JP7403931B2 - Resin molded bodies and fiber reinforced resin molded bodies - Google Patents

Description

The present disclosure relates to a resin molded article.

BACKGROUND ART Conventionally, a fiber-reinforced resin molded body is known in which a sheet molding compound is laminated on a prepreg as a base material (for example, see Patent Document 1). In such a fiber-reinforced resin molded product, local protrusions such as reinforcing ribs and bosses are formed on the surface of the fiber-reinforced resin molded product using a sheet molding compound.

Patent No. 4015584 (paragraph [0020])

In conventional resin molded articles , it is desired to stabilize the fixation between the portion made of the sheet molding compound and the base material.

A first aspect of the invention made to solve the above problem is that a surface layer component made of a sheet molding compound containing a first thermosetting resin is partially formed on at least one of the front and back surfaces of a plate-shaped base material. The base material includes reinforcing fibers having a longer fiber length than the fibers contained in the sheet molding compound, and a second thermosetting resin, and the first thermosetting resin and the A fiber-reinforced resin molded article in which the base material and the surface layer component are integrated by curing the second thermosetting resin, wherein the surface layer component is embedded in the base material and the surface layer component is embedded in the base material. a shaped part consisting of a protrusion or a recess on a surface facing opposite to the base material, a portion of the surface layer component other than the shaped part is arranged substantially flush with the base material; The second thermosetting resin is a fiber-reinforced resin molded article having a higher curing temperature or a longer curing time than the first thermosetting resin.

Here, a high curing temperature means that the temperature required to cure the thermosetting resin in a certain period of time is high. Moreover, a long curing time means that the time required to cure the thermosetting resin at a constant temperature is long.

A second aspect of the invention is that the base material is made of a thermosetting resin foam and a pair of fiber sheets made of the reinforcing fibers are laminated on at least one of the front and back surfaces of a foam sheet having open cells. In addition, the foamed sheet and the pair of fiber sheets are impregnated with the second thermosetting resin, and the portion of the foamed sheet that overlaps with the surface layer component in the thickness direction is impregnated with the second thermosetting resin. The fiber-reinforced resin molded article according to the first aspect is compressed in the thickness direction compared to a portion that does not overlap with the surface layer constituent portion.

A third aspect of the invention is the first aspect, wherein a plurality of the surface layer constituent parts are provided on the at least one surface of the base material at a distance from each other, and each surface layer constituent part is provided with the shaping part . Or the fiber-reinforced resin molded article according to the second aspect .

A fourth aspect of the invention is a base material comprising a sheet molding compound containing a first thermosetting resin, reinforcing fibers having a longer fiber length than the fibers contained in the sheet molding compound, and a second thermosetting resin. The sheet molding compound is partially overlapped on at least one surface of the front and back surfaces of the base sheet, and the first thermosetting resin and the second thermosetting resin are heated and press-molded. A method for producing a fiber-reinforced resin molded article, which comprises curing a thermosetting resin to integrate a base material formed from the base material sheet and a surface layer component formed from the sheet molding compound, When forming the surface layer component, a shaped portion consisting of a protrusion or a recess is formed on the surface of the surface layer component facing opposite to the base material, and as the second thermosetting resin, This is a method for producing a fiber reinforced resin molded body, using a thermosetting resin that takes a longer time to harden at the temperature of the hot press molding than the first thermosetting resin.

A fifth aspect of the invention is that, as the base material sheet, a fiber sheet made of the reinforcing fiber is laminated on at least one of the front and back surfaces of a foamed sheet made of a thermosetting resin foam and having open cells, and This is a method for producing a fiber-reinforced resin molded article according to the fourth aspect , using a fiber-reinforced resin molded article impregnated with the second thermosetting resin.

A sixth aspect of the invention is that a plurality of surface forming portions for forming the shaping portion of the surface layer forming portion are provided on the molding surface of the molding die for performing the hot press molding, and the hot press molding The fiber-reinforced resin according to the fourth aspect or the fifth aspect , wherein a plurality of sheet molding compounds are prepared, and the plurality of sheet molding compounds are separated from each other and stacked on the surface forming portion of the molding surface. This is a method for manufacturing a molded object.

