WO2002094553A1

WO2002094553A1 - Resin form, method for preparing the same, and core material and mold using the same

Info

Publication number: WO2002094553A1
Application number: PCT/JP2001/004340
Authority: WO
Inventors: Masahiko Suzuki
Original assignee: K.U.S Co., Ltd.
Priority date: 2001-05-23
Filing date: 2001-05-23
Publication date: 2002-11-28

Abstract

A soft porous core material (1) for a resin form which comprises a double raschel three dimensional knitting fabric (1), wherein binding yarns (4) are arranged between a face structure (2) and a back structure (3) orthogonally to bind the two structures in one piece and form a doubly knitted structure, wherein the face and back structures are each comprised of finely knitted portions (5) and thickly knitted portions (6) formed by combining two finely knitted portions (5) present right and left, wherein the thickly knitted portions (6) are arranged in line intermittently and adjacent thickly knitted portions (6) are different in phase by one pitch in the longitudinal direction, wherein a stitch (9) is formed in a way such that a finely knitted portion (5) is formed by dividing a thickly knitted portion (6)into two parts, and two finely knitted portions (5) present in right and left are again combined to form an adjacent thickly knitted portion (6), wherein the face and back structures comprise fiber bundles and binding yarns (4) comprise mainly synthetic fiber filaments and occasionally those in combination with mineral fiber bundles, and wherein a three dimensional shape is fixed by heat setting; and a resin form prepared by impregnating the core material (1) with a compounded resin, followed by forming and hardening.

Description

Technical Field of the Invention

The present invention relates to a resin molded product, a method for producing the same, and a core material and a molding die used for the resin molded product. A manufacturing method that can easily mold the compact

Method, core material and mold.

Background art

Conventionally, honeycomb structures have been manufactured by laminating thin objects or laminating corrugated sheets.

Therefore, there was a problem that there were many manufacturing processes. Flat products can be easily manufactured, but it is difficult to manufacture products with partially different wall thickness, curved products, and boxes. Also, there was no molded article having flexibility in the thickness direction. The present invention is directed to a resin molded body capable of easily producing a part having a partially different thickness or a curved part with a small number of production steps, a production method capable of easily molding the molded body, and a core material. It was developed to provide a mold.

On the other hand, conventionally, in the process of manufacturing a resin molded body using a thermosetting resin material, the male and female molds are pressed by applying pressure from a large device from outside the molding die. The female and male molds are clamped with clamps or airbags, and then the resin is injected into the mold with high pressure. Pressing by the above-mentioned external pressure requires a press machine. Pressing by applying an external pressure to a high-viscosity compounded resin requires a large pressurizing device, and the pressure It requires a robust mold that can withstand high temperatures, and both its equipment and the mold are very expensive. In particular, in order to manufacture large products, a crane is required to move a robust and heavy mold, and workability is unlikely to deteriorate.

In molding using fibers, since the fiber reinforcing material is removed inside the mold, there is flow resistance of the injected resin, and the resin cannot be poured quickly unless the injection pressure is increased. For rapid injection, the mold must be strong enough to withstand high injection pressures. Also, if the injection pressure is lowered, there is a problem that it takes a long time to inject the resin material and productivity is deteriorated.

Pressing resin into the clamped mold is difficult to balance the viscosity of the resin material, pressurization speed, etc., and when the rigidity of the mold is weak, If deformation occurs and the material and injection conditions are not balanced, there are problems such as unevenness in the thickness of the molded product.

A second object of the present invention is to provide a method of manufacturing a resin molded article that can easily produce a large molded article without performing pressing by externally large pressure in view of those circumstances. I have. Disclosure of the invention

The present invention has taken the following technical means in order to solve the above problems and achieve the object. The term “compound resin” used herein refers to a material resin obtained by compounding and kneading various materials used in general FRP molding. Further, the term “honeycomb” is not limited to a shape having a hexagonal through hole, but includes a square, a triangle, and the like. The constitution of the invention of the resin molded article is as follows.

(1) A large number of through-holes are formed on the front and back of a flexible and permeable material, and a thick honeycomb-shaped soft porous core material (soft porous plate-shaped body) is formed. A resin molded product that is impregnated with a compounded resin, molded and cured in a mold.

(2) A large number of through holes are formed on the front and back of a flexible and permeable material. Then, a resin molded body is formed by impregnating a compounded resin into a thick honeycomb-shaped plate-shaped soft porous core material, and partially forming a thick-thin portion, followed by molding and curing.

(3) A large number of through-holes are formed through the front and back of a flexible and permeable plate-shaped material, and a thick honeycomb-shaped porous core material is impregnated with a compound resin.

This is formed into a three-dimensional shape having a rising portion from a flat portion, and is molded and cured.

(4) A large number of through-holes are formed through the front and back of a flexible and permeable plate-like material, and a thick porous soft porous core material is impregnated with the compound resin. This is a resin molded body that is molded and cured as a single piece with an intervening cloth impregnated with the compounded resin sandwiched between the upper and lower two sheets.

(5) Impregnated with a compound resin into a thick honeycomb-shaped soft porous core material in which a number of poorly formed through holes are formed on the front and back of a flexible and permeable plate-like material This is a resin molded body that is formed by integrally laminating this on a mold surface having a surface material layer formed on the mold surface and hardening.

(6) A large number of through-holes are formed through the front and back of a flexible and permeable plate-shaped material, and a thick honeycomb-shaped soft porous core material is impregnated with a compound resin. This is molded into a tube and cured to form a resin molded body.

(7) The resin molded product according to any one of (1) to (6), wherein the soft porous core material is a three-dimensional knitted fabric of a double-ruple Russell pattern.

(8) The resin molded article according to any one of (1) to (6), wherein the soft porous core material is formed by punching holes in a heat-resistant and solvent-resistant foamed resin plate by punching.

(9) Impregnated with compound resin in the front and back tissues except for the middle of the soft porous core material formed into a thick honeycomb with many through holes formed on the front and back of the flexible and permeable material The resin molded article according to any one of (1) to (8), wherein the molded article is molded and cured to have elasticity in the thickness direction. (10) The resin molded article according to any one of (1) to (6), wherein the soft porous core material has a large number of through holes formed in a fibrous porous plate.

Further, the present invention has taken the following technical means in order to solve the above-mentioned problems and achieve the object. The term “compound resin” as used herein refers to a material resin obtained by compounding and kneading various materials used for general FRP and other molding. The surface material layer is a resin material layer containing a material suitable for the surface layer, and is formed by coating or spraying. In this case, the compounded resin and the glass strand chiyo and soap can be sprayed simultaneously to form a layer. Impregnation means that it is included inside or attached to the outside. The constitution of the invention of the method for producing a resin molded article is as follows.

(11) a step of preparing a thick honeycomb-shaped soft porous core material (soft porous plate material) having a large number of through holes penetrating the front and back of a flexible and permeable plate material; A step of impregnating the soft porous core material with a compounded resin; a step of forming a surface material layer on a molding surface of a mold; and a step of integrally forming and curing the soft porous core material on the surface material layer. And a method for producing a resin molded body.

(12) A step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating the front and back of a flexible and permeable plate-like material; A step of impregnating the compounded resin, a step of forming a surface layer on the molding surface of the mold, and a step of laminating the soft porous core material on the surface layer to form a partially thick and thin portion in the male and female molds. Forming a resin and integrally molding and curing the same.

(13) A step of preparing a thick 82-cam-shaped soft porous core material having a large number of through-holes penetrating the front and back of a flexible and permeable plate-like material; A step of impregnating the resin with the compounded resin, a step of forming a surface layer on the molding surface of the mold, and a step of sticking the soft porous core material to the molding surface and partially stretching or shrinking to flatten the material. Forming a three-dimensional shape having a rising portion from a part, and integrally molding and curing the same. (14) a step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating the front and back of a flexible and permeable plate-shaped material, and blending the soft porous core material with the thick porous honeycomb material; A step of impregnating the resin, a step of forming a surface material layer on the molding surface of the mold, and an intermediate cloth impregnated with the compounded resin interposed between each of the plurality of the soft porous cores described above. A method of manufacturing a resin molded body, comprising the steps of forming an integral molding and curing step on a surface material layer.

(15) a step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating on the front and back of a flexible and permeable plate-like material; A step of impregnating the compounded resin, a step of forming a surface layer on the molding surface of the male and female molds, and a step of winding the soft porous core material on the surface layer of the peripheral surface of the columnar male mold, and covering the female mold. A method of manufacturing a resin molded article, comprising: attaching, integrally molding into a tube, and curing.

(16) A step of forming a surface layer on the forming surface of the male and female molds, a step of forming a fiber reinforced layer impregnated with the compounded resin on the surface layer of the female mold, and a plate-shaped soft porous core A resin molded body comprising: a step of impregnating a compounded resin into a material; and a step of laminating a plate-shaped soft porous core material impregnated with the compounded resin on the fiber reinforced material layer, and integrally molding and curing the mold. Manufacturing method.

(17) a step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating on the front and back of a flexible and permeable plate-shaped material; A step of impregnating the compounded resin, a step of arranging the existing molded body on the molding surface of the female mold, and a step of arranging the soft porous core material on the existing molded body and integrally molding and hardening the mold. And a method for producing a resin molded body.

(18) a step of individually molding an outer molded body and an inner molded body having a space at a joint; a step of impregnating a compounded resin into a plate-shaped soft porous core material; A method for producing a resin molded body, comprising: a step of arranging an inner molded body thereon, and a step of integrally molding and curing by pressurizing the inner molded body. (19) A step of preparing a soft porous core material with the binding yarn of the double Russell turtle pattern solid knitted fabric as a thick single yarn, a step of impregnating the mixed resin into the front and back tissues of the soft porous core material, and forming a mold. The step of arranging the soft porous core material on the surface and molding and hardening the resin, the front and back texture portions are hard, and the elasticity of the binding yarn maintains flexibility in the thickness direction. How to make the body.

(20) The method for producing a resin molded product according to any one of (11) to (18), wherein the porous core material is a double Russell tortoiseshell pattern three-dimensional knitted fabric.

(21) The resin molded article according to (20), wherein a reinforcing fiber such as a carbon fiber, a Kepler fiber, or a glass fiber is mixed in addition to the polymer synthetic fiber as the yarn used for the double Russell tortoiseshell three-dimensional cloth. Manufacturing method.

(22) The method for producing a resin molded article according to any one of (11) to (18), wherein the porous core material is formed by punching holes in a heat-resistant and solvent-resistant foamed resin plate.

(23) The method for producing a resin honeycomb molded body according to any one of (11) to (18), wherein the porous core material is formed by forming a large number of through holes in a fibrous porous plate.

