WO2011052243A1 - 繊維強化成形体及びその製造方法 - Google Patents

繊維強化成形体及びその製造方法 Download PDF

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Publication number
WO2011052243A1
WO2011052243A1 PCT/JP2010/051287 JP2010051287W WO2011052243A1 WO 2011052243 A1 WO2011052243 A1 WO 2011052243A1 JP 2010051287 W JP2010051287 W JP 2010051287W WO 2011052243 A1 WO2011052243 A1 WO 2011052243A1
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WIPO (PCT)
Prior art keywords
thermosetting resin
resin foam
fiber
compression
impregnated
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/JP2010/051287
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English (en)
French (fr)
Japanese (ja)
Inventor
陽介 春日
杉浦　好典
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Inoac Corp
Original Assignee
Inoue MTP KK
Inoac Corp
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Filing date
Publication date
Application filed by Inoue MTP KK, Inoac Corp filed Critical Inoue MTP KK
Priority to EP20100826378 priority Critical patent/EP2495099B1/en
Priority to CN201080046260.2A priority patent/CN102574358B/zh
Priority to US13/498,251 priority patent/US8628842B2/en
Publication of WO2011052243A1 publication Critical patent/WO2011052243A1/ja
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/06—Fibrous reinforcements only
    • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
    • B29C70/086—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers and with one or more layers of pure plastics material, e.g. foam layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs
    • B29C70/467—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs and impregnating the reinforcements during mould closing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
    • B29C70/546—Measures for feeding or distributing the matrix material in the reinforcing structure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29D—PRODUCING PARTICULAR ARTICLES FROM PLASTICS OR FROM SUBSTANCES IN A PLASTIC STATE
    • B29D99/00—Subject matter not provided for in other groups of this subclass
    • B29D99/001—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings
    • B29D99/0021—Producing wall or panel-like structures, e.g. for hulls, fuselages, or buildings provided with plain or filled structures, e.g. cores, placed between two or more plates or sheets, e.g. in a matrix
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    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/08—Impregnating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2105/00—Condition, form or state of moulded material or of the material to be shaped
    • B29K2105/04—Condition, form or state of moulded material or of the material to be shaped cellular or porous
    • B29K2105/045—Condition, form or state of moulded material or of the material to be shaped cellular or porous with open cells
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/40—Symmetrical or sandwich layers, e.g. ABA, ABCBA, ABCCBA
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
    • B32B2260/023—Two or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/04—Impregnation, embedding, or binder material
    • B32B2260/046—Synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/106—Carbon fibres, e.g. graphite fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0278—Polyurethane
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/02—Cellular or porous
    • B32B2305/022—Foam
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2305/00—Condition, form or state of the layers or laminate
    • B32B2305/08—Reinforcements
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/50—Properties of the layers or laminate having particular mechanical properties
    • B32B2307/546—Flexural strength; Flexion stiffness
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T156/00—Adhesive bonding and miscellaneous chemical manufacture
    • Y10T156/10—Methods of surface bonding and/or assembly therefor
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955—Void-containing component partially impregnated with adjacent component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/249921—Web or sheet containing structurally defined element or component
    • Y10T428/249953—Composite having voids in a component [e.g., porous, cellular, etc.]
    • Y10T428/249955—Void-containing component partially impregnated with adjacent component
    • Y10T428/249958—Void-containing component is synthetic resin or natural rubbers

Definitions

  • the present invention relates to a fiber reinforced molded article comprising a core material and a fiber reinforcing material provided on both surfaces of the core material, and a method for producing the same.
  • a lightweight, thin, and highly rigid member is required as a casing of a notebook computer.
  • a molded body formed for the purpose of light weight, thin wall, and high rigidity for example, there is a carbon fiber reinforced molded body obtained by laminating and curing a carbon fiber prepreg.
  • the carbon fiber prepreg contains a semi-cured thermosetting resin, the thermosetting resin is completely cured in a relatively short time when stored at room temperature. For this reason, there is a problem that it is difficult to handle the carbon fiber prepreg, and the production cost of the carbon fiber reinforced molded article using the carbon fiber prepreg is increased.
  • Patent Document 1 discloses a fiber reinforced product in which a plurality of sheet-like fiber reinforced layers in which the fiber directions of carbon fibers are aligned are laminated so that each fiber direction has a specific arrangement.
  • the fiber reinforced layer having the same fiber direction is very expensive, there is a problem that the cost of the fiber reinforced molded product increases as the number of fiber reinforced layers increases.
  • the fiber-reinforced molded product has a specific gravity of about 1.6, which is not sufficient in terms of reducing the weight of components that make up the casing of a notebook personal computer.
  • Patent Document 2 discloses a sandwich structure composed of a core material having a gap and a fiber reinforcing material made of continuous carbon fibers and a matrix resin disposed on both surfaces of the core material.
  • a core material having a gap and a fiber reinforcing material made of continuous carbon fibers and a matrix resin disposed on both surfaces of the core material.
  • the present invention has been made in view of the above points, and an object thereof is to provide a lightweight, thin, and highly rigid fiber-reinforced molded article suitable for a casing of a portable device such as a notebook personal computer and a method for manufacturing the same. .
  • a fiber-reinforced molded body having a core material and a fiber reinforcing material provided on both surfaces of the core material,
  • the core material is formed by impregnating a thermosetting resin foam having open cells with a first thermosetting resin, and curing the first thermosetting resin in a state where the thermosetting resin foam is compressed.