In the first and fourth aspects of the invention , the second thermosetting resin contained in the base material has a higher curing temperature than the first thermosetting resin contained in the sheet molding compound, or Time is getting longer. Therefore, when manufacturing a fiber-reinforced resin molded article, the first thermosetting resin can be cured and then the second thermosetting resin can be cured, and the first thermosetting resin can be cured and hardened. It becomes easy to form the base material in a state that follows the shape of the surface layer component. Thereby, the surface layer component is embedded in the base material, and it becomes possible to stabilize the fixation between the surface layer component made of the sheet molding compound and the base material. In addition, by arranging the portion of the surface layer component other than the shaped portion consisting of protrusions or recesses substantially flush with the base material, the dimensional accuracy of the protrusion amount of the protrusion or the depth of the recess can be stabilized. It becomes possible to achieve this goal.

In the second aspect of the invention , the base material is provided with a foam sheet having open cells. The portion of the foam sheet that overlaps with the surface layer component in the thickness direction is compressed in the thickness direction compared to the portion that does not overlap with the surface layer component in the thickness direction. According to the present invention, by compressing the portion of the foam sheet that overlaps with the surface layer component in the thickness direction, it is possible to easily form the surface layer component in a state embedded in the base material. Also, according to the fifth aspect of the invention , by compressing the portion of the foam sheet that overlaps with the sheet molding compound in the thickness direction, it is possible to easily form the surface layer component in a state embedded in the base material.

In the third and sixth aspects of the invention , a plurality of shaped parts each consisting of a protrusion or a recess are provided. According to the present invention, the amount of sheet molding compound used to form the surface layer component can be reduced compared to the case where the surface layer component made of one sheet molding compound is formed over all of the plurality of shaped parts. It becomes possible to do so.

A perspective view of a fiber reinforced resin molded article according to an embodiment of the present disclosure Side sectional view of fiber reinforced resin molded body Enlarged side sectional view around the boss of the fiber-reinforced resin molded body Side sectional view of the base material sheet and sheet molding compound before hot press molding with a molding die Side cross-sectional view of the base material and surface layer components after hot press molding with a molding die (A) Enlarged side sectional view of the base sheet and sheet molding compound before hot press molding, (B) Base sheet and surface layer configuration when the first thermosetting resin is cured in the molding die. Enlarged side sectional view of (A) Enlarged side view of the base material sheet deformed within the mold, (B) Enlarged side sectional view of the base material formed within the mold. Graph conceptually showing the relationship between heating time and degree of curing of the first and second thermosetting resins A perspective view of a fiber-reinforced resin molded body according to another embodiment Side sectional view of a fiber-reinforced resin molded article according to another embodiment Side sectional view of a fiber-reinforced resin molded body according to another embodiment

FIG. 1 shows a fiber-reinforced resin molded article 10 according to an embodiment of the present disclosure. The fiber-reinforced resin molded body 10 of this embodiment is used for, for example, bicycle parts. The fiber-reinforced resin molded body 10 has a plate-shaped base material 20, and protrusions (specifically, reinforcing ribs 13 and bosses 14) are formed from a first surface 20A, which is one of the front and back surfaces of the base material 20. ) has a prominent structure. Note that in this embodiment, the second surface 20B (see FIG. 2), which is the other surface of the base material 20, is a flat surface, but the second surface 20B may have unevenness. , it may be a curved surface.

Specifically, as shown in FIG. 2, the fiber-reinforced resin molded body 10 includes a surface layer component 30 that constitutes the reinforcing ribs 13 and the bosses 14 that are partially laminated on the first surface 20A of the base material 20. It becomes. The surface layer component 30 is made of a sheet molding compound (hereinafter referred to as SMC) containing fibers and a first thermosetting resin.

As shown in FIGS. 2 and 3, the surface layer component 30 has a shaped portion on the surface facing away from the base material 20. As shown in FIGS. Specifically, the surface layer forming portion 30 includes a base portion 31 having a thin plate shape and stacked on the base material 20, and the above-mentioned features protruding from an exposed surface 31A of the base portion 31 facing opposite to the base material 20. It consists of a surface protrusion 32 as a shaped part. Moreover, in this embodiment, the surface layer structure part 30 which forms the reinforcing rib 13 and the surface layer structure part 30 which forms the boss 14 are provided separately and arranged apart from each other. The surface protrusions 32 of each surface layer component 30 constitute reinforcing ribs 13 and bosses 14, respectively.