Further, the present invention has taken the following technical means in order to solve the above-mentioned problems and achieve the object. The term “fiber bundle yarn” as used herein refers to a yarn in which a bundle of fibers is twisted (single-twisted yarn, single-twisted yarn, or multi-twisted yarn). Single yarn refers to a single linear yarn. Impregnation refers to either being included between a large number of fine fibers or being attached to a single yarn or a cloth. Intermediate cloth shoulder refers to a cloth-like (woven cloth, knitted cloth, net, non-woven fabric, mineral fiber fabric, soto, resin preform) that can impregnate the compounded resin. The compounded resin refers to a soft syrup-like resin obtained by compounding and kneading materials necessary for forming a molded article.

(24) A double woven structure made of a double Russell three-dimensional knitted fabric, with a binding yarn that sets the wall thickness between the front and back textures intersects orthogonally and connects the front and back tissues together. The front and back tissues are each composed of a thin knit part and a thick knit part where the left and right thin knit parts are joined. The thick knit parts are intermittently connected in series, and the adjacent thick knit parts are in the vertical direction. In 1 The pitch phase is made different, and the thin stitch is formed by the thick stitch being bifurcated to the left and right, the left and right thin stitches are combined to form the next thick stitch, and the stitch is formed. The front and back texture is composed of fiber bundle yarns, and the binding yarn is mainly a synthetic fiber single yarn, mineral fiber bundle yarns are selectively mixed, and the three-dimensional shape is fixed by heat setting. Soft porous core material (soft porous plate-shaped body).

(25) The flexible porous core material for a resin honeycomb molded body, wherein the front and back texture is composed of one selected from a single fiber or a mixed fiber of synthetic fibers and mineral fibers.

(26) The soft porous core material for a resin honeycomb molded body according to any one of (24) and (25), wherein the synthetic fiber is a polymer synthetic fiber such as polyester or a Kepler fiber.

(27) The mineral fiber is one selected from a carbon fiber, a simple substance of glass fiber, and a composite, and is a soft porous material for a resin honeycomb molded body according to any one of (24) to (25). Core material.

(28) The mixing of synthetic fibers and mineral fibers in the binding yarn is one selected from ply twisting, aligning, or alternating arrangement of synthetic fibers and mineral fibers (24) to (27). A soft porous core material for a resin non-cam molded article according to any one of the above.

(29) The mixing of synthetic fibers and mineral fibers in the binding yarn may be alternately arranged in the longitudinal direction of the thick knit portion and the thin knit portion (24) to (27). The described soft porous core material for a resin honeycomb molded body.

(30) The resin honeycomb molding according to any one of (24) to (27), wherein the mixing ratio of the mineral fiber to the synthetic fiber in the binding yarn is 20% by volume to 50% by volume. Soft porous core material for body.

(31) A double-knitted fabric is formed by a double Russell three-dimensional knitted fabric, which intersects perpendicularly to set the thickness between the front and back tissues and joins the front and back tissues together. The front and back tissues are each composed of a thin knitted part and a thick knitted part where the left and right thin knitted parts are joined. The thick knitted parts are intermittently connected in series, and the adjacent thick knitted parts are in the vertical direction. Pick The thin stitch is formed by branching the thick stitch; the right stitch is formed by joining the left and right thin stitches to form the next thick stitch. The front and back texture is composed of a fiber bundle yarn, the binding yarn is mainly a synthetic fiber single yarn, a mineral fiber bundle yarn is selectively mixed, and a three-dimensional shape is fixed by a heat set. A resin molded article in which a core material is impregnated with a soft syrup-like compound resin, and the elasticity of the binding yarn is used to provide elasticity in the thickness direction of the molded article.

(32) The resin molded article according to (31), wherein the molded article has a partially changed thickness due to male and female molding.

(33) The resin molded article according to any one of (31) and (32), wherein a surface layer formed in advance on a molding surface of a molding die is bonded to the molded article.

(34) An intervening cloth impregnated with a compound resin is sandwiched between a plurality of soft porous cores made of a double Russell three-dimensional knitted fabric with binding yarns perpendicular to the front and back tissues. A double 82 cam is formed integrally with the double honeycomb, and an intervening cloth layer impregnated with a compounded resin is laminated on the front and back surfaces of the double honeycomb, respectively, and integrally formed to form a binding yarn. A resin molded article having elasticity in the thickness direction of the molded article due to elasticity.

(35) A soft porous core material consisting of a double Russell three-dimensional knitted fabric in which the binding yarns are perpendicular to the front and back textures, and are joined together with a pre-formed compact between each of the multiple pieces. A double honeycomb is formed on the front and back surfaces of the double honeycomb, and each of the preformed bodies is overlapped and integrally formed. The elasticity of the binding yarn provides elasticity in the thickness direction. Resin molding

(36) A soft porous core made of a double Russell three-dimensional knitted fabric in which the binding yarns are perpendicular to the front and back textures, with an intervening fabric layer impregnated with the compounded resin interposed between the soft porous cores. The process of forming a double honeycomb by integral molding and the process of laminating an interposed cloth layer impregnated with a compounded resin on the front and back surfaces of the double honeycomb, and integrally molding with a molding die are combined to form a soft honeycomb. For elasticity of binding yarn of porous core material Thus, a method for producing a resin molded article having elasticity in the thickness direction of the molded article. Further, the present invention has taken the following technical means in order to solve the above-mentioned problems and achieve the object. The preform fiber referred to here is a fiber preformed into the shape to be molded by spraying a fiber reinforcing material (glass, carbon or other fiber) together with the resin onto the mold surface, or attaching it by hand. . The compounded resin is a soft candy resin in which various materials necessary and sufficient for FRP molding and other moldings are mixed. The specific contents of the invention are as follows.

(37) In a molding method using a thermosetting resin material, a thermosetting resin material is charged into a molding die without pressurization, the molds are aligned, and the mold is not clamped by external pressure. A method for producing a resin molded body, which is molded by clamping the mold under reduced pressure in the mold.

(38) In a molding method using a thermosetting resin material, the mold is set, and the thermosetting resin material is put into the molding die without applying pressure. A method for producing a resin molded article which is molded by clamping the mold by reducing the pressure in the mold.

(39) The method for producing a resin molded article according to any one of (38) and (39), wherein the pressure reduction is performed in a range of 2.5 cmHg to 20 cmHg.

(40) A step of setting the fiber reinforced material in the female mold, a step of introducing the compounded resin into the female mold without applying pressure, a step of arranging the male mold in the female mold and lightly clamping the mold, A method for producing a resin molded product, comprising: a step of reducing the pressure in a mold; and a step of closing and curing and curing the reduced pressure hole when the compounded resin overflows in the reduced pressure hole.

(41) In the resin molded body, a step of setting the fiber reinforcing material in the female mold, a step of arranging the male mold and lightly clamping the mold, and injecting the compounded resin from the mold material injection hole without pressure. Production of a resin molded body comprising a combination of a process, a process of closing the material injection hole to reduce the pressure in the male and female molds, and a process of closing and curing and curing the compounded resin when the resin overflows in the pressure reduction hole. Method. (42) Consists of a combination of male and female molds.The female mold is configured to directly charge the compounded resin without pressure, and the male mold has a pressure reduction hole from the mating surface inside the seal to the outside of the mold. A resin mold in which a pressure reducing means is connected to the pressure reducing hole.

(43) The male mold has a combination of a male and a male, and the male mold has a decompression hole formed from the mating surface inside the seal to the outside of the mold, and a decompression means is connected to the decompression hole. Is a resin mold with a non-pressurized material injection hole that passes from the outside to the molding section.

(44) The seal is disposed to face each of the male and female molds, and the female seal has a seal formed with a recess on the upper surface fitted into the female seal fitting recess (42), ( 43) The resin mold according to any one of the above.

(45) The resin mold according to any one of (42) and (43), wherein the decompression means is a low-pressure decompression device in a range of 2.5 cmHg to 20 cmHg.

Further, the present invention provides the following windmill blades and reinforcing members.

(46) An outer shell formed in a cylindrical shape, and a reinforcing rib fitted and fixed inside the outer shell, wherein the outer shell is formed of a soft porous sheet-shaped core material, and upper and lower surfaces of the core material. And a hardening resin filled in voids of the core material and the reinforcing sheet, wherein the reinforcing ribs comprise a three-dimensional core material made of synthetic resin foam, and a sheet provided around the core material. A blade for a windmill, comprising: a core-shaped core material, a reinforcing sheet provided around the core material, and a curable resin filled in voids of the core material and the reinforcing sheet.

(47) A three-dimensional core made of a synthetic resin foam, a sheet-shaped core provided around the core, a reinforcing sheet provided around the core, a core and a reinforcing core. A reinforcing member made of a curable resin filled in the voids of the resin.

A composite member in which one or more reinforcing members of (48) and (47) are arranged, the outside of which is surrounded by a reinforcing sheet, and integrally formed.

(49) The composite member according to (47), wherein a block made of a foamed resin is provided between the reinforcing member and the reinforcing sheet. (50) One or more reinforcing members of (47) are arranged, the outside of which is surrounded by a reinforcing sheet, and integrally molded windmill blades.

(51) The blade for a windmill according to (50), wherein a block made of a foamed resin is provided between the reinforcing member and the reinforcing sheet.

(52) Combining a block made of a foam material and a flexible sheet-like porous core material into a mold, then filling the compounded resin and molding integrally to form windmill blades Method. BRIEF DESCRIPTION OF THE FIGURES

FIG. 1 is a perspective view of a soft multi-hole core material.

FIG. 2 is a plan view of a soft porous plate.

FIG. 3 is a longitudinal sectional front view of a mold and a soft porous core material showing a molding method.

FIG. 4 is a vertical sectional front view showing an embodiment of the resin honeycomb structure of the present invention. FIG. 5 is a plan view showing a part of the mesh of the soft porous core material.

FIG. 6 is a perspective view showing a second embodiment of the soft porous core material.

FIG. 7 is a vertical sectional front view showing a second embodiment of the resin two-cam structure.

FIG. 8 is a vertical sectional front view showing a third embodiment of the resin honeycomb structure.

FIG. 9 is a front view showing an embodiment of a molding die used in the production method of the present invention. FIG. 10 is a plan view of a soft porous core material processed.

FIG. 11 is a perspective view of a resin honeycomb formed body according to the first embodiment.

FIG. 12 is a partial vertical sectional front view of the resin honeycomb molded body of FIG.

FIG. 13 is a partial vertical sectional front view of the resin honeycomb formed body of the second embodiment.

FIG. 14 is a longitudinal sectional front view of a molding die showing a method of uniting molding with an FRP molded body. FIG. 15 is a longitudinal sectional front view of a resin honeycomb molded body showing a third embodiment.