  • the fiber reinforcing material is formed by impregnating a carbon fiber woven fabric with a second thermosetting resin and curing it
  • Wa is the total weight of the thermosetting resin foam and the carbon fiber fabric
  • Wb is the total weight of the first and second thermosetting resins, the thermosetting resin foam and the carbon fiber fabric
  • the specific gravity of the fiber reinforced molded product is 1.2 or more and 1.5 or less
  • thermosetting resin foam is a urethane resin foam or a melamine resin foam.
  • first thermosetting resin is selected from the group consisting of an epoxy resin, a phenol resin, and a mixture of an epoxy resin and a phenol resin.
  • second thermosetting resin is selected from the group consisting of an epoxy resin, a phenol resin, and a mixture of an epoxy resin and a phenol resin.
  • the fiber-reinforced molded article according to (1) wherein the compression ratio C is 1000 or more and 2600 or less.
  • the core material is a mixture of a melamine resin foam and a phenol resin
  • the fiber reinforcement is a mixture of a carbon fiber woven fabric and a phenol resin, and is disposed one by one on both sides of the core material,
  • thermosetting resin foam having open cells with a first thermosetting resin to obtain an impregnated thermosetting resin foam
  • the first thermosetting resin impregnated in the carbon fiber fabric is compressed by extruding the first thermosetting resin impregnated in the thermosetting resin foam by compressing the laminate, and the first thermosetting resin is heated by heating the laminate.
  • a compression heating step of integrally forming the core material and the fiber reinforcing material by curing Wa is the total weight of the thermosetting resin foam and the carbon fiber fabric, and Wb is the total weight of the first thermosetting resin, the thermosetting resin foam, and the carbon fiber fabric.
  • R the resin ratio
  • Wb the thickness of the thermosetting resin foam
  • C (Tb ⁇ Ta) / Ta ⁇ 100 It is characterized by compressing so that the compression rate C represented may be 200-5000.
  • a method for producing a fiber reinforced molded article having a core material and a fiber reinforcing material provided on both surfaces of the core material An impregnation step of impregnating a carbon fiber fabric with a second thermosetting resin to obtain an impregnated carbon fiber fabric; A laminating step of obtaining a laminate by disposing the impregnated carbon fiber fabric on both surfaces of a thermosetting resin foam having open cells; Compressing the laminate to extrude the second thermosetting resin impregnated in the carbon fiber fabric to impregnate the thermosetting resin foam, and heating the laminate to provide the second thermosetting resin.
  • thermosetting resin foam having open cells with a first thermosetting resin to obtain an impregnated thermosetting resin foam
  • Wa is a total weight of the thermosetting resin foam and the carbon fiber fabric
  • Wb is the first and second thermosetting resins, the thermosetting resin foam
  • R the resin ratio
  • Tb the thickness of the thermosetting resin foam before compression
  • C (Tb ⁇ Ta) / Ta ⁇ 100 It is characterized by compressing so that the compression rate C represented may be 200-5000.
  • the fiber reinforcing material has a carbon fiber fabric. Since the direction of the fiber contained in this carbon fiber fabric is two or more, the strength of the fiber-reinforced molded product does not vary depending on the direction. Therefore, according to the present invention, since a uniform strength can be obtained without increasing the number of layers, a fiber-reinforced molded body can be provided at a low cost. Further, the resin ratio R is 50 or more and 80 or less, and the core material is obtained by curing the first and / or second thermosetting resin in a compressed state of the thermosetting resin foam having open cells. The compression ratio C is in the range of 200 or more and 5000 or less.
  • the fiber-reinforced molded body can be made thin, and light weight and high rigidity can be realized.
  • the thermosetting resin foam having open cells adjacent cells (also referred to as bubbles or pores) communicate with each other, so that the first and / or second thermosetting resin is in the core part. Uniformly impregnated and retained.
  • the first and / or second thermosetting resin adheres to the cell skeleton of the thermosetting resin foam and is cured, the skeleton strength of the cell increases over the entire thermosetting resin foam. To do. Thereby, the bending strength improvement of a fiber reinforced molded object and the adhesive strength improvement effect of a core material and a fiber reinforced reinforcement material are acquired.
  • the prepreg since the prepreg is not used, the thermosetting resin is not cured during storage, so that the thermosetting resin can be stored at room temperature for a long time. For this reason, manufacturing cost can be held down.
  • the present invention relating to a method for producing a fiber reinforced molded body can easily provide a fiber reinforced molded body that can realize cost reduction, thinness, light weight and high rigidity.
  • a fiber reinforced molded body 10 according to an embodiment of the present invention shown in FIG. 1 includes a core material 11 and a fiber reinforcing material 21 laminated and integrated on both surfaces of the core material 11, and is a portable device such as a notebook computer.
  • Used in the case of The fiber-reinforced molded body 10 is a plate having a predetermined size.
  • the fiber reinforced molded body 10 has a thickness of 0.3 mm or more and 2.0 mm or less and a flexural modulus (JIS K 7074-1988 A method) of 30 GPa or more and 60 GPa or less, preferably 35 GPa or more and 55 GPa or less.
  • the specific gravity of the fiber reinforced molded body 10 is 1.2 or more and 1.5 or less, preferably 1.28 or more and 1.35 or less. If the thickness is less than 0.3 mm, rigidity cannot be obtained, and if it is thicker than 2.0 mm, for example, the entire portable device becomes thick and is not suitable for use as a casing of the portable device.
  • outsert molding such as injection molding
  • thermosetting to be described later Injecting a functional resin.
  • the core material 11 is obtained by curing the thermosetting resin in a state where the thermosetting resin foam is impregnated with the first thermosetting resin and the thermosetting resin foam is compressed.