The base material 20 has a structure in which a pair of fiber sheets 22, 22 are laminated on both the front and back surfaces of a foamed sheet 21. The foamed sheet 21 is made of open-cell foam made of a thermosetting resin, and the foamed sheet 21 is impregnated with a second thermosetting resin. Further, in this embodiment, the fiber sheet 22 is made of reinforcing fibers having a longer fiber length than the SMC fibers constituting the surface layer component 30, and the fiber sheet 22 also includes a second thermosetting resin. Impregnated. Then, the second thermosetting resin impregnated into the foam sheet 21 and the pair of fiber sheets 22, 22 is cured, so that the foam sheet 21 and the pair of fiber sheets 22, 22 are integrated.

Here, the base portion 31 of the surface layer forming portion 30 is embedded in the base material 20 and is in close contact with the base material 20. The portions of the surface layer forming portion 30 other than the surface protrusions 32 are arranged substantially flush with the base material 20. Specifically, the exposed surface 31A of the base portion 31 of the surface layer component 30 and the first surface 20A of the base material 20 are substantially flush with each other.

In addition, the portion of the foamed sheet 21 of the base material 20 that overlaps with the surface layer component 30 in the thickness direction is compressed by approximately the same amount as the thickness of the base portion 31, compared to the portion that does not overlap with the surface layer component 30 in the thickness direction. It has become thinner.

In the fiber-reinforced resin molded body 10, the first thermosetting resin contained in the surface layer component 30 and the second thermosetting resin impregnated into the base material 20 are cured, so that the surface layer component 30 and the second thermosetting resin are hardened. The base material 20 is integrated. Here, the second thermosetting resin is more difficult to thermoset than the first thermosetting resin. That is, the second thermosetting resin has a longer curing time than the first thermosetting resin, which is the time required for curing at a constant temperature, or a longer curing time than the first thermosetting resin. The curing temperature is increasing.

Details of each component of the fiber-reinforced resin molded body 10, that is, the foam sheet 21, the fiber sheet 22, the first thermosetting resin, the second thermosetting resin, and the SMC, are as follows. ing.

Examples of the foam forming the foam sheet 21 include urethane resin foam, melamine resin foam, and the like. Further, the thickness of the foamed sheet 21 is, for example, 0.1 to 29.5 mm, while the thickness of the base material 20 is 0.5 to 30 mm.

As the fiber sheet 22, for example, one made of fibers such as carbon fiber, glass fiber, aramid fiber, etc. can be used. Further, the fiber sheet 22 may be in the form of, for example, a woven fabric, a knitted fabric, a nonwoven fabric, or the like. Examples of weaving methods for the fabric include plain weave, twill weave, satin weave, and triaxial weave. Further, the fiber sheet 22 may be composed of fibers oriented in one direction or in multiple directions. Note that carbon fiber is preferable as the fiber constituting the fiber sheet 22 from the viewpoint of reducing weight and improving rigidity. Moreover, from the viewpoint of improving rigidity, it is preferable that the fiber sheet 22 is made of a fiber fabric. Examples of the fiber sheet 22 impregnated with a thermosetting resin include prepreg.

Further, the fibers constituting the fiber sheet 22 preferably have longer fiber lengths than SMC fibers, such as fibers having a longer number average fiber length than SMC fibers. Furthermore, examples of the fiber sheet 22 include those made of continuous fibers or discontinuous fibers. From the viewpoint of rigidity, the fiber sheet 22 preferably has a fiber length of 5 mm or more. Further, the fiber sheet 22 preferably has a basis weight of 90 to 400 g/m ² from the viewpoints of rigidity, impregnability with the second thermosetting resin, and light weight.

As the SMC, for example, one containing fibers such as carbon fibers and glass fibers can be used. In addition, from the viewpoint of weight reduction and rigidity improvement, carbon fiber is preferable as the fiber constituting the SMC. The fibers constituting the SMC preferably have a fiber length of 30 mm or less.

Examples of the first thermosetting resin of SMC include epoxy resin, vinyl ester resin, unsaturated polyester resin, phenol resin, epoxy acrylate resin, or a mixed resin of two or more of these resins. can be mentioned.