FIG. I6 is a longitudinal sectional front view of a resin honeycomb molded body according to the fourth embodiment. FIG. 17 is a plan view showing a method of forming a tubular resin honeycomb formed body. FIG. 18 is a partial front view of a thick knit portion of a soft porous core material.

FIG. 19 is a front view of the binding yarn showing the second embodiment.

FIG. 20 is a front view of the binding yarn showing the third embodiment.

FIG. 21 is a front view of a binding yarn showing a fourth embodiment.

FIG. 22 is a vertical sectional front view of a molding die used in the molding method of the present invention.

FIG. 23 is a partial longitudinal front view of the resin honeycomb formed body.

FIG. 24 is a longitudinal sectional front view of a resin honeycomb molded body according to the second embodiment. FIG. 25 is a vertical sectional front view of the molding die.

FIG. 26 is a vertical sectional front view showing a state in which the mold is clamped.

FIG. 27 is a longitudinal sectional front view of a molding die showing a second embodiment.

FIG. 28 is a perspective view of a main part showing an embodiment of a wind turbine blade according to the present invention.

FIG. 29 is an enlarged sectional view of the outer shell of the blade of FIG.

30a and 30b are enlarged cross-sectional views of the reinforcing rib of FIG. 28, respectively. FIG. 31 is a cross-sectional view of the blade of FIG. 28 before assembly.

FIG. 32 is a sectional view showing another embodiment of the wind turbine blade according to the present invention.o

33a to 33c are process diagrams showing one embodiment of a method for manufacturing a blade of a wind turbine according to the present invention.

FIGS. 34a to 34b are process diagrams showing another embodiment of the method for manufacturing a wind turbine blade according to the present invention. BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, embodiments of the present invention will be described with reference to the drawings. Figure 1 is a double FIG. 2 is a perspective view of a soft porous core material (hereinafter simply referred to as a soft porous core material) for a resin molded body made of a Russell three-dimensional knitted fabric, and FIG. 2 is a plan view.

The soft porous core material 1 is composed of a double-layered, three-dimensional knitted fabric by Sosel. The material is selected from synthetic fibers such as polyester fiber, vinylon fiber, Kevlar fiber (trademark of DuPont), and mineral fibers such as carbon fiber and glass fiber.

The double-laced three-dimensional knitted fabric is a double-faced double-sided knitted fabric by a Russell knitting machine, in which a tortoiseshell pattern is set up.

In FIG. 1, a large number of binding yarns 4 are interposed between a front structure 2 and a back structure 3 to have a predetermined thickness, and are formed into a body having an arbitrary thickness, for example, 2 mm to 20 mm. Have been.

Organizationally, as shown in the left part of FIG. 2, a large number of thin knitted portions (braided yarns) 5 are joined adjacently at their longitudinal ends to form a thick knitted portion 6, A coarse portion 7 is formed between the left and right thick knit portions 6, and a wool 8 that is zigzag between the right and left thick knit portions 6 is knitted in the coarse portion 7.

After the knitting is completed, the suture 8 is cut off and stretched in the left-right direction in FIG. 2, and as shown in the right part in FIG. The thick knitted portion 6 is composed of a thick knitted portion 6 and a thick knitted portion 6 joined together, the thick knitted portion 6 is intermittently connected in series, and the adjacent thick knitted portion 6 has a pitch difference of one pitch in the vertical direction. The part 5 is formed by dividing the thick knit part 6 into two parts on the left and right, and the left and right thin knit parts 5 are joined to form the next thick knit part 6, so that a large number of turtle pattern stitches 9 are formed. . By heat setting this, the shape of the stitch 9 of the tortoiseshell pattern can be fixed.

The yarn used for the front and back textures 2 and 3 is, for example, a single or mixed material of a synthetic fiber bundle yarn and a mineral fiber bundle yarn, has flexibility, and can easily impregnate a compound resin. If a single yarn of synthetic fiber is used for the binding yarn 4, the binding yarn 4 has elasticity. Elasticity in the front and back direction occurs.

However, in order to impregnate the compounded resin moderately, a bundle of fibers such as a single-twisted yarn, a single-twisted yarn, a multi-twisted yarn, and a tying yarn (pulling yarn) of a bundle of fine fibers is preferable. In addition, it can be used as a twine of a fiber bundle yarn and a thick single yarn, and can be aligned. The arrangement of the binding yarns 4 can be set at an arbitrary interval, for example, from 0.2 mm to 1 mm, depending on the purpose of use, or can form intermittently dense portions. When this gap is narrower, the compounded resin adheres in a plate shape.

FIG. 3 is a side view of the thick knitting portion 6. Since the organization can be set arbitrarily, a schematic diagram is shown. In the figure, the binding yarn 4 is composed of a ply-twisted yarn of a synthetic fiber single yarn 4a and a mineral fiber bundle yarn 4b. Polyester fiber was selected as synthetic fiber, and carbon fiber was selected as mineral fiber.

The binding yarn 4 is composed at the upper end in the front texture 2 and is formed by passing over several yarns and descending into the back texture 3 to join the front and back textures 2 and 3 together. I have. This varies depending on the organization.

FIG. 4 is a schematic view showing a second embodiment of the binding yarn 4. As shown in FIG. The binding yarn 4 is a combination of a synthetic fiber single yarn 4a and a mineral fiber bundle yarn 4b. If necessary, a not-shown entanglement thread can be entangled.

FIG. 5 is a schematic view showing a third embodiment of the binding yarn 4. As shown in FIG. The binding yarn 4 shows an aspect in which the synthetic fiber single yarn 4a and the mineral fiber bundle yarn 4b are alternately arranged and knitted between the front and back tissues 2 and 3.

FIG. 6 is a schematic view showing a fourth embodiment of the binding yarn 4. As shown in FIG. The binding yarn 4 is formed by alternately arranging a plurality of yarn rows of the synthetic fiber single yarn 4 a and a plurality of yarn rows of the mineral fiber bundle yarn 4 b between the front and back tissues 2 and 3 and integrally knitting. An embodiment is shown. In each of the above embodiments, the mixing ratio of the mineral fiber bundle yarn 4b to the synthetic fiber single yarn 4a in the binding yarn 4 is arbitrarily set in the range of 20% by volume to 50% by volume.

FIG. 7 is a plan view showing a state where the stitch 9 of the soft porous core material 1 is partially moved. The double Russell three-dimensional knitted fabric can deform the stitch 9 in a free direction. In addition, since the binding yarn 4 has elasticity, the binding yarn 4 has a rigidity so that it does not collapse even if it is placed flat and pressed down on the surface structure 2 by hand.

Next, a method for manufacturing the resin honeycomb molded body 1 will be described. A soft syrup-shaped compounded resin is impregnated into a soft porous core material 1 made of a double ply and a solid three-dimensional knitted fabric shown in FIG. The impregnation method is arbitrary such as dipping, coating, spraying and the like. As the compounded resin, a mixture of various necessary materials used in general FRP molding or a resin equivalent thereto can be used.

FIG. 8 shows a state in which the soft porous core material 1 impregnated with the compounded resin is placed flat on the mold 10.

When synthetic fiber bundle yarns are used for the front and back tissues 2 and 3, the compounded resin 11 is impregnated between fine fibers. Even if the binding yarn 4 is only a single yarn 4a made of a synthetic fiber, the compound resin 11 is impregnated between adjacent single yarns 4a. When the mineral fiber bundle yarn 4b is added, the compound resin 11 is impregnated between the fine fibers of the fiber bundle yarn 4b. If the mold 10 is curved, it curves accordingly.

The soft porous core material 1 is cured (5 to 20 minutes depending on the material and temperature) in a molding die, and the compounded resin 11 is cured with time, whereby a resin 82 cam molded body 12 is formed. As a result, as shown in FIG. 9, the compound resin 11 is hard to adhere to the thick single yarn 4a, but the compound resin 11 is interposed between the thin mineral fiber bundle yarns 4b. It is also possible to see the plate-like connection between adjacent binding yarns 4 by impregnating them.

That is, in the case of a linear single yarn, regardless of the material, the compounded resin is hard to adhere, and may peel off even if it adheres. Regarding the fiber bundle yarn, regardless of the material, the compounded resin enters between the fine fibers by capillary action, and the compounded resin is united with the fibers, so that peeling does not easily occur. In addition, since the fine fibers are fluffed right and left and front and back, the compound resin is impregnated between the adjacent fibers and the adjacent fibers are united together. For example, adjacent ones of the binding yarns 4 densely arranged along the length of the thick knit portion 6 can be connected in a plate shape.

From the above, a thick single yarn 4a was used as the binding yarn 4, and when the mineral fiber bundle yarn 4b was added to this, the thick single yarn 4a was impregnated with the mineral fiber bundle yarn 4b. Since the resin is adhered and integrally formed, the resin honeycomb molded body 12 is elastic in the thickness direction due to the elasticity of the thick single yarn 4a of the synthetic fiber when pressed in the thickness direction. 1 and 2

As shown in FIG. 7, the soft porous core material 1 can freely change the width of the stitch 9 and can be made thinner by applying pressure in the thickness direction. After being impregnated, a box-shaped three-dimensional molding can be facilitated by the male and female molds. Even in such a case, elasticity in the thickness direction (for example, only the corner portions) can be provided by setting the binding yarn 4.

The soft porous core material 1 can be integrally formed as a molded body by laminating a material having different aspects (material composition and thickness) into a plurality of layers by impregnating a compounded resin. Also, an intervening cloth layer (woven cloth, knitted cloth, net, non-woven cloth, glass mat, etc.) 13 in which the compounded resin is impregnated between the layers can be integrally cured and formed as a molded article. .

FIG. 10 is a longitudinal sectional front view of a resin honeycomb molded body 12 in which a plurality of soft porous core materials 1 are laminated. An outline of a method of manufacturing the molded body 12 is as follows. First, a compound resin is impregnated into an intervening cloth layer 13 made of a fiber reinforcing material mat (for example, a glass strand mat) to form a soft porous core material 1 between the soft porous core materials 1. The upper and lower soft porous cores 1 are adhered to each other by a compound resin impregnated in an intervening cloth layer 13 made of fiber-reinforced mats, and are integrally molded as a double honeycomb 14.

By this method, the binding resin 4 can be prevented from being impregnated with the compounded resin, and the elasticity of the binding yarn 4 can be maintained. Therefore, the quality, thickness, array density, and the like of the binding yarn 4 are set according to the required elasticity.

After that, the fiber reinforced material impregnated with the compound resin in the mold (not shown) The interposed cloth layer 15 made of mat is arranged, and the double honeycomb 14 is stacked thereon, and the interposed cloth layer 15 made of fiber-reinforced mat impregnated with the compounded resin is stacked thereon. Tighten and mold integrally. In FIG. 10, the binding yarn 4 is curved due to pressurization by a mold, and this shape is heat set by heat during molding.