  • the following compression ratio C is in the range of 200 to 5000, particularly preferably 1000 to 2600.
  • thermosetting resin foam having open cells is not particularly limited, and can be selected from, for example, a urethane resin foam or a melamine resin foam.
  • the thermosetting resin foam is preferably flame retardant.
  • the melamine resin since the melamine resin has good flame retardancy, it is preferable to use the melamine resin as a thermosetting resin foam.
  • the thickness before compression of the thermosetting resin foam varies depending on the target compression ratio, but is preferably 1 mm or more and 25 mm or less, for example. When the thickness is within this range, an appropriate amount of the first thermosetting resin can be impregnated, and the yield after heat compression is good. If the thickness is less than 1 mm, the impregnated first thermosetting resin is not held by the thermosetting resin foam, and the first thermosetting resin flows out and the resin ratio varies. A rate (rigidity) falls and the fiber reinforced molded object 10 which has a uniform bending elastic modulus cannot be obtained.
  • the thermosetting resin foam preferably has a density before compression of 5 kg / m 3 or more and 80 kg / m 3 or less from the viewpoints of easy compression, impregnation, light weight and rigidity.
  • the first thermosetting resin impregnated in the thermosetting resin foam is not particularly limited, but the thermosetting resin itself needs to have a certain degree of rigidity in order to increase the rigidity of the fiber reinforced molded body 10. For this reason, it can select from the group which consists of a mixture of an epoxy resin, a phenol resin, an epoxy resin, and a phenol resin.
  • the first thermosetting resin is preferably flame retardant. Since the phenol resin has good flame retardancy, it is suitable as the first thermosetting resin to be impregnated into the thermosetting resin foam.
  • the fiber reinforcing material 21 is made of a carbon fiber fabric impregnated with a second thermosetting resin and cured.
  • the carbon fiber fabric is excellent in light weight and high rigidity.
  • the carbon fiber fabric particularly refers to a fabric in which the directions of fibers are arranged in two or more directions. For example, plain weave composed of warp and weft, twill weave, satin weave, and triaxial weave composed of three-direction yarn.
  • the carbon fiber fabric preferably has a fiber weight of 90 g / m 2 or more and 400 g / m 2 or less from the viewpoint of impregnation and rigidity of the second thermosetting resin.
  • the second thermosetting resin impregnated in the carbon fiber fabric is not particularly limited, but the thermosetting resin itself needs to have a certain degree of rigidity in order to increase the rigidity of the fiber reinforced molded body 10. For this reason, it can select from the group which consists of a mixture of an epoxy resin, a phenol resin, an epoxy resin, and a phenol resin.
  • the thermosetting resin is preferably flame retardant. Since the phenol resin has good flame retardancy, it is suitable as a thermosetting resin impregnated in the carbon fiber fabric.
  • the first and second thermosetting resins are preferably impregnated into the thermosetting resin foam and the carbon fiber woven fabric so that the following resin ratio R is 50 or more and 80 or less, particularly 55 or more and 70 or less. .
  • the resin ratio R is the total weight of the thermosetting resin foam and the carbon fiber fabric before impregnation with the thermosetting resin, and the thermosetting resin (first and second thermosetting resins) impregnated with Wb and the heat.
  • R (Wb ⁇ Wa) / Wb ⁇ 100.
  • the weight after impregnation in the formula of the resin ratio R is the weight after drying after impregnation and removing the solvent when the thermosetting resin is dissolved in the solvent, and after removing the solvent. If it exists, it may be either before or after integration of the core material and the reinforcing material.
  • Integration of the core material 11 and the fiber reinforcing material 21 is performed by curing the thermosetting resin in a compressed state of the laminate of the thermosetting resin foam impregnated with the thermosetting resin and the carbon fiber fabric.
  • the thermosetting resin (first thermosetting resin) impregnated in the thermosetting resin foam and the thermosetting resin (second thermosetting resin) impregnated in the carbon fiber fabric may be the same or different. In order to improve the adhesion between the core material 11 and the fiber reinforcing material 21, it is preferable to use the same type.
  • thermosetting resin foam is impregnated with the first thermosetting resin, and the fiber reinforcing material is impregnated with the second thermosetting resin.
  • Second thermosetting The thermosetting resin foam is impregnated with the first thermosetting resin without using the thermosetting resin, and the first thermosetting resin is extruded into the fiber reinforcing material when the thermosetting resin foam is compressed to impregnate the fiber reinforcing material.
  • the second thermosetting resin is impregnated into the fiber reinforcing material without using the first thermosetting resin, and the second thermosetting resin is heated during compression of the thermosetting resin foam.
  • the thermosetting resin foam may be impregnated by being extruded into the curable resin foam.
  • the resin ratio R is the total weight of the thermosetting resin foam and the carbon fiber fabric before impregnation with the thermosetting resin
  • Wb is the first thermosetting resin and the thermosetting resin foam.
  • R (Wb ⁇ Wa) / Wb ⁇ 100 when the total weight of the body and the carbon fiber fabric is used.
  • the resin ratio R is the total weight of the thermosetting resin foam and the carbon fiber fabric before impregnation with the thermosetting resin
  • Wb is the second thermosetting resin and the thermosetting resin foam.
  • R (Wb ⁇ Wa) / Wb ⁇ 100 when the total weight of the body and the carbon fiber fabric is used.
  • the method for producing a fiber-reinforced molded body of the present invention includes an impregnation step, a lamination step, and a compression heating step.
  • the carbon fiber fabric 21A is impregnated with the second thermosetting resin 21B to form the impregnated carbon fiber fabric 21C.
