterioration and discoloration of the matrix resin 29 of the fiber reinforced resin layer 5 are suppressed, and portions not impregnated with the matrix resin 29 are generated in the first fiber sheet 31 and the second fiber sheet 33. can be suppressed.

Thus, the preferred embodiment has been described as an illustration of the invention. However, the present invention is not limited to this, and can also be applied to embodiments in which modifications, replacements, additions, omissions, etc. are made as appropriate. Further, it is also possible to combine the constituent elements described in the above embodiment to form a new embodiment. Also, the components described in the attached drawings and detailed description may include components that are not essential for solving the problem. Therefore, it should not be determined that those non-essential components are essential just because they are described in the accompanying drawings and detailed description.

For example, the first and second embodiments may be configured as follows.

FIG. 15 is a schematic plan view of a resin injection molded product 1 according to a modification. FIG. 16 is a cross-sectional view of the resin injection molding 1 taken along line XVI--XVI of FIG. In the first embodiment, the thick protrusion 11 (thick portion 9) of the core material is provided in a rectangular annular shape at the peripheral edge of the core material 3, but the present invention is not limited to this. . As shown in FIGS. 15 and 16, the thick convex portion 11 of the core material 3 may be spaced inwardly from the periphery of the core material 3 .

In addition, the thick-walled protrusions 11 of the core material 3 may be provided in such a manner as to divide the ring into a plurality of pieces, or may be provided in a manner of forming a plurality of wall-like bodies arranged in parallel to each other. , can be provided in any position and in any shape. The thick convex portion 11 of the core material 3 preferably extends in at least one in-plane direction of the core material 3 in order to reinforce the rigidity of the core material 3 . These matters are the same in the above-described second embodiment.

In the resin injection molded product 1 according to the second embodiment, an aspect in which a plurality of through holes 35 are formed as the resin flow paths 17 in the thick convex portion 11 of the core material 3 was exemplified. Without being limited to this, the matrix resin 29 is applied to the outer periphery of the thick convex portion 11 of the core material 3 in the same manner as the core material 3 of the resin injection molded product 1 according to the first embodiment. A second groove-shaped concave portion 21 for circulation may be formed together with a plurality of through holes 35 .

In the resin injection molded product 1 according to the first and second embodiments, the thick portion 9 of the core material 3 protrudes only on the back side of the core material 3, but the present invention is not limited to this. The thick portion 9 of the core material 3 may protrude on the front side of the core material 3 , that is, on the design surface side of the resin injection molded product 1 , or may protrude on both the front and back sides of the core material 3 . In these cases, the thick portion 9 of the core material 3 also has a first groove-like concave portion 19 or a through hole 35 formed in the portion that protrudes to the front side, similarly to the thick convex portion 11 on the back side of the core material 3 . It is preferable that the second groove-shaped concave portion 21 is also formed.

In the resin injection molded product 1 according to the first and second embodiments, the fiber-reinforced resin layer 5 covers the entire core material 3, and the first fiber sheet-like material 31 covering the surface of the core material 3 and the , and the second fiber sheet-like material 33 covering the back surface and both side surfaces of the core material 3, but the present invention is not limited to this. The fiber-reinforced resin layer 5 may be provided only on the front surface or the back surface of the resin injection molded product 1 .

When the fiber-reinforced resin layer 5 is provided only on the back surface of the resin injection-molded product 1, the surface of the core material 3 does not have the first fiber sheet-like material 31, and is provided with a surface layer consisting only of the matrix resin 29. good too. Further, when the fiber-reinforced resin layer 5 is provided only on the front surface of the resin injection molded product 1, the back surface of the core material 3 does not have the second fiber sheet-like material 33 and is provided with a surface layer consisting only of the matrix resin 29. may be

In the resin injection-molded product 1 according to the first and second embodiments, the configuration in which the core material 1 is composed of the first core material constituent 23 and the second core material constituent 25 was exemplified. It is not limited to this. The core material 1 may be a one-piece resin molded product formed by integrating the first core material component 23 and the second core material component 25 .

In the method of manufacturing the resin injection molded product 1 according to the first and second embodiments, the impregnation step exemplifies injecting the matrix resin 29 from the outer peripheral side of the cavity 119 inward. It is not limited to this. For example, in the molding apparatus 101, the gate 125 downstream of the resin injection port 123 opens in the height direction of the cavity 119 at the central portion of the core mold 113, and in the impregnation step, the first fiber sheet-like material 31, A matrix resin 29 may be injected toward the central portion of the laminate of the core material 3 and the second fiber sheet-like material 33 .

Although a thermosetting resin is used as the matrix resin 29 in the resin injection molded product 1 according to the above embodiment, the present invention is not limited to this. The matrix resin 29 may be thermoplastic resin such as olefin resin, polyester resin, thermoplastic epoxy resin, amide resin, thermoplastic polyurethane resin, sulfide resin, and acrylic resin. A single thermoplastic resin may be used as the matrix resin, or two or more thermoplastic resins may be used in combination.