The reinforcing ribs 13 provided on the surface layer component 30 may have a protrusion amount of 0.1 to 30 mm and a minimum width of 0.5 to 10 mm, for example. Further, as the boss 14, for example, one having a protrusion amount of 0.1 to 30 mm and a difference between the inner diameter and the outer diameter of 0.5 to 10.0 mm can be mentioned.

Examples of the second thermosetting resin of the base material 20 include epoxy resin, phenol resin, or a mixed resin of these resins. By using these resins, rigidity can be improved.

The fiber-reinforced resin molded body 10 is manufactured as follows. First, multiple sheets are prepared. Specifically, a foamed sheet 21 having open cells, a pair of fiber sheets 22, 22, and an SMC 30S containing a first thermosetting resin are prepared. The foam sheet 21 and each fiber sheet 22 are impregnated with a second thermosetting resin. The second curable resin may have a higher curing temperature or a longer curing time than the first curable resin. Note that only one of the foam sheet 21 and the fiber sheet 22 may be impregnated with the second thermosetting resin. Further, as the foamed sheet 21, one with a density of 5 to 80 kg/m ³ is used from the viewpoints of ease of compression in hot press molding, impregnation with the second thermosetting resin, lightness, and rigidity, which will be described later. is preferable.

In the example of this embodiment, a mixed resin of vinyl ester resin and epoxy acrylate resin is used as the first thermosetting resin, and the curing time is longer than that of the first thermosetting resin as the second thermosetting resin. In addition, a phenolic resin that takes a long time to cure was used. Further, the foam sheet 21 was made of urethane resin foam, the fiber sheet 22 was a prepreg made of carbon fiber fabric, and the SMC was made of carbon fiber.

Next, the foamed sheet 21, the fiber sheet 22, and the SMC 30S are stacked on top of each other and heated and press-molded using the molding die 70.

In FIG. 4, a molding die 70 is shown. As shown in the figure, the molding die 70 is composed of an upper die 71 and a lower die 72. In this embodiment, the molding surface of the upper mold 71 is flat, while the molding surface of the lower mold 72 has molding recesses 73 and 74 as surface forming parts for forming the reinforcing ribs 13 and the bosses 14, respectively. is provided. Specifically, the molding recess 73 is groove-shaped, and the molding recess 74 is a cylindrical recess. Note that the molding surface of the lower mold 72 is flat except for the portions where the molding recesses 73 and 74 are provided.

To perform hot press molding, first, the molding die 70 is opened, and the SMC30S is partially overlapped on the molding surface of the lower mold 72 so as to cover the molding recesses 73 and 74 of the lower mold 72. (See FIGS. 4 and 6(A)). In this embodiment, the SMC 30S that covers the molded recess 73 and the SMC 30S that covers the molded recess 74 are provided separately and arranged apart from each other. Furthermore, the amount of each SMC 30S is greater than the amount required to fill each molding recess 73, 74, that is, the amount required to form the reinforcing ribs 13 and bosses 14.

Then, the base sheet 20S, in which a pair of fiber sheets 22, 22 are stacked on both sides of the foamed sheet 21, is stacked on the SMC 30S, and the molding die 70 is closed. Then, as shown in FIGS. 5 and 6(B), the heated and fluidized SMC 30S flows into the molding recesses 73 and 74. Further, the surplus portion of the SMC 30S that cannot fit into the molding recesses 73 and 74 remains on the molding recesses 73 and 74 in the form of a thin plate. On the other hand, the base material sheet 20S (especially the foamed sheet 21) is compressed by being heated and pressed into the molding die 70.

Here, as described above, the second thermosetting resin of the base sheet 20S has a longer curing time than the first thermosetting resin of the SMC 30S. Therefore, as shown in FIG. 6B, the first thermosetting resin of SMC30S is cured before the second thermosetting resin in the molding die 70 (FIG. (B), FIG. 7(A), and FIG. 7(B), the portions of the first and second thermosetting resins that include the fully cured thermosetting resin are shown in gray). Here, FIG. 8 conceptually shows the relationship between the degree of curing of the first and second thermosetting resins and the heating time at a constant heating temperature within the molding die 70. In FIG. 7, timings T1 and T2 when the first and second thermosetting resins are completely cured are the states shown in FIGS. 6(B) and 7(B), respectively.

