JP6861055B2 - Fiber reinforced resin molded product and its manufacturing method - Google Patents

Description

The present invention relates to a fiber reinforced resin molded product and a method for producing the same.

Conventionally, there has been known a structure in which the ends of two base materials formed of a sheet-shaped fiber aggregate are overlapped and bonded with an adhesive (see Patent Document 1). Patent Document 1 describes that a prepreg is produced by impregnating an adhered base material with a resin and drying it.

Japanese Unexamined Patent Publication No. 2003-166164

However, due to the thickness of the laminated fiber aggregates, a step is formed on the surface of the base material at the end portion of the base material. In order to reduce this step, shaving work (sanding) after curing the resin is required, which increases the manufacturing cost.

The present invention has been made in view of such conventional problems, and an object of the present invention is to reduce or eliminate the need for shaving work after resin curing by reducing the step generated at the end of the fiber woven fabric. It is an object of the present invention to provide a resin molded product and a method for producing the same.

In the method for producing a fiber-reinforced resin molded product according to one aspect of the present invention, a fiber woven fabric in which a plurality of first fiber bundles and a plurality of second fiber bundles are woven is prepared, and is located on the side of the fiber woven fabric. The end of one of the 1 fiber bundle and the 2nd fiber bundle having a large angle formed with the outer peripheral direction in which the extension direction of the fiber bundle is the direction along the side of the fiber woven fabric. The portion is cut into a wavy shape that repeats periodically, and the end portion of one of the cut fiber bundles is opened.

According to one embodiment of the present invention, it is possible to reduce the step generated at the end of the fiber woven fabric and reduce or eliminate the shaving work after the resin is cured.

FIG. 1A is a top view of the fiber reinforced resin molded product according to the embodiment. FIG. 1B is a top view showing a state in which the paint 3 is applied to the upper surface of the fiber reinforced resin molded product of FIG. 1A. FIG. 2A is a top view illustrating a method for manufacturing a fiber reinforced resin molded product. FIG. 2B is a top view illustrating a method for manufacturing a fiber reinforced resin molded product. FIG. 2C is a top view illustrating a method for manufacturing a fiber reinforced resin molded product. FIG. 2D is a top view illustrating a method for manufacturing a fiber reinforced resin molded product. FIG. 2E is a top view illustrating a method for manufacturing a fiber reinforced resin molded product. FIG. 2F is a top view illustrating a method for manufacturing a fiber reinforced resin molded product. FIG. 3A is an enlarged top view of the right side region (R) of FIG. 2A in FIG. 2B and a cross-sectional view taken along the X-axis direction. FIG. 3B is an enlarged top view of the right side region (R) in FIG. 2D and a cross-sectional view taken along the X-axis direction. FIG. 3C is an enlarged top view of the right side region (R) in FIG. 2E and a cross-sectional view taken along the X-axis direction. FIG. 3D is an enlarged top view of the right side region (R) in FIG. 1A and a cross-sectional view taken along the X-axis direction.

Next, an embodiment will be described in detail with reference to the drawings.

As shown in FIG. 1A, the fiber-reinforced resin molded product according to the embodiment includes a sheet-shaped fiber aggregate 2, a fiber woven fabric 1 laminated on a part of the surface of the fiber aggregate 2, and a fiber aggregate. 2 and the resin impregnated in the fiber woven fabric 1. A fiber-reinforced resin molded product is made by putting fibers (fiber aggregate 2, fiber woven fabric 1) in plastic (resin) to improve the strength and then molding it into a predetermined shape. Spacecraft, aircraft, ships , Bicycles, automobiles, railroad vehicle interior / exterior and skeleton structures, sporting goods, or used as housing equipment such as unit baths and septic tanks. The fiber woven fabric 1 and the fiber aggregate 2 are joined by a resin.

The fiber aggregate 2 is an aggregate of sheet-shaped fibers, and regardless of the type of fiber, for example, PAN-based or pitch-based carbon fiber, glass fiber, aramid fiber, or polyethylene fiber can be used. The fiber assembly 2 may be a UD (UniDirection) material (including a 0 ° material) in which fibers are aligned in one direction, or a cloth material (woven fabric) in which a plurality of intersecting fiber bundles are woven together. It may be a non-woven fabric. Further, a plurality of UD materials, cloth materials, and non-woven fabric sheets may be laminated. The fiber may be a short fiber (chopped fiber) cut to a length of about several millimeters.