As a result, the plurality of soft porous core materials 1 are connected as a double honeycomb 14 by the intervening cloth layer 13, and the surface is protected by the molded article layer in which the intervening cloth layer 15, which may be a fiber reinforcing material mat, is hardened. The resulting resin honeycomb molded body 12 has excellent rigidity. In this case, if necessary, a surface layer (for example, for coloring) can be formed on the molding surface of the mold in advance.

In place of the intermediate cloth layer 13 in the middle of the double honeycomb 14 and the cloth layers 15 on the front and back, a preformed molded body is interposed, and the soft porous core material 1 is included in the soft porous core material 1 by clamping. It can be integrally joined by the compounded resin attached. In this case, a preformed molded article having good adhesiveness with the compounded resin is selected, and a soft molded article can also be used. In addition, hardness, wall thickness, material, and the like can be changed for a plurality of layers.

Even if the front and back surfaces of the resin honeycomb molded body 12 are hard, since the binding yarn 4 has elasticity, the molded body 12 has flexibility in the thickness direction of the molded body 12 even when pressed from the outside, so that Absorb pressure. For this reason, even if an external impact is applied, for example, it is extremely difficult to open the damaged hole because the impact is absorbed.

Further, since the resin honeycomb molded body 12 can be easily molded by a male and female mold, for example, when the double honeycomb 14 is used for a bumper of an automobile, the impact of a collision can be absorbed. When used in ships, etc., it can improve buoyancy by itself, mitigate the impact of collisions in case of marine accidents, do not leak into the ship even if the outside is damaged, and use severely broken debris as a floating body You can do it.

The present invention is not limited to the above embodiment, and may be used in various fields. Yes, and design changes can be made appropriately according to the purpose. For example, the material can be changed vertically above and below the intervening cloth layer 13 of the double honeycomb 14. The material of the soft porous core material 1 can also be partially changed in the plane direction. The front and back layers (intervening cloth layers) of the resin honeycomb molded body 12 may be mixed with a flame-retardant material, a weather-resistant material, a wear-resistant material, and the like.

Next, a method of three-dimensionally forming the soft porous core material by a mold will be described. First, a soft water-blended resin is impregnated in the soft porous core material 1 made of the double-rassel turtle-shaped three-dimensional knitted fabric. As the impregnation method, immersion, coating by spraying or the like, and other methods are optional.

As a result, the mixed resin is impregnated into the front and back tissues and adheres to the surface. With regard to the binding yarn 4, the compounded resin adheres to the surface, and the compounded resin adhering to the surface of the adjacent binding yarns 4 is united with each other to form the knitting yarn bundle 5 and the thick knit portion 6 Then, they are connected in a plate shape to form a flat tortoiseshell connection.

Next, as shown in FIG. 11, the soft porous core material 1 impregnated with the compounded resin is accommodated in the molding part 21 of the lower mold 20. The upper mold 22 is overlaid on the lower mold 20, closed and molded, and the compounded resin is cured over time. In this case, as shown in FIG. 3, a surface material layer 26 can be formed on the molding surface of the mold. A coloring material may be added to the surface material layer 26, or a glass strand chip, mat, cloth or the like impregnated with the compounded resin may be superposed. This improves the appearance and the strength.

Then, after curing, the mold is removed and a resin honeycomb molded body 12 is formed. In the upper mold 22 of FIG. 3, the lower surface is not flat, but is a male mold and has a protruding portion 22 a. As shown in Fig. 2, the binding yarn 4 is bent and deformed in the portion where the formed portion spacing is small on the side of the protruding portion 2 2a, and it is formed and hardened as it is deformed to form a plate. The resin honeycomb formed body 12 has a partially different thickness. In FIG. 11, if the surface layer 26 is formed on the molding surface of the mold, as shown in FIG. 12, an 82 cam molded body 1 2 in which the surface layer 26 and the soft porous core 1 are united is formed. Becomes Therefore, if the surface material layer 26 is not formed, a honeycomb structure having through holes is obtained.

Also, as shown in FIG. 7, the soft porous core material 1 made of double Russell turtle-patterned three-dimensional knitted fabric can gather the turtle-patterned meshes 9 in a plane and partially narrow the holes, as shown in FIG. According to the curvature of the mold like a plane boat, a three-dimensional solid resin cam like a boat can be formed. In addition, since it can be bent freely, it can be formed into a box-like three-dimensional shape having a flat portion and a rising portion. In addition to male and female mold molding, male and female molds can be individually molded by hand.

The soft porous core material 1 made of the double Russell tortoiseshell three-dimensional knitted fabric uses a somewhat thick single yarn as the binding yarn 4, and impregnates the compound resin into the front structure 2 and the back structure 3 in FIG. Mold and cure in the mold. When the mold is removed, the compounded resin in the surface structure 2 and the back structure 3 is hardened, resulting in a hard honeycomb structure on the front and back. When pressed in the direction of the back structure, a resin honeycomb structure that expands and contracts in the thickness direction is obtained by the elasticity of the thick single binding yarn 4.

FIG. 13 is a perspective view of a plate-like soft porous core material 23 made of a heat-resistant and solvent-resistant soft foam resin block. A large number of punched through holes 24 are formed on the surface by a punching machine. The shape of the through hole 24 may be any shape such as a square, a circle, and a triangle.

When the compounded resin is impregnated into the porous core material 23 made of the soft foamed resin block and cured in the same manner as described above, a resin honeycomb molded body is formed. The advantage of the soft porous core material 23 made of the soft foamed resin block is that the thickness can be arbitrarily selected, and the shape and size of the prize through hole 24 can be arbitrarily formed. In particular, the size and shape of the through hole 24 can be partially changed That is.

FIG. 14 shows a product obtained by sandwiching an intervening cloth 25 impregnated with a compound resin between two soft porous core materials 1 and integrally molding and curing the same as described above. In this case, the material of the upper and lower soft porous core materials 1 can be changed. This material includes differences in material, wall thickness, through-hole size, color, etc. Examples of the intervening cloth 25 include a woven cloth, a knitted cloth, a nonwoven cloth, paper, wood, a glass strander, a soft cloth, and the like.

In FIG. 15, a preformed resin molded body 27 is arranged on the inner surface of a mold (not shown), and a soft porous core material 1 impregnated with a compound resin is arranged thereon, and is integrally molded and cured as described above. It is a thing. As the preformed resin molded article 27, one having adhesiveness to the compounded resin can be arbitrarily selected.

Further, the soft porous core material 1 can be wound around the male surface of the columnar body to form a tubular resin honeycomb molded body.

The application of the resin honeycomb molded body can be used in various fields. For example, it can be used for FRP molded core material, sound insulation wall material, heat insulation wall material, floor material, ceiling material, road surface pavement material, box material, pipe material, and other various fields. The resin honeycomb structure that does not use glass fiber is flammable and can be recycled. Next, a method for forming a three-dimensional shape such as a box using the above-mentioned soft porous core material in the form of a plate will be described. As shown in FIG. 16, a surface material layer 33 is formed on the surface of the male mold 31, and a soft porous core material 1 impregnated with a compounded resin is adhered thereon. In this case, as shown in Fig. 17, the soft porous core material 1 is folded in four in the left-right direction, and the portion that hits the mold is cut so that it does not overlap with the adjacent one when folded horizontally. They can be attached, or they can be covered from above, and the stitches in the overlapping area can be packed and attached as shown in Fig. 7.

The female mold 32 is placed on top of this, molded by clamping, and the compounded resin is cured over time. In this case, a surface material layer 33 is also formed on the inner surface of the female mold. After curing, when the mold is released, a box-shaped hollow resin honeycomb molded body 34 is formed. In the female mold 32 shown in FIG. 16, since the lower surface of the top plate is not flat and has a projection 32a, the soft porous core material 1 is pressed by the projection 32a from above by molding. Then, the binding yarn 4 where the protruding portion 3 2a is present is bent and deformed, and is formed and hardened into a plate shape while being deformed, so that the completed resin honeycomb formed body 34 is shown in FIG. As shown in the figure, a thin portion 34a is formed partially, and has a different thickness.

The surface material layer 33 can be colored at the same time as the resin honeycomb molded body 34 is formed by adding a coloring material. In addition, a cloth or a mat impregnated with the compounded resin can be applied on the applied or sprayed layer to make the whole or part of the layer thicker.

When the binding yarn 4 is set as a thick single yarn (including a composite yarn of fine single yarn) and the compounded resin is impregnated with the soft porous core material 1, the mixed resin is well impregnated on the front and back structures 2 and 3. However, it is difficult to attach to the thick single binding yarn 4. Therefore, when this is molded, the front and back structures 2 and 3 become a hard molded body, but since the binding yarn 4 has the elasticity of a single yarn remaining, this resin honeycomb molded body 34 is It is possible to maintain flexibility in the thickness direction.

In this case, as described above, in order to improve the elastic strength of the binding yarn 4, mineral fibers such as carbon fiber, Kepler fiber, and glass fiber are twisted or tied with the synthetic fiber, or the mineral fibers are intermittently interlocked. The fibers can be arranged in an array of synthetic fibers (see Figures 3-5).

As described above, since a large force is not applied to the molds 31 and 32, the molds can be formed by FRP or the like. For example, a 200 mm x 200 mm x 400 mm millimeter of resin honeycomb molded body for a refrigerator of a large freezer truck can be easily molded by FRP to form a large-sized housing. A large housing that is excellent, lightweight, and excellent in heat insulation can be molded. Also, since it is molded by male and female molds, it has excellent dimensional accuracy.

FIG. 20 is a resin c showing an embodiment in which an intervening cloth 25 impregnated with a compound resin is sandwiched between each of a plurality of soft porous core materials 1 and integrally molded and cured in the same manner as described above. This is a two-cam molding 34. In this case, the material of the upper and lower soft porous core materials 1 can be changed. This material includes differences in material, wall thickness, through-hole size, color, etc. Further, examples of the intervening cloth 25 include woven cloth, knitted cloth, non-woven cloth, paper, wood, glass strand mat and cloth. As an application, for example, it can be used as a wall for an aircraft or a ship, or as a blade for a windmill of a wind power generator. In a ship, the use of multiple layers not only improves the buoyancy of the hull, but also does not allow water to enter the interior even if a breach occurs in the outer layer, and does not sink.

FIG. 21 shows a method of uniting the FRP molded body 36 and the soft porous core material 1. Wooden plywood is often used as a reinforcing material in FRP bathtubs. Wood and metal are also used for the feet. In FIG. 21, the outer tank 37 and the inner tank 38 are formed in advance as an FRP molded body 36. The portion of the foot 17a of the outer tub 37 is recessed, and a reinforcing material 37b such as wood is fitted therein.