  • the carbon fiber fabric 21 ⁇ / b> A and the second thermosetting resin 21 ⁇ / b> B are as described in the fiber reinforced molded body 10.
  • the second thermosetting resin 21B is in an uncured liquid form when impregnated.
  • the second thermosetting resin 21B is preferably in a form dissolved in a solvent.
  • the impregnated carbon fiber fabric 21C is at a temperature at which the second thermosetting resin 21B does not cure.
  • the solvent is removed from the impregnated carbon fiber fabric 21C by drying.
  • the impregnation means can be performed by an appropriate method such as a method of immersing the carbon fiber fabric 21A in a tank in which the liquid thermosetting resin 21B is stored, a method of spraying, a method of using a roll coater, or the like.
  • the carbon fiber fabric 21A is preferably impregnated with the second thermosetting resin 21B so that the above-described resin ratio R is 50 or more and 80 or less, particularly 55 or more and 70 or less.
  • the thermosetting resin 21B impregnated in the carbon fiber fabric 21A is compressed and heated as described later.
  • the thermosetting resin foam 11A is impregnated.
  • Wb ⁇ Wa in the formula of the resin ratio R is equal to the weight of the second thermosetting resin 21B impregnated in the carbon fiber fabric 21A in the impregnation step.
  • the weight after impregnation in the formula of the resin ratio R is the weight after drying after the impregnation and removing the solvent when the thermosetting resin is dissolved in the solvent.
  • the impregnated carbon fiber fabric 21C obtained in the impregnation step of FIG. 2 (a) is disposed and laminated on both surfaces of the thermosetting resin foam 11A having open cells. It is assumed that the body 10A.
  • the thermosetting resin foam 11 ⁇ / b> A having open cells is as described in the fiber reinforced molded body 10.
  • the laminating operation is performed on the upper surface of the press-molding lower die 31 used in the compression heating step of FIG. 2C to be performed next, the impregnated carbon fiber fabric 21C, the thermosetting resin foam 11A, and the impregnated carbon fiber. You may superimpose in order of textile 21C.
  • the impregnated carbon fiber fabric 21C and the thermosetting resin foam 11A having open cells preferably have the same plane size, but if they are different, they can be trimmed after the compression heating step described later. Good.
  • the laminated body 10A is compressed and heated by the lower mold 31 for press molding and the upper mold 33.
  • the interval between the press-molding lower die 31 and the upper die 33 is adjusted so that the above-described compression ratio C is 200 or more and 5000 or less, particularly preferably 1000 or more and 2600 or less.
  • a spacer is provided at an appropriate position between the press molding lower mold 31 and the upper mold 33 to ensure a target interval between the press molding lower mold 31 and the upper mold 33.
  • the heating method of the laminate is not particularly limited, but heating means such as a heater is provided in the press molding lower mold 31 and the upper mold 33, and heating is performed via the press molding lower mold 31 and the upper mold 33. Simple.
  • the heating temperature is set to be equal to or higher than the curing temperature of the second thermosetting resin.
  • the second thermosetting resin is extruded from the impregnated carbon fiber fabric 21C, and the second thermosetting resin is in contact with the impregnated carbon fiber fabric 21C.
  • the resin foam 11A is impregnated, and the entire laminate 10A is impregnated.
  • the second thermosetting resin 21B impregnated in the entire laminate 10A is cured in a state where the thermosetting resin foam 11A is compressed by heating.
  • the core material 11 is formed from the heat-constituting resin foam 11A
  • the fiber reinforcing material 21 is formed from the impregnated carbon fiber fabric 21C
  • the core material 11 and the fiber reinforcing material 21 are integrated to form a fiber reinforced molded body. 10 is formed. Thereafter, the heat compression is released to obtain the fiber reinforced molded body 10.
  • thermosetting resin foam 11A having open cells is impregnated with the first thermosetting resin 11B, and the impregnated heat is obtained.
  • a curable resin foam 11C is formed.
  • the thermosetting resin foam 11 ⁇ / b> A and the first thermosetting resin 11 ⁇ / b> B having open cells are as described in the fiber reinforced molded body 10.
  • the first thermosetting resin 11B is in an uncured liquid form when impregnated. In order to facilitate the impregnation, the first thermosetting resin 11B is preferably dissolved in a solvent.
  • the impregnated thermosetting resin foam 11C is at a temperature at which the first thermosetting resin 21 does not cure.
  • the solvent is removed from the impregnated thermosetting resin foam 11C by drying.
  • the impregnation means is performed by an appropriate method such as a method of immersing the thermosetting resin foam 11A in a tank storing the liquid thermosetting resin 11B, a method of spraying, a method of using a roll coater, or the like.
  • thermosetting resin foam 11A is preferably impregnated with the first thermosetting resin 11B so that the above-described resin ratio R is 50 or more and 80 or less, particularly 55 or more and 70 or less.
  • the thermosetting resin foam 11A is impregnated with the first thermosetting resin 11B in the impregnation step, and the thermosetting resin foam 11A is impregnated with the first thermosetting resin 11B.
  • the carbon fiber fabric 21A is impregnated in the compression heating step.
  • Wb-Wa in the formula of the resin ratio R is equal to the weight of the first thermosetting resin 11B impregnated in the thermosetting resin foam 11A.
  • the weight after impregnation in the resin ratio formula is the weight after the first thermosetting resin 11B is dissolved in a solvent and dried after the impregnation to remove the solvent.
  • the carbon fiber fabric 21A is disposed on both surfaces of the impregnated thermosetting resin foam 11C to obtain a laminate 10B.