The fiber woven fabric 1 is a sheet-shaped woven fabric (including a fiber knit and a fabric cloth) in which a plurality of fiber bundles are crossed and woven. One fiber bundle is a bundle of fibers in units of thousands to tens of thousands, and the above-mentioned fibers can be used regardless of the type of fiber. In addition, the weaving method of the fiber bundle does not matter. Here, an example of plain weave (including basket weave, roe weave, and satin weave) in which warp threads (warp threads) and weft threads (weft threads) are woven alternately is shown, but in addition to this, twill weave (satin weave, twill) It can also be applied to satin weave (red weave, satin weave).

The resin is a member (base material: matrix) on the side to be reinforced, and the type thereof does not matter. For example, thermosetting resins such as unsaturated polyester, epoxy resin, polyamide resin, and phenol resin can be used. Alternatively, a thermoplastic resin may be used as the resin.

As shown in FIG. 1A, the fiber woven fabric 1 is overlapped and joined to a part of the surface of the fiber assembly 2. That is, the fiber woven fabric 1 is cut into a predetermined shape in advance, and is joined so as to be overlapped only on a part of the fiber aggregate 2 instead of the entire surface of the sheet-shaped fiber aggregate 2. In FIG. 1A, the shape of the fiber woven fabric 1 exemplifies a square shape. The predetermined shape is not limited to the square shape, and can be arbitrarily determined by the user. It may be another polygon or a shape having a curved outer circumference.

In the embodiment, the fiber woven fabric 1 is cut into a predetermined shape in advance, and the entire fiber woven fabric 1 is overlapped and joined to a part of the surface of the fiber assembly 2, but the present invention is limited to this. Not done. For example, as described in Patent Document 1, only the end portion of the fiber woven fabric 1 may overlap and be joined to the surface of the fiber assembly 2. That is, at least the end portion of the fiber woven fabric 1 may be overlapped and joined to the surface of the fiber assembly 2.

The fiber woven fabric 1 has a plurality of first fiber bundles 10 and a plurality of second fiber bundles 11 intersecting the plurality of first fiber bundles 10, and a plurality of first fiber bundles 10 and a plurality of second fiber bundles 11 And are woven together. FIG. 1A shows an example of a plain weave in which warp threads (warp threads) and weft threads (weft threads) are woven alternately. The first fiber bundle 10 corresponds to a warp (warp), and the second fiber bundle 11 corresponds to a weft (weft).

Of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the fiber woven fabric 1, one of the fiber bundles having a large angle forming with the outer peripheral direction of the fiber woven fabric 1 has a wave that is periodically repeated. It is cut into a shape and opened. For example, the outer peripheral portion 21 of the square fiber woven fabric 1 shown in FIG. 1A is composed of four regions: a right side region, a left side region, an upper side region, and a lower side region. In the right-hand side region, the outer peripheral direction of the fiber woven fabric 1 coincides with the Y-axis direction. Therefore, the fiber bundle having a large angle formed by the direction in which the fiber bundle extends is the outer peripheral direction (Y-axis direction) of the fiber woven fabric 1 is the second fiber bundle 11. Therefore, in the right-hand side region, the end portion of the second fiber bundle 11 is cut into a corrugated shape and opened. Similarly, in the left side region of the fiber woven fabric 1, the end portion of the first fiber bundle 10 is cut into a corrugated shape and opened. Then, at the upper side portion and the lower side portion of the fiber woven fabric 1, the end portion of the first fiber bundle 10 is cut into a wavy shape and the fiber is opened. As a result, the step at the end of the fiber bundle can be smoothed.

Here, a case is shown in which the direction in which the first fiber bundle 10 or the second fiber bundle 11 extends is parallel or perpendicular to the outer peripheral direction (X-axis direction, Y-axis direction) of the fiber woven fabric 1. May be tilted rather than parallel or vertical. In this case as well, one and the other fiber bundle may be determined according to the size of the angle formed by the direction in which the fiber bundle extends and the outer peripheral direction of the fiber woven fabric 1.