The soft porous core material 1 impregnated with the compounded resin is disposed inside the outer tank 37. In this case, the soft porous core material 1 is cut out at four corners that are not needed, and is formed into a substantially cross-shaped plane. Thereafter, the inner tank 38 is fitted into the outer tank 37 from above the soft porous core material 1 and pressurized.

As the resin blended with the soft porous core material 1 hardens over time, the inner and outer tanks 17 and 18 and the soft porous core material 1 are integrally bonded, and as shown in FIG. A cam compact 34 is formed. As can be clearly understood from FIG. 22, the thickness of the soft porous core material 1 is large at the bottom and the thickness of the soft porous core material 1 is small at the side wall.

As described above, the soft multi-porous core material 1 impregnated with the compounded resin is sandwiched between the upper and lower FRP molded bodies 36 and molded and cured, so that the FRP molded body 36 and the soft porous core material 1 can be easily formed. Combined molding can be performed. In FIG. 21, the soft porous core material 1 was formed between the molded bodies, but the FRP molded body and the soft porous core material 1 can be housed in a male and female mold.

In addition, a fiber reinforcement layer is formed on the molding surface of the female mold, Impregnating the compounded resin, and then impregnating the compounded resin into the soft porous core material 1, arranging it so as to be in contact with the ribs, closing the male mold, molding and curing integrally Can be.

FIG. 23 is a vertical sectional front perspective view of a resin honeycomb formed body of another embodiment. This method may be that shown in FIG. A large number of through holes 39 are formed at the bottom of the inner tank 38, and the through holes 39 communicate with the lower honeycomb holes. An air supply pipe 40 is provided so as to communicate from the outer tank 37 to the inner soft porous core material 1. The resin honeycomb formed body 34 as the bathtub can generate air bubbles in the bathtub by sending air from an air supply means (not shown) through an air supply pipe 40.

FIG. 24 shows a method of forming a resin honeycomb formed body 34 made of a tubular body. A surface material layer 33 is formed on the peripheral surface of the male mold 31, and a soft porous core material 1 impregnated with a compounded resin is wound around the peripheral surface, and a female mold 32 is formed on the peripheral surface. A tube of the resin honeycomb molded body 34 can be obtained by forming the resin honeycomb molded body and curing it.

The shape of the resin honeycomb formed body 34 can be freely changed, and the resin honeycomb formed body 34 can be used in various fields. For example, soundproof wall materials, heat insulating wall materials, flooring materials, ceiling materials, box bodies, tank bodies, pipe bodies, sheds, aircraft, ships, boats, floats, wind turbine blades for wind power generation, and many other areas Can be used. In addition, the resin honeycomb molded body 34 that is not using mineral fibers can be recycled because it is flammable. In addition, it can be used as a protective cover for antennas because it can be made thinner and has excellent radio wave transmission.

The present invention is not limited to the above embodiment, and the design can be appropriately changed according to the purpose. For example, a metal molded product can be inserted into the inside of a soft porous core material, the middle of a multilayer, a resin molded product, or the like to be integrally molded.

An embodiment of the decompression method of the present invention will be described with reference to FIGS. You. Fig. 25 is a vertical front view of the molding die, and Fig. 26 is a vertical front view of the clamped die.

The molding dies 41 and 42 are composed of a female mold 41 and a male mold 42. In the figure, reference numeral 43 is a mating surface, 44 is a seal, 45 is a material injection hole, 46 is a pressure reducing hole, and 47 is a pressure reducing means.

A preform fiber 48 in which a fiber reinforced material (glass fiber or the like) was preliminarily formed was placed in a molding portion of the female mold 41 and was then sorted. However, it is also possible to use fiber reinforced mat cloth without preforming. The male mold 42 was lightly tightened on the female mold 41 until the seal 44 hit the surface. Then, the compounded resin was injected from the material injection holes 45 without pressure.

In this case, the theoretical amount of the compounded resin required for the molded body is put in the funnel above the material injection hole 45, and when the compounded resin has completely entered the mold, the opening of the material injection hole 45 is closed. The molds 41 and 42 were depressurized at a low pressure (2.5 = Hg to 20 == Hg) by a decompression means 47 connected to the decompression hole 46.

When the pressure was reduced slowly by the decompression means 4 7 inside the molding dies 4 1 and 4 2, the pressure was reduced, and the mold was closed.The seal 44 was crushed, and when the compounded resin came out of the decompression hole 46, The decompression holes 46 were closed, and the outer peripheries of the male and female molds 41, 42 were fixed (see Fig. 26).

By curing in this state with the mold clamped, the compounded resin was cured, and a shallow box-shaped resin molded body (not shown) was completed.

As can be clearly understood from FIG. 25, the male mold 42 supported by the seal 44 is in a floating state, so that the compounded resin has no resistance from the material injection hole 45 even if no pressure is applied. Without entering the molds 4 1 and 4 2. Therefore, in the production of any large-sized compact having a side exceeding 2 meters, the required amount of material can be filled into the molds 41 and 42 in a very short time.

Next, the depressurizing hole 46 is formed from the mold mating surface 43 outward and upward, and the inside of the forming dies 41 and 42 is depressurized, whereby the mold is clamped and the preform is formed. Air bubbles between the fibers of the fibers 48 are sucked out, and the compounded resin permeates completely between the fibers.

That is, in the conventional molding method, the compounded resin is injected by a strong external pressure, so the small air bubbles between the fibers are trapped between the fibers as they are, and the resin often flows and wraps the resin. According to the present invention, by reducing the pressure in the molds 41 and 42, any fine air bubbles between the fibers can be completely sucked out from between the fibers.

Also, by reducing the pressure at a low pressure so that the resin material is drawn at a speed lower than the flow speed of the compounded resin, a large load is not applied to the molds 41 and 42, and the resin material is drawn uniformly. Therefore, since it is not necessary to increase the strength of the molds 41 and 42, the cost of the mold is significantly reduced. Naturally, the weight of the mold can be reduced.

In the conventional molding method, the compounded resin is injected under pressure, so if the molds of the male and female molds 41 and 42 are not firmly tightened, the mold will be misaligned. According to the present invention, the insides of the male and female dies 41 and 42 approach each other by reducing the pressure inside the molding dies 41 and 42 with low pressure. Pressing this resin material eliminates the need for large-scale mold clamping equipment and work as in the past.

In other words, much less force is required to pull out the gas inside the mold under reduced pressure than to push a viscous fluid under a strong external pressure. As a result, the equipment and the mold structure can be significantly simplified.

FIG. 27 is a vertical sectional front view of a molding die showing production of a deep tank or the like. First, in FIG. 27, the male mold 42 is removed, and the preform fiber 48 is set in the molded portion of the female mold 41. Thereafter, a theoretical amount of the compounded resin necessary for molding the molded body is poured into the female mold 41 so as to be poured without pressure.

Then, set the male mold 42, and lightly tighten it until the upper and lower seals 44, 44 contact each other. The seal 44 of the female mold 41 has a recess on the upper surface, and the seal 44 of the male mold 42 is in close contact with the recess of the female mold 44, and Since the contact area is large, close contact is excellent, and the decompression action is effective quickly. When light pressure is applied to the molds 41 and 42, the mold is loosely clamped by the negative pressure.

The pressure is reduced at a low pressure until the compounded resin comes out from the pressure reducing hole 46, and the pressure reducing hole 46 is closed when the compounded resin comes out. As a result, the molding dies 41 and 42 are firmly closed by the internal negative pressure, so that the outer circumferences of the molding dies 41 and 42 are fixed so that they do not float up and down to prevent mold displacement. I do.

When cured, the compounded resin in the molds 41 and 42 is hardened to form a deep tank-shaped molded body (not shown). As described above, even with a large molded body having a side of more than 2 meters, since a large external material injection pressure is not applied to the molding dies 41 and 42, a molding die composed of a thin FRP molded body is sufficient. In time, the mold cost burden can be reduced. Naturally, with the reduction in the weight of the mold, large-scale equipment for work is not required, and workability is improved.

In the method of the present invention, as described above, the compounded resin is not pressed into the mold by applying an external pressure. The time for material injection is extremely short.

In addition, by adjusting the mold and reducing the pressure at a low pressure, the mold is naturally tightened and inevitably presses the resin, eliminating the need for large-scale equipment and cumbersome work.

Up to this point, molding using preform fibers has been described. However, the present invention relates to an FRP type in which a fiber reinforcing material (such as a cloth mat) is disposed in a molding die, including the above-mentioned compounded resin. The present invention can be applied to any molding using a thermosetting resin material without using a soft porous core material and a fiber reinforced material. That is, for example, molding of artificial proxy stone, urethane injection molding, and the like can be performed without injection of resin under pressure and molding without a mold clamping press.

FIG. 28 shows a wind turbine used in a wind power generator or the like to which the resin molded article of the present invention is applied. 4 shows an embodiment of a blade. The blade 51 includes a cylindrical outer shell 52 and a reinforcing rib 53 fitted and fixed inside the outer shell 52. The outer shell 52 has a closed-loop cross-section, starting at the narrow rear end 54, curving at the front end 55, and returning to the rear end 54 again. As shown in FIG. 29, the outer shell 52 has a soft porous sheet-like core material 56, a reinforcing sheet 57 integrally formed on the upper and lower surfaces of the core material 56, and a core material. 5 and the curable resin filled in the voids of the reinforcing sheet 57. The core material 56 may use the above-mentioned double rassel turtle pattern solid knitted fabric or the like. As the curable resin, a two-part curable resin such as an epoxy resin, or a thermosetting resin such as a phenol resin, a urea resin, or a melamine resin is used. The reinforcing sheet is preferably a strand mat or roving made of reinforcing fibers such as glass fiber, carbon fiber, and Kevlar fiber. The reinforcing sheet 57 may be used only on one side of the core material 56.

As shown in FIG. 30a, the reinforcing rib 53 includes a cross-sectional I-shaped core material 59 made of a synthetic resin foam, and a sheet-shaped core material 5 provided around the core. 6, a reinforcing sheet 60 provided around the core material 56, and a curable resin filled in the voids of the core material 56 and the reinforcing sheet 60. A reinforcing sheet may be interposed between the sheet-like core material 56 and the three-dimensional core material 59. In particular, in the case where the curable resin and the three-dimensional core material 59 react with each other, it is preferable to interpose a reinforcing sheet having airtightness. As the sheet-like core material 56, the reinforcing sheet 60, and the curable resin, the same materials as those used for the outer shell 52 can be used. As the three-dimensional core material 59, other materials may be used as long as they are lightweight and can withstand a compressive load, but synthetic resin foams, particularly styrene foam, are preferred. Further, the cross-sectional shape is not limited to the I-shape, and various cross-sectional shapes such as a rectangular shape and a C-shape can be adopted.