  • 21 A of carbon fiber fabrics are as having demonstrated in the fiber reinforcement molded object 10.
  • the laminating operation is performed on the upper surface of the lower mold 31 for press molding used in the compression heating step of FIG. 3C to be performed next, the carbon fiber fabric 21A, the impregnated thermosetting resin foam 11C, and the carbon fiber fabric 21A. You may carry out in order of.
  • the impregnated thermosetting resin foam 11C and the carbon fiber woven fabric 21A preferably have the same plane size, but if they are different, they may be trimmed after the compression heating step described later.
  • the laminate 10B is compressed and heated by the press mold lower mold 31 and the upper mold 33.
  • the interval between the press mold lower mold 31 and the upper mold 33 is set so that the above-described compression ratio C is 200 or more and 5000 or less, particularly preferably 1000 or more and 2600 or less.
  • a spacer is installed at an appropriate position between the press mold lower mold 31 and the upper mold 33 so that the target gap is set between the press mold lower mold 31 and the upper mold 33. Is done.
  • the heating method of the laminate is not particularly limited, but it is easy to perform heating via the press molding lower mold 31 and the upper mold 33 by providing heating means such as a heater in the press molding lower mold 31 and the upper mold 33. It is.
  • the heating temperature is set to be equal to or higher than the curing temperature of the first thermosetting resin.
  • the first thermosetting resin 11B is extruded from the impregnated thermosetting resin foam 11C of the laminated body 10B and comes into contact with the impregnated thermosetting resin foam 11C.
  • the carbon fiber fabric 21A is impregnated and the entire laminate 10B is impregnated.
  • the first thermosetting resin 11B impregnated in the entire laminate 10B is cured in a state where the impregnated thermosetting resin foam 11C is compressed by heating.
  • the core material 11 is formed from the impregnated thermally structured resin foam 11C
  • the fiber reinforcing material 21 is formed from the carbon fiber fabric 21A.
  • the core material 11 and the fiber reinforcing material 21 are integrated to form a fiber reinforced molded body. 10 is formed. Thereafter, the heat compression is released to obtain the fiber reinforced molded body 10.
  • the impregnation process (impregnation process A mentioned later) to the thermosetting resin foam of 1st thermosetting resin in said 1st, 2nd embodiment, and 2nd thermosetting. It includes two impregnation steps of an impregnation step (impregnation step B described later) of the resin into the carbon fiber fabric.
  • an impregnation step (impregnation step B described later) of the resin into the carbon fiber fabric.
  • the thermosetting resin foam 11A having open cells is impregnated with the first thermosetting resin 11B, and the impregnated thermosetting resin foam 11C is impregnated. Get.
  • the carbon fiber fabric 21A is impregnated with the second thermosetting resin 21B to form an impregnated carbon fiber fabric 21C.
  • the materials, dimensions, and the like of the thermosetting resin foam 11A, the first thermosetting resin 11B, the carbon fiber fabric 21A, and the second thermosetting resin 21B having open cells are as described above.
  • the first and second thermosetting resins 11B and 21B are in the form of an uncured liquid when impregnated.
  • the first and second thermosetting resins 11B and 21B are preferably dissolved in a solvent.
  • the impregnated thermosetting resin foam 11C and the impregnated carbon fiber fabric 21C are obtained as follows:
  • the solvent is removed from the impregnated thermosetting resin foam 11C and the impregnated carbon fiber fabric 21C by drying at a temperature at which the first and second thermosetting resins 11B and 21B are not cured.
  • the impregnation means is performed by an appropriate method such as a method of immersing a thermosetting resin foam or carbon fiber fabric in a tank storing a liquid thermosetting resin, a method of spraying, a method of using a roll coater, or the like.
  • the amount of the first thermosetting resin 11B impregnated into the thermosetting resin foam 11A and the amount of the second thermosetting resin 21B impregnated into the carbon fiber fabric 21A are such that the resin ratio R described above is 50 or more and 80 or less. In particular, it is preferably set to be 55 or more and 70 or less.
  • the sum of the weight of the first thermosetting resin 11B impregnated in the thermosetting resin foam 11A and the weight of the second thermosetting resin 21B impregnated in the carbon fiber fabric 21A is a resin ratio. Equal to Wb-Wa in the formula of R. Note that the weight after impregnation in the resin ratio formula is the weight after drying after impregnation and removing the solvent when the thermosetting resin is used in a solvent.
  • the laminated body 10C is obtained by disposing the impregnated carbon fiber fabric 21C on both surfaces of the impregnated thermosetting resin foam 11C.
  • the laminating operation is performed on the upper surface of the press mold lower mold 31 used in the compression heating step of FIG. 4C to be performed next, impregnated carbon fiber fabric 21C, impregnated thermosetting resin foam 11C, and impregnated.
  • the carbon fiber fabric 21C may be stacked in this order.
  • the impregnated thermosetting resin foam 11C and the impregnated carbon fiber woven fabric 21C preferably have the same plane size, but if they are different, they may be trimmed after the compression heating step described later.
  • the laminated body 10C is compressed and heated by the press molding lower mold 31 and the upper mold 33.
  • the above-described compression rate C is set to 200 to 5000, particularly preferably 1000 to 2600.
  • a spacer is installed at an appropriate position between the press mold lower mold 31 and the upper mold 33 so that the target gap is set between the press mold lower mold 31 and the upper mold 33.
  • the heating method is not particularly limited, but it is easy to perform heating via the press molding lower mold 31 and the upper mold 33 by providing heating means such as a heater in the press molding lower mold 31 and the upper mold 33.