When the first thermosetting resin hardens, the surface layer component 30 is formed from the SMC 30S. At this time, the reinforcing ribs 13 and bosses 14 (i.e., the respective surface protrusions 32) are formed by the portions of the SMC 30S that have entered the molding recesses 73 and 74, and the portions of the SMC 30S that have entered the molding recesses 73 and 74 form the reinforcing ribs 13 and bosses 14, respectively. The base portion 31 is formed by the thin plate-like surplus portion that was not present.

Here, as shown in FIG. 8, even after the first thermosetting resin is completely cured, the second thermosetting resin is not completely cured until timing T2, so that the base sheet 20S is cured. As shown in the change from FIG. 6(B) to FIG. 7(A), the base sheet 20S can be deformed to follow the shape of the surface layer component 30. Thereby, the base part 31 can be embedded in the base material sheet 20S, and the parts of the base part 31 and the base material sheet 20S that face the lower mold 72 can be made substantially flush with each other. In addition, at this time, the portion of the foamed sheet 21 of the base material sheet 20S that overlaps with the base portion 31 of the surface layer component 30 in the thickness direction is smaller than the portion that does not overlap with the base portion 31 in the thickness direction. It will be compressed by approximately the same amount as the thickness.

As shown in FIG. 7(B), when the second thermosetting resin of the base sheet 20S is completely cured, the base sheet 20S is cured. At this time, the foam sheet 21 and the pair of fiber sheets 22, 22 are integrated to form the base material 20, and the base material 20 and the surface layer component 30 are integrated (see FIG. 5).

Next, the molding die 70 is opened, the base material 20 and the surface layer component 30 are removed from the molding die 70, and the fiber-reinforced resin molded article 10 shown in FIG. 2 is completed.

The configuration of the fiber-reinforced resin molded body 10 and the method for manufacturing the fiber-reinforced resin molded body 10 according to the present embodiment have been described above. Next, the effects of the fiber-reinforced resin molded body 10 and its manufacturing method will be explained.

In the fiber-reinforced resin molded article 10 and the manufacturing method thereof of the present embodiment, the second thermosetting resin contained in the base material 20 has a higher curing temperature than the first thermosetting resin contained in the SMC. , or the curing time is longer. Therefore, when manufacturing the fiber-reinforced resin molded body 10, the first thermosetting resin of the SMC can be cured, and then the second thermosetting resin of the base sheet 20S can be cured, and the first thermosetting resin can be cured. It becomes easy to form the base material 20 in a state that follows the shape of the surface layer component 30 which has become hard due to hardening of the thermosetting resin. Thereby, the surface layer component 30 is embedded in the base material 20, and it becomes possible to stabilize the fixation between the surface layer component 30 made of SMC and the base material 20. Further, by arranging the base portion 31 of the surface layer forming portion 30 substantially flush with the base material, it is possible to stabilize the dimensional accuracy of the amount of protrusion of the surface protrusion 32. Furthermore, since the base portion 31 is substantially flush with the first surface 20A of the base material 20, a space approximately equal to the thickness of the base portion 31 is created between the lower mold 72 and the base material sheet 20S. This makes it possible to improve the thickness accuracy of the base material 20 and to improve the degree of freedom in designing the base material 20.

In the fiber-reinforced resin molded article 10 of this embodiment, the base material 20 is provided with a foamed sheet 21 having open cells. The portion of the foamed sheet 21 that overlaps with the surface layer component 30 in the thickness direction is compressed in the thickness direction compared to the portion that does not overlap with the surface layer component 30 in the thickness direction. According to the fiber-reinforced resin molded article 10 of the present embodiment, the surface layer component 30 is formed in a state embedded in the base material 20 by compressing the portion of the foam sheet 21 that overlaps with the surface layer component 30 in the thickness direction. The base portion 31 and the first surface 20A of the base material 20 can be easily disposed substantially flush with each other. Also, according to the method for manufacturing the fiber-reinforced resin molded body 10 of the present embodiment, by compressing the portion of the foamed sheet 21 that overlaps with the SMC 30S in the thickness direction, the surface layer component 30 is embedded in the base material 20. It can be made easier to form. Moreover, according to the present embodiment, the foamed sheet 21 absorbs distortion during hot press molding, and sink marks and the like do not occur in the portion of the second surface 20B of the base material 20 that overlaps with the surface layer component 30 in the thickness direction. This makes it possible to prevent the second surface 20B from having an uneven appearance.