As shown in Fig. 3 Ob, two or more reinforcing ribs 53 are arranged, and the entire outside of them is a composite reinforcing rib 61 surrounded by a single reinforcing sheet 60. Can also. In that case, provide a reinforcing sheet for each reinforcing rib 56. Instead, only the entire reinforcing sheet 60 may be used.

The blade 51 can be formed by separately forming the outer shell 52 and the reinforcing rib 53 and then combining them.However, usually, the reinforcing rib is first formed, and then the outer shell 53 is formed. The laminated sheet to be formed is wound and molded integrally. That is, for the reinforcing rib 53, a sheet-like core material 56 impregnated with a compounded resin material obtained by mixing a curable resin material and a hardening agent in advance is wound around a three-dimensional core material 59. Then, a reinforcing sheet 60 is wound therearound to prepare a reinforcing rib intermediate. Next, the reinforcing rib intermediate body is housed in a mold, and the curable resin is cured while maintaining a predetermined shape. In the case of thermosetting resin, it is cured while heating. The mold is usually a split mold divided into left and right in Fig. 30a.On the other hand, as for the outer shell 52, first, a flexible sheet-like core material 56 is impregnated with a liquid or paste-like curable resin material. Then, a reinforcing sheet 57 is overlaid to prepare an outer shell intermediate. In this state, the laminated sheet as an intermediate is flexible. However, it may be preformed with a heat set or the like in advance. Then, the outer shell intermediate body and the molded reinforcing rib are accommodated in a mold, and the curable resin is cured while maintaining a predetermined shape. Upper and lower split dies having parting lines at the rear end 54 and the front end 55 of the blade are used. The molding is preferably performed by the negative pressure molding method described above. However, a pressing molding method is also possible. The blade 51 configured as described above is light in weight and high in strength because the outer shell 52 positioned on the contour carries a tensile load and a compressive load. In addition, since the outer shell 52 has a closed loop shape, it has high strength against torsion. Further, since the reinforcing ribs 53 are provided, the strength is further enhanced. Further, the reinforcing rib 53 has a high secondary moment of cross-section because the peripheral portion becomes a strength member, and has high strength against bending stress. In addition, the three-dimensional core material 59 made of synthetic resin foam inside has a high buckling strength because it bears a compressive load. So, for example, it is possible to manufacture blades with a width of several tens of centimeters to 2-3 meters and a length of several meters to several tens of meters, It is suitably used as a blade of an electric windmill.

In addition, as shown in FIG. 31, it is preferable to manufacture the part as a part that can be joined on the way with the seal joints 62 and 63 as shown in FIG. 31 in relation to the limitation of the molding die and the transportation. In that case, it can be assembled at the construction site of the wind turbine using an adhesive or the like. In such a case, the above-mentioned reinforcing ribs may be continuous and long, and the outer shell 52 may be constructed by joining short ones.

The blade 65 shown in FIG. 32 is obtained by combining a plurality of pros and hooks 66 similar to the reinforcing rib 53 of FIG. 30a. Since the configuration and manufacturing method of each block 66 are the same as those in FIG. 30a, the same reference numerals are given and the description is omitted. The blocks 66 are arranged in parallel, and their surroundings are integrally surrounded by an outer shell 52 shown in FIG. Since the structure and manufacturing method of the outer shell 52 are the same as those shown in FIGS. 28 and 29, the same reference numerals are given and the description is omitted.

In the blade 65, the vertical reinforcing sheet 67 between the adjacent blocks 66 serves as a reinforcing rib connecting the upper and lower outer shells 52. Further, the three-dimensional core material 59 made of a synthetic resin foam filled in the interior of each block 66 is lightweight and has high strength against a compressive load. Therefore, the blades 50 are lightweight and high in strength as a whole. As shown in Fig. 31, it is also preferable to manufacture this product separately and assemble it at the wind turbine installation site. '

In the embodiment of FIG. 28, the inside of the outer shell 52 is a cavity except for the reinforcing rib 53, but as in the case of FIG. 32, a synthetic resin foam is provided in the cavity. Is also good. In this case, the material of the synthetic resin foam may be filled in the hollow portion and then foamed, or the blade 51 may be assembled by incorporating a block foamed in a predetermined shape in advance. Good. In the embodiment of FIG. 28, the reinforcing ribs 53 are arranged so as to extend in the longitudinal direction of the blade 51. However, they may be arranged so as to extend in a direction crossing the blade 51 or in an oblique direction. In addition, the reinforcing ribs 53 in FIGS. 30a and 30b are not only used as reinforcing ribs for wind turbine blades, but also in a chassis of a car, other strength members of a car, It can be applied as a strength member where weight reduction is desired, such as building beams and other strength members.

FIGS. 33a to 33c show another embodiment of the method for manufacturing the above-described wind turbine blade. In this manufacturing method, first, as shown in FIG. 33a, an upper mold 70a and a lower mold 70b that form the upper surface side and the lower surface side of the blade are prepared. Further, as shown in FIG. 33b, blocks 71a, 71b, 71G of the synthetic resin foam divided into several parts and several preformed fiber sheets 72a to g are prepared. The block is the same as the three-dimensional core 59 of the reinforcing rib 53 in FIG. 28, for example, styrene foam. In this embodiment, three blocks are used: a front block 71a for the blade, a center block 71b and a block 71c on the rear side.

The preformed fiber sheet (preform fiber) 72 ag can be prepared by spraying a fiber reinforcing material (glass, carbon or other fiber) together with the resin onto the mold surface, or by manually attaching it to a predetermined shape. A molded fiber. Further, the fiber reinforced material may be simply formed into a predetermined shape by a heat set. Note that a flexible porous sheet-like core material similar to the sheet-like core material 56 in FIG. 28, for example, a double-rasel three-dimensional knitted fabric, is cut into a predetermined shape and heat-set into a predetermined shape. Can also be used. In the embodiment of ζ, the preformed core material is a fiber sheet 72 a having a V-shaped or U-shaped cross section constituting the front side of the blade and a fiber sheet 72 having a V-shaped cross section constituting the rear side. b, a loosely curved fiber sheet 7 2 c forming the upper surface side of the blade, a loosely curved fiber sheet 7 2 d forming the lower surface, and three fiber sheets 7 whose upper and lower ends are bent to form the reinforcing ribs 7 2 e to g.

Then, as shown in Fig. 33c, the preformed fiber sheets 72a-g are combined between and around the foam blocks 71a-c. At that time, an adhesive may be used, or the adhesive may be stuck with an adhesive tape or a stapler. Also, it is only necessary to put them in the mold in order and set them without joining them in advance. Next, as shown in FIG. 33d, the set material 73 is put into dies 70 and 70b, and the compounded resin is injected and molded. The compounded resin refers to a soft candy resin in which various materials necessary and sufficient for FRP molding and other moldings are compounded. As a result, the compounded resin is filled in the gaps between the preformed fiber sheets 72a to 72g, and is molded into cavities of molds 70a and 70b. Then, remove the mold and trim the burr to complete the blade 74.

FIGS. 34a and 34b show an embodiment of an integral molding method using the same reinforcing ribs as in the case of FIG. In other words, instead of the central block 7 lb in Fig. 33 b and the preformed fiber sheet 72 en to surrounding it, a soft porous core material 7 was previously set around the block 71 b. 5 is wound and set in a mold, and a reinforcing rib (bone) 76 formed by injecting a compounding resin is used. The other point is that the front and rear blocks 7 1a and 7 1b, the front and rear preformed fiber sheets h 7 2a and 7 2b and the upper and lower preformed fiber sheets 7 2c and 7 2d are used. Is the same. These parts are assembled as shown in Fig. 34b, put into a mold, injected with compounded resin, molded, demolded, and trimmed with burrs as in Fig. 33.

When integrally molded as shown in Fig. 33 and Fig. 34, compared to the case where each part is molded in a state where it has been cured with a compounded resin in advance, and these parts are bonded and assembled to make a finished product, It can be manufactured with high precision. In other words, when assembled in a package, there is variation in accuracy and variation in weight, so quality control is difficult, and the quality of the finished product varies depending on the capabilities of the workers. However, by integrally molding as shown in Fig. 33 and Fig. 34, the man-hour for assembling the product is small, and the accuracy and weight can be stabilized. In addition, the management of workers becomes easier. In addition, since it is an integral molded product with no seams, the strength is increased and there is no place to peel off. In addition, the quality is constant, work management becomes easier, the number of man-hours is reduced, and the performance is increased. In the case where a foamable resin material is injected into a mold and foamed in the mold to be integrally molded, only a size that can mold the foam can be manufactured, but the block is molded in advance as described above. After that, by integrally molding the whole, it is possible to integrally mold the one with a size of several tens of meters. In addition, in the case of the manufacturing method shown in Fig. 33, the strength should be further increased by connecting the foam blocks together, using a long one in which only the reinforcing ribs 76 are pre-formed, and integrally forming them. Can be.

The resin molded article of the present invention configured as described above has the following excellent effects.

(1) A porous core material formed into a thick honeycomb with many through-holes formed on the front and back of a flexible and permeable material, impregnated with a compounded resin, Because it is, it can be molded into any shape. Therefore, it is possible to obtain a resin honeycomb formed body having a shape suitable for the application.

(2) In the case where the porous core material impregnated with the compounded resin is partially molded into a thick and thin portion in a molding die, a resin honeycomb molded body more suitable for use can be obtained.

(3) The porous core material impregnated with the compounded resin is formed into a box-shaped three-dimensional shape with a rising part from a flat part by a mold or by hand, and then molded and cured to form a box-shaped honeycomb. It is possible to obtain a fat honeycomb formed body having an integrated structure.

(4) In the case where the porous core material impregnated with the compounded resin is sandwiched between the upper and lower two layers with a cloth impregnated with the compounded resin sandwiched and molded and cured, a more rigid resin molded body is obtained. be able to.

(5) A resin honeycomb molded body in which a porous core material impregnated with a compounded resin is superimposed on a mold surface having a surface material layer formed on the mold surface and integrally molded and cured, has a smooth surface. .

(6) Making the soft porous core material impregnated with the compounded resin into a tube and curing it Therefore, a tubular honeycomb formed body can be easily obtained.

(7) The resin honeycomb molded body in which the soft porous core material is a double-layered, soselled creature pattern three-dimensional knitted fabric can be manufactured by simply impregnating the three-dimensional knitted fabric with a compounded resin. The resin honeycomb structure, in which the through holes are formed by punching the foamed resin plate, is used to open the through holes in the foamed resin plate, so that the size and position of the holes can be freely selected. The rigidity can be adjusted.

(9) A resin honeycomb structure that expands and contracts in the thickness direction can be easily obtained. (10) For the resin honeycomb structure in which the soft porous core material is a fibrous porous plate in which a large number of through holes are formed, waste paper or the like can be used.