  • the heating temperature is set to be equal to or higher than the curing temperature of the first and second thermosetting resins 11B and 21B.
  • the compression in the compression heating step ensures that the second thermosetting resin 21B of the impregnated carbon fiber fabric 21C and the first thermosetting resin 11B of the impregnated thermosetting resin foam 11C come into contact with each other.
  • the first thermosetting resin 11B of the impregnated thermosetting resin foam 11C and the second thermosetting resin 21B of the impregnated carbon fiber fabric 21C are impregnated with the heat in the compression heating step. Is cured in a compressed state.
  • the core material 11 is formed from the impregnated thermally structured resin foam 11C
  • the fiber reinforcing material 21 is formed from the impregnated carbon fiber fabric 21C.
  • the core material 11 and the fiber reinforcing material 21 are integrated to strengthen the fiber.
  • a molded body 10 is formed. Thereafter, the heat compression is released to obtain the fiber reinforced molded body 10.
  • Example 1 Phenol resin (Asahi Organic Materials Co., Ltd., product name: PAPS-4 and Asahi Organic Materials Co., Ltd., product name: Hexamethylenetetramine mixed at 100: 12) as methanol as the first and second thermosetting resin in 30 wt. It dissolved so that it might become a concentration of%.
  • a plain weave carbon fiber fabric (manufactured by Toho Tex Co., Ltd., product name: W-3101, fiber weight 200 g / m 2 ) is dipped in this phenolic resin solution, taken out and air-dried at room temperature of 25 ° C for 2 hours Further, it was dried in an atmosphere at 60 ° C. for 1 hour to form two impregnated carbon fiber fabrics.
  • the carbon fiber fabric used was cut into a plane size of 200 ⁇ 300 mm (weight 12 g / sheet).
  • the impregnated carbon fiber fabric after drying was 28 g per sheet.
  • thermosetting resin foam having open cells a melamine resin foam cut out to a thickness of 10 mm and a planar size of 200 ⁇ 300 mm (weight 5.4 g) (manufactured by BASF, product name: Vasotect V3012, density 9 kg / m 3) ) Is immersed in a phenolic resin solution in the same manner as the carbon fiber fabric, taken out, dried naturally at room temperature of 25 ° C. for 2 hours, and further dried in an atmosphere of 60 ° C. for 1 hour to impregnate the thermosetting resin. A foam was formed. The weight of the impregnated thermosetting resin foam after drying was 27 g. In addition, the resin ratio R in Example 1 was 65.
  • an impregnated carbon fiber woven fabric, an impregnated thermosetting resin foam, and an impregnated carbon fiber woven fabric are placed on a stainless lower mold (flat plate) for press molding that has been preliminarily coated with a release agent.
  • a laminate in which the impregnated carbon fiber fabric was disposed on both surfaces of the impregnated thermosetting resin foam was set on the lower mold for press molding.
  • the laminate on the lower mold for press molding is pressed with the upper mold for press molding (flat plate shape) at 180 ° C. for 3 minutes, applying a surface pressure of 5 MPa, and compressed and heated.
  • Phenolic resins first and second thermosetting resins
  • the heating at that time was performed by a casting heater attached to the upper and lower press dies.
  • a 0.9 mm thick stainless steel spacer was interposed between the lower mold and the upper mold to adjust the distance between the lower mold and the upper mold, thereby adjusting the compression thickness of the laminate.
  • the lower mold and the upper mold were opened, and a fiber reinforcing material was integrally laminated on both surfaces of the core material to obtain a fiber reinforced molded body.
  • This fiber reinforced molded body was trimmed to 170 ⁇ 260 mm to obtain a fiber reinforced molded body of Example 1.
  • the specific gravity, the overall thickness, and the thickness of the core material were measured.
  • the specific gravity was 1.30, the total thickness was 0.89 mm, and the thickness of the core material was 0.43 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.43 mm) and calculated to be 2225.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 1 was measured in order to judge the rigidity. As a result of the measurement, the flexural modulus was 50 GPa (fiber direction).
  • Example 2 The fiber reinforced molded product of Example 2 was prepared in the same manner as in Example 1 (resin ratio R was also set to 65 as in Example 1) except that the thickness of the thermosetting resin foam having open cells was 5 mm. Obtained. About the fiber reinforced molded object of Example 2, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.89 mm, and the thickness of the core material was 0.43 mm. The compression rate C of the thermosetting resin foam constituting the core material is determined by the thickness (5 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( It was 1062 when calculated using 0.43 mm). In addition, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 2 was measured in order to determine rigidity. The measurement result was a flexural modulus of 49 GPa (fiber direction).
  • Example 3 The fiber reinforced molding of Example 3 in the same manner as in Example 1 (resin ratio R was also set to 65 as in Example 1) except that the thickness of the thermosetting resin foam having open cells was 11.5 mm. Got the body. About the fiber reinforced molded object of Example 3, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.32, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate C of the thermosetting resin foam constituting the core material is determined by the thickness (11.5 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression). ) (0.44 mm) was 2513. In addition, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 3 was measured in order to determine rigidity. The measurement result was a flexural modulus of 51 GPa (fiber direction).
  • Example 4 The fiber reinforced molding of Example 4 except that the thickness of the thermosetting resin foam having open cells was 1.4 mm (resin ratio R was also 65 as in Example 1). Got the body. About the fiber reinforced molded object of Example 4, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.28, the overall thickness was 0.89 mm, and the thickness of the core material was 0.43 mm. The compression rate C of the thermosetting resin foam constituting the core material is determined by the thickness (1.4 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression). ) (0.43 mm) was 225. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 4 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 46 GPa (fiber direction).