In this embodiment, a plurality of surface layer constituent parts 30 are provided with surface protrusions 32, and the plurality of surface layer constituent parts 30 are arranged apart from each other. According to the present embodiment, the amount of SMC used to form the surface layer component 30 is reduced compared to the case where the surface layer component 30 made of one SMC is formed over all the plurality of surface protrusions 32. It becomes possible to do so.

[Confirmation experiment]
Hereinafter, an experimental example in which the fiber-reinforced resin molded body 10 was manufactured by the above-mentioned manufacturing method will be described.

<Materials>
In this experimental example, the following materials were used for each component constituting the fiber-reinforced resin molded body 10.
Foam sheet 21: "Basotect (registered trademark) G+" manufactured by INOAC Corporation (density: 9.2 kg/m ³ , thickness 5.0 mm, cut into a size of 200 mm x 200 mm was used.)
Fiber sheet 22: "W-3161-L" manufactured by Toho Tenax Co., Ltd. (a carbon fiber fabric made of continuous fibers, with a basis weight of 200 g/m ² . A sheet cut to the same size as the foam sheet 21 was used. )
Second thermosetting resin: “Sumilite Resin (registered trademark) PR-55791” manufactured by Sumitomo Bakelite Co., Ltd. (phenolic resin. Glass transition temperature: 151°C)
Sheet molding compound (SMC): "Pyrofil (registered trademark) STR120N131" manufactured by Mitsubishi Chemical Corporation (thickness 2.0 mm, fiber length 25.4 mm. A mixture of vinyl ester resin and epoxy acrylate resin as the first thermosetting resin) Contains resin.Glass transition temperature: 130℃)

<Molding conditions>
The molding conditions for hot press molding in this experimental example were a molding temperature of 150° C., a molding pressure of 20 MPa, and a molding time of 10 minutes.

<Experiment results>
When hot press molding was performed using the above materials and molding conditions, the reinforcing ribs 13 and bosses 14 were formed, and the base portion 31 of the surface layer component 30 and the first surface 20A of the base material 20 were flush with each other. A fiber-reinforced resin molded article 10 was obtained. Specifically, in the fiber-reinforced resin molded body 10, the thickness of the portion excluding the reinforcing ribs 13 and the bosses 14 (namely, the surface protrusions 32) was 1.0 mm. Specifically, in the portion of the fiber-reinforced resin molded article 10 where the base material 20 and the surface layer component 30 did not overlap in the thickness direction, the foam sheet 21 had a thickness of 0.50 mm, and each fiber sheet 22 had a thickness of 0.25 mm. In addition, in the portion where the base material 20 and the surface layer component 30 overlap in the thickness direction in the fiber-reinforced resin molded product 10, the foam sheet 21 has a thickness of 0.10 mm, each fiber sheet 22 has a thickness of 0.25 mm, and the base layer of the surface layer component 30 has a thickness of 0.10 mm. The portion 31 was 0.40 mm.

In this fiber-reinforced resin molded article 10, it was confirmed that the base material 20 and the surface layer component 30 made of SMC were sufficiently fixed, and the dimensional accuracy was good. Furthermore, the portion of the second surface 20B of the base material 20 that overlapped with the surface layer component 30 in the thickness direction had a good appearance without any sink marks or the like resulting in an uneven appearance.

In addition, when the molding temperature and molding pressure were the same as above, and the molding time of hot press molding was 3 minutes, it was confirmed that the first thermosetting resin of SMC was cured, while the second thermosetting resin was confirmed to be cured. The thermosetting resin was not completely cured, and when the base material 20 was removed from the molding die 70, the base material 20 was deformed. That is, the timing at which three minutes of molding time have elapsed is considered to be after timing T1 shown in FIG. 8 and before timing T2. When the molding time is 10 minutes, timing T2 shown in FIG. Both are completely cured, and the fiber-reinforced resin molded article 10 in good condition as described above can be manufactured.