(11) Can be widely used and recyclable.

(12) A honeycomb structure can be easily obtained regardless of the size of the holes.

(13) A tubular honeycomb structure can be easily formed.

The porous core material of the present invention configured as described above has the following excellent effects.

(1) The excellent resin honeycomb formed body can be easily manufactured.

(2) Since it can be wound around a columnar mold in a state where the compounded resin is impregnated, a resin honeycomb structure tube can be easily formed in a short time.

(3) In the mold, a fiber reinforced material layer impregnated with the compounded resin is formed, and a soft porous core material impregnated with the compounded resin is stacked on top of this to form the FRP portion and the honeycomb portion. Can easily be formed.

(4) An existing molded body is placed and placed in a mold, and a soft porous core material impregnated with a compounded resin is laminated on top of this, and molded, for example, by combining a FRP part and a honeycomb part. A honeycomb formed body can be easily formed.

(5) A soft porous core material impregnated with a compounded resin is sandwiched between the outer and inner tanks of the FRP molded bathtub, and the inner and outer tanks are formed by pressing and molding and curing together. There is an effect that a resin honeycomb molded body as a bathtub having an excellent heat retaining property and rigidity having a honeycomb structure formed in the middle can be formed. In the case of a bathtub, pores communicating with the lower honeycomb structure are formed at the bottom of the inner bath, so that air is supplied from the outside, so that a structure that generates air bubbles in the bathtub can be easily achieved.

(6) The resin honeycomb structure, in which the soft porous core material is a double-layered, sosel turtle-patterned three-dimensional knitted fabric, uses a thick single yarn as a binding yarn that connects the front and back tissues, thereby impregnating the mixed resin. When formed by molding, the front and back structures are hard, and the elasticity of the binding yarn in the thickness direction makes it possible to obtain a flexible resin honeycomb molded body.

(7) Since a united molded body of the FRP portion and the honeycomb structure portion can be easily formed, a wide range of applications is expected.

The manufacturing method of the present invention configured as described above has the following excellent effects.

(1) The soft porous core material for the resin honeycomb formed body is made of a double raschel three-dimensional knitted fabric, and a binding yarn that sets the thickness between the front and back textures intersects perpendicularly to make the front and back texture. Since the double knitted structure is formed by joining together, it has a thick 82-cam structure, and the resin honeycomb molded body can be easily formed simply by impregnating the compounded resin and curing. Can be formed. Further, since the front and back textures are composed of bundles of synthetic fibers, the compounded resin is excellent in impregnating property, and the binding yarns are mixed resin when single yarns of synthetic fibers and bundles of mineral fibers are mixed. It is possible to obtain a resin honeycomb molded body using the elasticity of the synthetic fiber single yarn and maintaining the elasticity in the thickness direction of the molded body, while at the same time utilizing the elasticity of the synthetic fiber single yarn.

(2) When the front and back tissues are composed of one selected from a single or mixed fiber bundle of synthetic fibers and mineral fibers, the rigidity of the front and back tissues is set arbitrarily according to the purpose. can do.

(3) The synthetic fiber is a high-molecular synthetic fiber such as polyester and Kepler fiber. At one time, it has excellent bondability with the compounded resin, and when a single yarn is used for the binding yarn, it has excellent elasticity.

(4) When the mineral fiber is selected from carbon fiber, glass fiber simple substance, and composite, it is excellent in adaptability to the compounded resin and the rigidity of the molded body is improved.

(5) When the mixing of synthetic fibers and mineral fibers in the binding yarn is selected from ply twisting and drawing, desired elasticity and rigidity can be set according to the purpose.

(6) When the mixture of synthetic fibers and mineral fibers in the binding yarn is alternately arranged along the longitudinal direction of the thick knit portion and the thin knit portion, the partial elasticity and rigidity are set according to the purpose. be able to.

(7) When the mixing ratio of the mineral fiber to the synthetic fiber in the binding yarn is from 20% by volume to 50% by volume, the rigidity and the elasticity can be adjusted and set.

(8) The double knitted fabric is formed from a double Russell three-dimensional knitted fabric, and a binding yarn that sets the thickness between the front and back textures intersects orthogonally and bonds the front and back tissues together. As the binding yarn, a synthetic fiber single yarn and a mineral fiber bundle yarn are mixed, and a soft porous core material, whose three-dimensional shape is fixed by a heat set, is impregnated with a soft syrup-like compounded resin and cured. A resin honeycomb molded body having elasticity in the thickness direction of the molded body due to the elasticity of the binding yarn has excellent elasticity in the thickness direction, and can have elasticity particularly at corners.

(9) When the thickness of the molded body is partially changed to be thin by the male and female molding, the thickness can be changed according to the thickness of the target molded body.

(10) When the molded body is integrally joined with a surface layer formed in advance on a molding surface of a molding die, a honeycomb structure without prize holes can be formed.

(11) A soft porous core material made of a double Russell three-dimensional knitted fabric in which the binding yarns are perpendicular to the front and back textures, with the compounded resin impregnated between each of the multiple pieces. A double honeycomb is formed integrally by sandwiching the cloth layer, and an interposed cloth layer impregnated with a compounded resin is overlapped on the front and back surfaces of the double honeycomb, and integrally formed. Due to the elasticity of the binding yarn, the molded body has elasticity in the thickness direction and does not burst even when subjected to an impact.

(12) A soft porous core made of double ply and sosell three-dimensional knitted fabric in which the binding yarns are perpendicular to the front and back textures. A formed body in which a double honeycomb is formed, and a preformed formed body is overlapped on the front and back surfaces of the double honeycomb and integrally bonded and formed, has elasticity in a thickness direction of the formed body due to elasticity of a binding yarn. The molding is easy and the molding accuracy can be increased.

(13) A soft porous core material consisting of a double Russell three-dimensional knitted fabric in which binding yarns are perpendicular to the front and back textures, with an intervening fabric layer impregnated with the compounded resin interposed between each of the soft porous cores. A resin honeycomb forming step of integrally forming a double honeycomb, and a step of laminating an interposed cloth layer impregnated with a compounded resin on the front and back surfaces of the double honeycomb and forming them integrally with a forming die. The method of manufacturing the body is such that the elasticity of the binding thread of the soft porous core material allows the molded body to have elasticity in the thickness direction, so that the resin honeycomb molding having elasticity can be easily performed in a simple process. The body can be manufactured with high precision.

(14) As a whole, it is possible to inexpensively manufacture even those having shapes that change quickly and easily.

The decompression molding method of the invention configured as described above has the following excellent effects.

(1) Since a large compact can be molded with a low-pressure decompressor and a simple mold, there is an effect that it can be easily carried out in a small factory without requiring large-scale facilities and complicated operations.

(2) The method of manufacturing a resin molded body at a low pressure in the range of 2,5 = Hg to 20 = Hg is low pressure, so a small decompressor is sufficient. Since it does not require rigidity, it can be used for molding large products with a lightweight and simple mold.

(3) A process of inserting and reinforcing the fiber reinforced material in the female mold, a process of introducing the compounded resin into the female mold without applying pressure, and a process of arranging the male mold in the female mold and lightly clamping the mold. The method of manufacturing a resin molded body, which comprises a step of reducing the pressure in the male and female molds and a step of closing and curing and curing the reduced pressure hole when the compounded resin overflows in the reduced pressure hole, comprises a fiber reinforced material set. Since the compounded resin is simply injected into the female mold without pressure, no matter how large the resin is, the compounded resin can be filled in an extremely short time. Next, the mold is clamped by reducing the pressure to a low pressure, so that the bubbles between the fibers of the fiber reinforced material are completely sucked out, and the compounded resin can be evenly and completely filled even in the corners of the complicated shape.

(4) A step of setting the fiber reinforced material in the female mold, a step of arranging the male mold and lightly clamping the mold, a step of injecting the compounded resin from the mold material injection hole without pressure, and In the method for manufacturing a resin molded body, which includes a step of reducing the pressure in the mold and a step of closing and curing and curing the compounded resin when the compounded resin overflows in the reduced pressure hole, an extra space is formed in the molding portion. At this point, the compounded resin is injected without pressure, so that the required amount of the compounded resin can be injected in a very short time, and the workability can be improved.

(5) Consists of a combination of male and female molds.The female mold is configured to directly charge the compounded resin under no pressure, while the male mold has a decompression hole from the mating surface inside the seal to the outside of the mold. In addition, the mold in which the decompression means is connected to the decompression hole has an effect that the compounded resin can be directly poured into the female mold without pressurization in a short time. Further, only by reduced pressure from the depressurization hole, ₉ therefor pressure based on a large area as the atmospheric pressure is obtained without requiring a large is rising, such mold clamping devices and work, and the resin is filled completely between the fibers, Can be molded.

(6) The male mold has a combination of a male and a male. The male mold has a decompression hole formed from the mating surface inside the seal to the outside of the mold, and a decompression means is connected to the decompression hole. The molding die, which has a non-pressurized material injection hole that passes from the outside to the molding die, can be filled with the compounded resin in a short time without pressurization. The resin can be completely and uniformly filled between the fibers and molded without any additional work.

(7) The resin molding die in which the seals are disposed opposite to the male and female molds, respectively, and the seals in which the concaves are formed on the upper surfaces of the female seal fitting concaves, are fitted. It becomes large and has excellent adhesion, and can improve the decompression effect.

(8) In the above method and the molding die, since the pressure for charging the resin is not used, the molding die can be simplified, the cost of the die can be reduced, and the necessity of a crane or the like due to weight reduction is eliminated. Large moldings can be easily manufactured even in small factories without the need for extensive equipment, such as the need for large mold clamping equipment and work.

(9) Since no pressure is required for filling the resin, it is possible to charge the resin in an extremely short time and to ensure the uniform filling of the resin even in a complicated shape, significantly reducing the molding time and improving productivity. Can be improved. At the same time, product quality is improved on average.

Claims

The scope of the claims

1. A large number of through-holes are formed on the front and back of a flexible and permeable material, and a thick honeycomb-shaped soft porous core material is impregnated with the compounded resin, which is then molded into a mold. A cured resin molded body.

2. The resin molded product according to claim 1, wherein the resin molded product partially forms a thick portion.

3. The resin molded article according to claim 1, which is formed in a three-dimensional shape having a rising portion from a flat portion.

4. The resin molded article according to claim 1, wherein the interposed cloth impregnated with the compounded resin is sandwiched between two upper and lower soft porous core materials impregnated with the compounded resin, and integrally molded and cured.

5. The resin molded article according to claim 1, wherein the soft porous core material impregnated with the compounded resin is laminated and integrally molded on a mold surface having a surface material layer formed on the mold surface and cured.