  • Example 5 The fiber reinforced molded product of Example 5 was prepared in the same manner as in Example 1 (the resin ratio R was also 65 as in Example 1) except that the thickness of the thermosetting resin foam having open cells was 22 mm. Obtained. About the fiber reinforced molded object of Example 5, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.35, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (22 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.44 mm) and calculated to be 4900. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 4 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 51 GPa (fiber direction).
  • Example 6 The carbon fiber fabric is impregnated with the above phenol resin solution so that the weight of the impregnated carbon fiber fabric after drying is 35 g per sheet and the weight of the impregnated thermosetting resin foam after drying is 45 g.
  • a fiber-reinforced molded body of Example 6 was obtained in the same manner as in Example 1 except that the resin ratio R contained in the entire thermosetting foam was 74.
  • the specific gravity was 1.45, the overall thickness was 0.98 mm, and the thickness of the core material was 0.52 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.53) and calculated to be 1823. Further, the flexural modulus (JIS K 7074-1988 A method) of the fiber reinforced molded body of Example 6 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 55 GPa (fiber direction).
  • Example 7 The above-mentioned phenol resin solution was impregnated so that the weight of the impregnated carbon fiber fabric after drying was 22 g per sheet, and the weight of the impregnated thermosetting resin foam after drying was 16 g, A fiber-reinforced molded article of Example 7 was obtained in the same manner as Example 1 except that the resin ratio R contained in the entire thermosetting foam was 51.
  • the resin ratio R contained in the entire thermosetting foam was 51.
  • specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the total thickness was 0.89 mm, and the thickness of the core material was 0.43 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.43 mm) and calculated to be 2225.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 7 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 45 GPa (fiber direction).
  • Example 8 In Example 8, the thermosetting resin foam was not impregnated with the thermosetting resin, but only the carbon fiber fabric was impregnated with the phenol resin as the thermosetting resin.
  • a fiber-reinforced molded body of Example 8 was obtained in the same manner as in Example 1 except that phenol resin was used so that the weight of the impregnated carbon fiber fabric after drying was 40 g and the resin ratio R was 66.
  • About the fiber reinforced molded object of Example 8 specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the total thickness was 0.89 mm, and the thickness of the core material was 0.43 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.43 mm) and calculated to be 2225.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 8 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 50 GPa (fiber direction).
  • Example 9 In Example 9, the carbon fiber fabric was not impregnated with resin, and only the thermosetting resin foam was impregnated with phenol resin as the thermosetting resin.
  • the fiber-reinforced molded body of Example 9 was the same as Example 1 except that the resin resin was R impregnated with a phenol resin so that the weight of the impregnated thermosetting resin foam after drying was 40 g. Got.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.43 mm) and calculated to be 2225.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 9 was measured in order to determine rigidity. The measurement result was a flexural modulus of 46 GPa (fiber direction).
  • Example 10 A urethane resin foam (Mortoprene MF80 manufactured by Inoac Corporation, density 72 kg / m 3 ) is used as the thermosetting resin foam having open cells, and the amount of impregnation of the first thermosetting resin into the thermosetting resin foam is as follows. Was adjusted in the same manner as in Example 1 except that the resin ratio R was 65. Thus, a fiber-reinforced molded body of Example 10 was obtained. About the fiber reinforced molded object of Example 10, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.35, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.44 mm) and calculated to be 2172.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 10 was measured in order to determine rigidity. The measurement result was a flexural modulus of 35 GPa (fiber direction).
  • Example 11 Example 1 was used except that an epoxy resin (manufactured by DIC Corporation, product name: Epicron 850 and DIC Corporation, product name: WH-108S mixed at 100: 30) was used as the thermosetting resin. (The resin ratio R was also 65), and a fiber-reinforced molded body of Example 11 was obtained. About the fiber reinforced molded object of Example 11, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the total thickness was 0.89 mm, and the thickness of the core material was 0.43 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.43 mm) and calculated to be 2225. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 11 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 49 GPa (fiber direction).
  • Comparative example 1 A fiber-reinforced molded article of Comparative Example 1 was obtained in the same manner as in Example 1 (resin ratio R was also 65) except that the thickness of the thermosetting resin foam having open cells was 0.95 mm.
  • the specific gravity was 1.29, the overall thickness was 0.89 mm, and the thickness of the core material was 0.43 mm.
  • the compression rate C of the thermosetting resin foam constituting the core material is determined by the thickness (0.95 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression). ) (0.43 mm) was 121.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Comparative Example 1 was measured in order to determine the rigidity.
  • the measurement result was a flexural modulus of 25 GPa (fiber direction).
  • the thermosetting resin foam had a small thickness before compression and a low compressibility, so that the flexural modulus (rigidity) was low.
  • Comparative example 2 Except that the thickness of the thermosetting resin foam having open cells was 30 mm, the fiber reinforced molded body of Comparative Example 2 was molded in the same manner as in Example 1 (resin ratio R was also 65). Since the thermosetting resin foam was too thick, it could not be compressed sufficiently, and only a fiber reinforced molded product with a large variation in thickness was obtained.
  • the compression rate C in Comparative Example 2 has a large variation in thickness. Therefore, it is assumed that the thickness of the core material in Comparative Example 2 is the same core material thickness (0.43 mm) as in Example 1, and the heat before compression When the thickness of the curable resin foam (30 mm) is used and calculation is performed according to the compressibility formula, 6877 is obtained. Since the compression ratio exceeded 5000, in Comparative Example 2, a good fiber-reinforced molded product could not be obtained.