[Other embodiments]
(1) In the above embodiment, the surface protrusion 32 was provided as a shaping portion on the surface of the surface layer component 30 facing away from the base material 20, but as shown in FIGS. 9 and 10, A recessed portion 32V may be provided in the recessed portion 32V. Also in this case, by arranging the base portion 31 of the surface layer forming portion 30 substantially flush with the base material 20, it is possible to stabilize the dimensional accuracy regarding the depth of the recessed portion 32V. Note that such a recess 32V may be a groove or a hole.

(2) In the above embodiment, the two surface protrusions 32, 32 that constitute the reinforcing rib 13 and the boss 14, respectively, may be provided in one surface layer component 30 (i.e., in one SMC may be formed from).

(3) In the above embodiment, the base material 20 has a structure in which the fiber sheet 22 is laminated on both the front and back surfaces of the foam sheet 21, but the fiber sheet 22 is laminated only on one of the front and back surfaces of the foam sheet 21. It may be a configuration. In this case, the surface layer component 30 may be laminated on the base material 20 from the fiber sheet 22 side, or may be laminated from the foam sheet 21 side as shown in FIG.

(4) In the above embodiment, the structure of the base material 20 in which the foam sheet 21 and the fiber sheet 22 are laminated may be a structure in which two or more foam sheets 21 are provided, or a structure in which three or more fiber sheets 22 are provided. The structure may be provided. In these cases, the base material 20 may have a structure in which foam sheets 21 and fiber sheets 22 are alternately laminated one by one, or may have a structure including adjacent foam sheets 21 or adjacent fiber sheets 22. It's okay. Moreover, in these cases, the outermost layer of the base material 20 on which the surface layer component 30 is laminated may be configured by the foam sheet 21 or the fiber sheet 22.

(5) In the above embodiment, the sheets constituting the base material 20 were the foam sheet 21 and the fiber sheet 22, but the fiber sheet 22 alone may be used. An example of this configuration is a configuration in which the base material 20 is made of prepreg.

(6) In the above embodiment, the surface layer forming portion 30 may be provided on both the front and back sides of the base material 20. In this case, when manufacturing the fiber-reinforced resin molded body 10, the SMC 30S is stacked on both the front and back sides of the base sheet 20S.

(7) In the above embodiment, the foamed sheet 21 and the fiber sheet 22 are impregnated with the same thermosetting resin, but they may be different. In this case, the thermosetting resin impregnated into the foam sheet 21 and the thermosetting resin impregnated into the fiber sheet 22 each have a higher curing temperature than the first thermosetting resin constituting the SMC. Or, a material with a long curing time is used.

(8) In the embodiment described above, the surface protrusion 32 of the surface layer forming portion 30 may be, for example, a protrusion, a protrusion wall, or a bar-shaped protrusion.

10 Fiber-reinforced resin molded body 20 Base material 30 Surface layer constituent part

Claims (4)

a surface layer component made of a sheet molding compound containing a first thermosetting resin;
A base material comprising a foam sheet impregnated with a second thermosetting resin having a higher curing temperature or a longer curing time than the first thermosetting resin,
The surface layer component is arranged on the foamed sheet, and the resin molded article has a shaped portion consisting of a protrusion or a recess on a surface facing opposite to the foamed sheet. 2. A fiber sheet impregnated with the second thermosetting resin is laminated on the base material such that the fiber sheet and the surface layer component sandwich the foam sheet. resin molded body. A surface layer component made of a sheet molding compound containing a first thermosetting resin is laminated on a base material including a foamed sheet,
The base material includes reinforcing fibers having a longer fiber length than the fibers contained in the sheet molding compound, and a second thermosetting resin that has a higher curing temperature or a longer curing time than the first thermosetting resin. including;
The surface layer forming part is a fiber-reinforced resin molded article having a shaped part consisting of a protrusion or a recess on a surface facing opposite to the base material. A surface layer component made of a sheet molding compound containing a first thermosetting resin is laminated on the base material,
The base material includes reinforcing fibers having a longer fiber length than the fibers contained in the sheet molding compound, and a second thermosetting resin that has a higher curing temperature or a longer curing time than the first thermosetting resin. including
The surface layer forming part is a fiber-reinforced resin molded article having a shaped part consisting of a recessed part on a surface facing opposite to the base material.

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