6. The resin molded article according to claim 1, wherein the resin molded article is molded and cured.

7. The resin molded article according to any one of claims 1, 2, 3, 4, 5 and 6, wherein the soft porous core material is a double-rassel sculpture three-dimensional knitted fabric.

8. The resin molding according to any one of claims 1, 2, 3, 4, 5, and 6, wherein the soft porous core material is formed by punching holes in a heat-resistant and solvent-resistant foamed resin plate. body.

9. A large number of perforated holes are formed on the front and back of the flexible and permeable material, and the composite resin is applied to the front and back of the thick porous soft core material except for the middle. The resin molded article according to any one of claims 1, 2, 3, 4, 5, 6, 7, or 8, wherein the resin molded article is impregnated, molded, and cured to have elasticity in a thickness direction.

10. A step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating on the front and back of a flexible and permeable plate-like material; A step of impregnating the resin, and a step of forming a surface layer on the molding surface of the mold. A process in which the soft porous core material is superposed on a surface material layer, integrally molded, and cured.

11. The method according to claim 10, further comprising a step of forming a surface layer on the molding surface of the mold before the step of molding and curing, and laminating the soft porous core material on the surface layer. Method for producing a resin molded article.

12. The method for producing a resin molded article according to claim 10, wherein the thickening and thinning portions are partially formed in the male and female molds in the molding and curing steps.

13. In the step of laminating the soft porous core material on the surface material layer, the soft porous core material is adhered to the surface material layer, partially stretched or contracted, and has a rising portion from a flat portion. 21. The method for producing a resin molded article according to claim 11, wherein the resin molded article is formed into a three-dimensional shape, and then integrally molded and cured.

14. The resin molded article according to claim 11, wherein an intervening cloth impregnated with a compounded resin is sandwiched between each of the plurality of the soft porous core materials stacked one on another, and they are arranged on the surface layer. Production method.

15 5. A step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating the front and back of a flexible and permeable material, and adding a compound resin to the soft porous core material. Impregnating, forming a surface layer on the male and female molding surfaces, winding the soft porous core material on the surface layer on the peripheral surface of the columnar male die, and covering the female die around the soft porous core. A method for producing a resin molded article, comprising: a step of integrally forming the resin molded article into a tube, followed by curing.

16. A step of forming a surface layer on the molding surface of the male and female molds, a step of forming a fiber reinforcement layer impregnated with the compounded resin on the surface layer of the female mold, and distributing the soft porous core material. A method for producing a resin molded body, comprising: a step of impregnating a composite resin; and a step of laminating a soft porous core material impregnated with a compounded resin on a fiber reinforced material layer, and integrally molding and curing the mold.

17. A step of preparing a thick honeycomb-shaped soft porous core material having a large number of through-holes penetrating the front and back of a flexible and permeable material; A step of impregnating a synthetic resin, a step of arranging an existing molded body on the molding surface of the female mold, a step of arranging the soft porous core material on the existing molded body, and molding and curing integrally with the mold clamp A method for producing a resin molded article comprising:

18. The step of individually molding the outer molded body and the inner molded body having a space at the joint, the step of impregnating the soft porous core material with the compounded resin, and the step of applying the soft porous core material to the inner surface of the outer molded body. A method for producing a resin molded body, comprising a step of arranging, a step of arranging an inner molded body thereon, and pressing and molding and curing the molded body at a time. '

1 9. A step of forming a soft porous core material using the binding yarn of the double Russell turtle pattern three-dimensional knitted fabric as a thick single yarn, a step of impregnating the mixed resin into the front and back tissues of the soft porous core material, and forming a mold. A method for producing a resin molded body in which the soft porous core material is arranged on a surface, molded and hardened, whereby the front and back texture portions are hard, and the elasticity of the binding yarn maintains the flexibility in the thickness direction.

20. The double knitted fabric is formed from a double Russell three-dimensional knitted fabric, and a binding yarn that sets the thickness between the front and back fabrics intersects perpendicularly to join the front and back fabrics together. The front and back tissues are each composed of a thin knit part and a thick knit part where the left and right thin knit parts are joined. The thick knit parts are intermittently connected in series, and the adjacent thick knit parts are in the vertical direction. The fine knitted part is formed by branching the left and right thin knitted parts together to form the next thick knitted part. The front and back texture is composed of fiber bundle yarn, and the binding yarn is mainly made of synthetic fiber single yarn, mineral fiber bundle yarn is selectively mixed, and the three-dimensional shape is fixed by heat setting. Soft porous core material for molded articles.

21. The soft porous core material according to claim 20, wherein the mineral fiber is one selected from a carbon fiber, a glass fiber simple substance, and a composite.

22. The blending of synthetic fibers and mineral fibers in the binding yarn is selected from the group consisting of synthesizing, aligning, and alternate arrangement of synthetic fibers and mineral fibers. Item 20. The soft porous core material according to any one of Items 20 and 21

23. The soft porous core material according to any one of claims 20, 21 and 22, wherein a mixing ratio of the mineral fiber to the synthetic fiber in the binding yarn is from 20% by volume to 50% by volume. .

2 4. A double woven structure formed by a double Russell three-dimensional knitted fabric, and a binding yarn that sets the thickness between the front and back structures intersects perpendicularly and bonds the front and back structures together. The front and back tissues are each composed of a thin knit part and a thick knit part where the left and right thin knit parts are joined. The thick knit parts are intermittently connected in series, and the adjacent thick knit parts are in the vertical direction. The fine knitted part is formed by branching the left and right thin knitted parts together to form the next thick knitted part. The front and back texture is composed of fiber bundle yarns, the binding yarns are mainly synthetic fiber single yarns, mineral fiber bundle yarns are selectively mixed, and the three-dimensional shape is fixed by heat treatment and software The soft porous core material is impregnated with the soft syrup-like compound resin and cured, and the elasticity of the molded body is provided in the thickness direction by the elasticity of the binding yarn. Comprising Te resin molding.

25. A soft porous core material consisting of a double Russell three-dimensional knitted fabric in which the binding yarns are perpendicular to the front and back tissues, sandwiches the interposed cloth impregnated with the compounded resin between each of the multiple soft core materials. To form a double honeycomb, and interposed fabric layers impregnated with a compound resin are formed on the front and back surfaces of the double honeycomb, respectively, and integrally formed. A resin molded article having elasticity in the thickness direction of the molded article.

26. A soft porous core material consisting of a double Russell three-dimensional knitted fabric in which the connecting yarns are perpendicular to the surface structure and the back structure. A double honeycomb is formed on the front and back surfaces of the double honeycomb, and each of the preformed preformed bodies is overlapped and integrally formed. The elasticity of the binding yarn provides elasticity in the thickness direction. Resin molded body.

2 7. Intermediate material impregnated with a compound resin between each of a plurality of soft porous cores made of double Russell three-dimensional knitted fabric with binding yarns perpendicular to the front and back textures A step of forming a double honeycomb by forming the honeycomb integrally with the cloth layer interposed therebetween; and a step of integrally forming an interposed cloth layer impregnated with the compounded resin on each of the front and back surfaces of the double honeycomb by a molding die. A method for producing a resin molded article comprising:

28. In the molding method using a thermosetting resin material, the thermosetting resin material is put into the mold without pressure, and the molds are aligned and the mold is not pressed by external pressure. A method of manufacturing a resin molded article which is molded by clamping the mold by reducing the pressure in the mold.

29. In the molding method using thermosetting resin material, the mold is set and the thermosetting resin material is put into the molding die without pressurization. A method for producing a resin molded article which is molded by clamping the mold by reducing the pressure in the mold.

30. The method for producing a resin molded product according to any one of claims 28 and 29, wherein the reduced pressure is performed at a low pressure in a range of 2.5 cmHg to 20 cmHg.

3 1. A process of inserting and reinforcing the fiber reinforced material into the female mold, a process of introducing the compounded resin into the female mold without applying pressure, and a process of arranging the male mold in the female mold and lightly clamping the mold. A method for producing a resin molded article, comprising: a step of reducing the pressure in the male and female molds; and a step of closing and curing and curing the reduced pressure hole when the compounded resin overflows in the reduced pressure hole.

3 2. A process of setting the fiber reinforced material in the female mold, a process of arranging the male mold and lightly clamping the mold, a process of injecting the compound resin through the mold material injection holes without pressure, and a process of material injection. A method for producing a resin molded product, comprising: a step of closing the holes to reduce the pressure in the male and female molds; and a step of closing, curing, and curing the reduced pressure holes when the compounded resin overflows in the reduced pressure holes.

3 3. Composed of male and female molds, female molds are configured to directly charge the compounded resin without pressure, and male molds have pressure reduction holes from the mating surface inside the seal to the outside of the mold. A resin mold in which a pressure reducing means is connected to the pressure reducing hole.

3 4. Composed of male and female molds, the male mold is formed with a decompression hole from the mating surface inside the seal to the outside of the mold, a decompression means is connected to the decompression hole, Has a non-pressurized material injection hole that penetrates from the outside to the molding Resin mold.

35. The seal, wherein the seal is disposed to face each of the male and female molds, and the female seal has a seal formed with a recess on the upper surface fitted in the female seal fitting recess. 34. The resin mold according to any one of 4.

36. The resin mold according to any one of claims 33 and 34, wherein the decompression means is a low pressure decompression device in a range of 2.5 cmHg to 20 cmHg.

37. It is composed of a cylindrical outer shell and reinforcing ribs fitted and fixed inside the outer shell.

The outer shell comprises a soft porous sheet-shaped core material, reinforcing sheets provided on the upper and lower surfaces of the core material, and a curable resin filled in voids of the core material and the reinforcing sheet,

The reinforcing ribs include a three-dimensional core made of a synthetic resin foam, a sheet-shaped core provided around the core, a reinforcing sheet provided around the core, and a gap between the core and the reinforcing sheet. Consisting of a curable resin filled into

Blades for windmills.

38. A three-dimensional core material made of synthetic resin foam, a sheet-shaped core material provided around the core material, a reinforcing sheet provided around the core material, and a core material and a reinforcing sheet. A reinforcing member made of a curable resin filled in the gap.

39. A composite member in which one or more reinforcing members according to claim 38 are arranged, the outside of which is surrounded by a reinforcing sheet, and which is integrally molded.

40. The composite member according to claim 39, wherein a block made of foam resin is provided between the reinforcing member and the reinforcing sheet.

41. A windmill blade integrally formed with a plurality of reinforcing members according to claim 38, the outside of which is surrounded by a reinforcing sheet.

42. The blade for a windmill according to claim 41, wherein a professional and a rubber made of foamed resin are provided between the reinforcing member and the reinforcing sheet.

4 3. A block made of foam material and a flexible sheet-like porous core A method for forming blades for wind turbines, which is put together in a mold, then filled with a compounded resin and integrally molded.