In the resin injection-molded product 1 according to the above-described embodiment, the first core material component 23 and the second core material component 25 are made of a resin material having a core-shell structure composed of a large number of foamed particles and a shell. is not limited to this. Both the first core material component 23 and the second core material component 25 may be made of foamed resin without a shell.

In the first embodiment, the resin injection molded product 1 is used for the roof panel of an automobile, but the present invention is not limited to this. The roof panel of an automobile is only an example of the application of the resin injection molded product 1, and the resin injection molded product 1 may be used for automobile parts other than the roof panel, such as automobile body panels, seats, suspensions, and floors. However, it is not limited to automobile applications, and can be widely used for other applications such as aircraft parts, automobile parts, ship parts, windmill blades, sports equipment, and building structural materials.

INDUSTRIAL APPLICABILITY As described above, the present invention provides a resin injection-molded product in which a fiber-reinforced resin layer formed by impregnating a fiber sheet with a matrix resin is provided on a core material made of a resin foam, and the resin injection-molded product using the RTM method. It is useful for a method of manufacturing a resin injection molded article.

t1 ... Thickness of the thin portion t2 ... Thickness of the thick portion d1 ... Depth of the first groove-shaped recess d2 ... Depth of the second groove-shaped recess Φ ... Diameter of the through hole 1 ... Resin injection molded product 3 ... Core material 5 ... Fiber reinforced resin layer 7 ... Thin portion 9 ... Thick portion 11 ... Thick convex portion 13 ... Outer peripheral side surface 15 ... Inner peripheral side surface 17 ... Resin channel 19 ... First groove-shaped recess (resin channel )
21 . . . second groove-shaped concave portion (resin flow path)
REFERENCE SIGNS LIST 22 : end surface 23 : first core material component 25 : second core material component 27 : fiber sheet 29 : matrix resin 31 : first fiber sheet 33 : second fiber sheet 35 … through hole (resin channel)
REFERENCE SIGNS LIST 101 ... Molding device 103 ... Mold 105 ... Vacuum suction device 107 ... Resin injection device 111 ... Cavity mold 113 ... Core mold 115 ... First molding surface 117 ... Second molding surface 119 ... Cavity 121 ... Vacuum suction port 123 ... Resin injection port 125 ... Gate 127 ... Vacuum suction path 129 ... On-off valve 131 ... Resin injection path 133 ... On-off valve 201 ... Gate residue

Claims (12)

a plate-shaped core material (3) made of resin foam;
a fiber reinforced resin layer (5) formed by impregnating a fiber sheet (27) with a matrix resin (29) provided on at least one side of the core material (3) in the thickness direction; ,
The core material (3) comprises a relatively thin thin portion (7) and a relatively thick thick portion protruding in the thickness direction of the core material (3) with respect to the thin portion (7). A resin injection molded product having a part (9),
A resin flow path (17) extending from one side to the other side in the in-plane direction of the core material (3) is provided only in the projecting portion (11) of the thick portion (9),
A resin injection molded product, wherein the resin channel (17) is filled with a matrix resin (29) of the fiber-reinforced resin layer (5). In the resin injection molded product according to claim 1,