  • Comparative example 3 Instead of a thermosetting resin foam having open cells, a urethane resin foam (made by Inoac Corporation, product name: Thermax, density 30 kg / m 3 ) having closed cells was processed to 200 ⁇ 300 ⁇ thickness 5 mm. The one (weight 9g) was used. A fiber-reinforced molded article of Comparative Example 3 was obtained in the same manner as in Example 8 except that the resin ratio R contained in the entire carbon fiber fabric and the thermosetting foam was changed to 57. About the fiber reinforced molded object of the comparative example 3, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.90 mm, and the thickness of the core material was 0.44 mm.
  • the compression rate C of the thermosetting resin foam constituting the core material is determined by the thickness (5 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( It was 1036 when calculated using 0.44 mm). Further, the bending elastic modulus (JIS K7074-1988 A method) was measured for the fiber-reinforced molded body of Comparative Example 3 in order to judge the rigidity. The measurement result was a flexural modulus of 22 GPa (fiber direction). Since a closed cell foam was used for the core material, the thermosetting resin was not uniformly dispersed and held in the core material, and the flexural modulus (rigidity) was lower than in each example.
  • Comparative example 4 A fiber-reinforced molded article of Comparative Example 4 was obtained in the same manner as in Example 1 except that the resin ratio R was 45.
  • the specific gravity, the overall thickness, and the thickness of the core material were measured.
  • the specific gravity was 1.29
  • the overall thickness was 0.89 mm
  • the thickness of the core material was 0.43 mm.
  • the compression ratio C of the thermosetting resin foam constituting the core material is determined by the thickness (10 mm) of the thermosetting resin foam before compression and the thickness of the core material (thickness of the thermosetting resin foam after compression) ( 0.43 mm) and calculated to be 2225.
  • the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 7 was measured in order to determine the rigidity.
  • the flexural modulus was 27 GPa (fiber direction).
  • the resin ratio was too low, less thermosetting resin was contained than in each example, and the flexural modulus (rigidity) was low.
  • Comparative example 5 A fiber-reinforced molded article of Comparative Example 5 was obtained in the same manner as in Example 1 except that the resin ratio R was 85. However, when the resin ratio R is too high, the thermosetting resin contained in the carbon fiber fabric and the thermosetting foam is excessively large and cannot be sufficiently compressed, and only a fiber reinforced molded product having a large thickness variation is obtained. I could't.
  • Table 1 shows the compression ratio, resin ratio, specific gravity, overall thickness, and flexural modulus in each example and comparative example.
  • Example 4 whose compression rate is as low as 225 has a low bending elastic modulus (rigidity) compared with other Examples.
  • Example 5 which has a high compression ratio of 4900, has a high specific gravity (heavy).
  • the compression rate is 200 or more and 5000 or less, more preferably 1000 or more and 2600 or less.
  • thermosetting resin foam and the carbon fiber fabric are of the same type, and the compression ratio is the same.
  • the flexural modulus in Comparative Example 4 with a resin ratio of 45, the flexural modulus is as low as 27 GPa, whereas in Example 8 with a resin ratio of 66, the flexural modulus is as high as 50 GPa. From this, it can be seen that the flexural modulus (rigidity) increases as the resin ratio increases. Since higher rigidity is better, higher resin ratio is preferable.
  • Examples 1 and 7 to 9 and Comparative Example 4 and Example 6 are compared, both have substantially the same compression ratio C, but Example 6 has a resin ratio R of 74 and a specific gravity of 1.45.
  • Comparative Example 4 having a resin ratio of 45 has a specific gravity of 1.29
  • Example 7 having a resin ratio of 51 has a specific gravity of 1.30.
  • the specific gravity tends to increase as the resin ratio increases.
  • a smaller specific gravity can reduce the weight, so that the resin ratio is preferably small. Therefore, in consideration of achieving both rigidity and weight reduction, the preferred resin ratio is 50 or more and 80 or less, and more preferably 55 or more and 70 or less.
  • the product according to the embodiment of the present invention is excellent in light weight, thin wall, and high rigidity, and is suitable as a casing of a portable device such as a notebook personal computer.
  • a fiber-reinforced molded body having uniform strength can be obtained without increasing the number of layers, a thin, lightweight, and highly rigid fiber-reinforced molded body can be provided.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Composite Materials (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)
  • Moulding By Coating Moulds (AREA)
PCT/JP2010/051287 2009-10-29 2010-01-29 繊維強化成形体及びその製造方法 Ceased WO2011052243A1 (ja)

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JPWO2016171060A1 (ja) * 2015-04-21 2018-02-15 三菱瓦斯化学株式会社 繊維強化熱可塑性樹脂組成物
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JPWO2016171060A1 (ja) * 2015-04-21 2018-02-15 三菱瓦斯化学株式会社 繊維強化熱可塑性樹脂組成物
JP2017030165A (ja) * 2015-07-29 2017-02-09 株式会社イノアックコーポレーション 炭素繊維複合材およびその製造方法
JP2018079630A (ja) * 2016-11-17 2018-05-24 株式会社イノアックコーポレーション 炭素繊維複合化粧板
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JP7229818B2 (ja) 2019-03-14 2023-02-28 株式会社イノアックコーポレーション 繊維強化成形体

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CN102574358A (zh) 2012-07-11
US8628842B2 (en) 2014-01-14
JP2011093175A (ja) 2011-05-12
EP2495099A1 (en) 2012-09-05
TW201114601A (en) 2011-05-01
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TWI379768B (enExample) 2012-12-21

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