As the resin flow path (17), an end surface ( 22), wherein a first groove-shaped concave portion (19) is provided. In the resin injection molded product according to claim 1 or 2,
The protruding portion (11) of the thick portion (9) is provided in an annular shape extending along the periphery of the core material (3),
A plurality of the first groove-shaped recesses (19) are provided at intervals in the circumferential direction of the projecting portion (11) of the thick portion (9).
A resin injection molded product characterized by: In the resin injection molded product according to any one of claims 1 to 3,
The protruding portion (11) of the thick portion (9) is provided in an annular shape extending along the periphery of the core material (3),
As the resin flow path (17), a second groove-shaped recess extending along the circumferential direction of the thick portion (9) is provided on the outer peripheral side surface (13) of the projecting portion (11) of the thick portion (9). (21) is provided
A resin injection molded product characterized by: a plate-shaped core material (3) made of resin foam;
a fiber reinforced resin layer (5) formed by impregnating a fiber sheet (27) with a matrix resin (29) provided on at least one side of the core material (3) in the thickness direction; ,
The core material (3) comprises a relatively thin thin portion (7) and a relatively thick thick portion protruding in the thickness direction of the core material (3) with respect to the thin portion (7). A resin injection molded product having a part (9),
The projecting portion (11) of the thick portion (9) is provided with a resin flow path (17) extending from one side to the other side in the in-plane direction of the core material (3),
The resin flow path (17) is filled with the matrix resin (29) of the fiber reinforced resin layer (5),
The resin flow path (17) is a through hole (35) penetrating from one side to the other side in the in-plane direction of the core material (3) in the projecting portion (11) of the thick portion (9). A resin injection molded product characterized by: In the resin injection molded product according to any one of claims 1 , 2 and 5 ,
Resin injection molding characterized in that the protruding portion (11) of the thick portion (9) constitutes a convex portion (11) extending in at least one in-plane direction of the core material (3). product. a preparation step of preparing a plate-like core material (3) made of resin foam and a fiber sheet-like material (27);
The core material (3) and the fiber sheet (27) are placed in a mold with the fiber sheet (27) disposed on at least one side of the core material (3) in the thickness direction. (103), by closing the mold (103), a cavity ( 119) and a set step to form
an impregnation step of impregnating the fiber sheet (27) with the matrix resin (29) by injecting the matrix resin (29) into the cavity (119);
By curing the matrix resin (29) impregnated into the fiber sheet (27), the fiber sheet (27) forms a fiber reinforced resin layer (5) solidified with the matrix resin (29). a molding curing step;
removing the resin injection molded product (1) in which the fiber-reinforced resin layer (5) is molded on the core material (3) from the mold (103) by opening the mold (103); including steps and
In the preparation step, as the core material (3), a relatively thin portion (7) and a relatively thin portion (7) protruding in the thickness direction of the core material (3) with respect to the thin portion (7) and a thick walled portion (9), and only a projecting portion (11) of the thick walled portion (9) is provided with a Prepare a core material (3) provided with an extending resin channel (17),
In the impregnation step, the matrix resin (29) is passed through the resin flow path (17) at a location corresponding to the protruded portion (11) of the thick portion (9) with respect to the cavity (119). A method for producing a resin injection molded product, characterized in that In the method for manufacturing a resin injection molded product according to claim 7 ,
In the preparation step, as the core material (3), the first groove-shaped concave portion (19), which is the resin flow path (17), is formed in the protruding portion (11) of the thick portion (9). A method for producing a resin injection molded product, characterized by preparing a core material (3) formed from at least one side surface (13) of the material (3) in the in-plane direction to an end surface (22) on the projecting side. . In the method for manufacturing a resin injection molded product according to claim 7 or 8,
In the preparation step, as the core material (3), the projecting portion (11) of the thick portion (9) is provided in an annular shape extending along the peripheral edge of the core material (3), and the first groove Prepare a core material (3) in which a plurality of recessed portions (19) are spaced apart from each other in the circumferential direction of the projected portion of the thick portion (9).
A method of manufacturing a resin injection molded product, characterized by: In the method for producing a resin injection molded product according to any one of claims 7 to 9,
In the preparation step, as the core material (3), the projecting portion (11) of the thick portion (9) is provided in an annular shape extending along the peripheral edge of the core material (3), and the resin flow path ( 17), the second groove-shaped recess (21) extending along the circumferential direction of the thick portion (9) on the outer peripheral side surface (13) of the protruding portion (11) of the thick portion (9) Prepare material (3)
A method of manufacturing a resin injection molded product, characterized by: a preparation step of preparing a plate-like core material (3) made of resin foam and a fiber sheet-like material (27);
The core material (3) and the fiber sheet (27) are placed in a mold with the fiber sheet (27) disposed on at least one side of the core material (3) in the thickness direction. (103), by closing the mold (103), a cavity ( 119) and a set step to form
an impregnation step of impregnating the fiber sheet (27) with the matrix resin (29) by injecting the matrix resin (29) into the cavity (119);
By curing the matrix resin (29) impregnated into the fiber sheet (27), the fiber sheet (27) forms a fiber reinforced resin layer (5) solidified with the matrix resin (29). a molding curing step;
removing the resin injection molded product (1) in which the fiber-reinforced resin layer (5) is molded on the core material (3) from the mold (103) by opening the mold (103); including steps and
In the preparation step, as the core material (3), a relatively thin portion (7) and a relatively thin portion (7) protruding in the thickness direction of the core material (3) with respect to the thin portion (7) and a thick wall portion (9), and penetrates from one side to the other side in the in-plane direction of the core material (3) in the protruding portion (11) of the thick portion (9). Prepare a core material (3) provided with a resin flow channel (17) in which
In the impregnation step, the matrix resin (29) is passed through the resin flow path (17) at a location corresponding to the protruded portion (11) of the thick portion (9) with respect to the cavity (119). to fill
A method of manufacturing a resin injection molded product, characterized by: In the method for manufacturing a resin injection molded product according to any one of claims 7, 8 and 11 ,
In the preparation step, a core material (3) is prepared as the core material (3), in which the projecting portion (11) of the thick portion (9) constitutes a projection (11) extending in at least one direction. A method of manufacturing a resin injection molded product, characterized by:

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