The ends of one of the two fiber bundles arranged in the outer peripheral direction of the fiber woven fabric 1 are collectively opened. In other words, the end of one fiber bundle that passes over the other fiber bundle that is closest to the end of the fiber woven fabric 1 and has a small angle with the outer peripheral direction of the fiber woven fabric 1 and below the other fiber bundle described above. The end of one of the fiber bundles passing through the fiber bundle is opened together. Specifically, in the right-hand side region of the outer peripheral portion 21 of FIG. 1A, the other fiber bundle having a small angle with the outer peripheral direction of the fiber woven fabric 1 is the first fiber bundle 10. Then, in the right-hand side region of the first fiber bundle 10, the first fiber bundle closest to the end of the fiber woven fabric 1 is designated by "10a". The end 11a of the second fiber bundle 11 passing over the first fiber bundle 10a and the end 11b of the second fiber bundle 11 passing under the first fiber bundle 10a are collectively opened. Therefore, the ends (11a, 11b) of the two second fiber bundles 11 adjacent to each other in the outer peripheral direction are integrated.

Here, the case where the ends of the two fiber bundles are integrated is shown, but the ends of the three or more fiber bundles may be integrated. The number of fiber bundles to be opened together may be aligned with the wavy period in which the second fiber bundle 11 is cut. The distribution of fiber lengths at the ends of the fiber bundle can be made uniform. Therefore, the step at the end of the fiber bundle can be made gentle. Of course, the fibers may be opened one by one without being put together.

Of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the fiber woven fabric 1, the other fiber bundle having a small angle with the outer peripheral direction of the fiber woven fabric 1 is extracted. For example, in the right-hand side region of the outer peripheral portion 21 of FIG. 1A, the first fiber bundle 10 which is the other fiber bundle having a small angle with the outer peripheral direction of the fiber woven fabric 1 is extracted. Similarly, the first fiber bundle 10 is extracted in the left side region, and the second fiber bundle 11 is extracted in the upper side region and the lower side region. In the example shown in FIG. 1A, two other fiber bundles located on the outer peripheral portion 21 are extracted. As a result, the step at the end of the fiber bundle can be made smooth.

Further, the other fiber bundle that is closest to the end of the fiber woven fabric 1 and has a small angle forming with the outer peripheral direction of the fiber woven fabric 1 is opened. Specifically, in the right-hand side region of the outer peripheral portion 21 of FIG. 1A, the first fiber bundle 10a closest to the end portion of the fiber woven fabric 1 and having a small angle forming with the outer peripheral direction of the fiber woven fabric 1 is opened. The first fiber bundle 10a is opened not only at its end but also as a whole. Similarly, in the left side region, the first fiber bundle 10 closest to the end of the fiber woven fabric 1 is opened, and in the upper side region and the lower side region, the second fiber bundle 11 closest to the end of the fiber woven fabric 1 is opened. ing. As a result, the step at the end of the fiber bundle can be smoothed.

FIG. 1B shows a state in which the paint 3 is applied to a region of the surface of the fiber-reinforced resin molded product excluding a part of the fiber woven fabric 1. The paint 3 is applied to the outer peripheral portion 21 of the fiber woven fabric 1 and the exposed region of the fiber aggregate 2, and the paint is not applied to the central portion of the fiber woven fabric 1 except for the outer peripheral portion 21. As a result, the weave patterns of the first fiber bundle 10 and the second fiber bundle 11 can be visually recognized in the central portion of the fiber woven fabric 1. While painting the surface of the fiber-reinforced resin molded product with a color and type of paint suitable for the application, the pattern of the fiber woven plastic 1 as the material of the fiber-reinforced resin molded product is expressed as a part of the fiber-reinforced resin molded product. be able to. At this time, the paint 3 is also applied to the end portion of the fiber woven fabric 1, but by smoothing the step at the end of the fiber bundle, it becomes difficult for shadows due to the step to be formed on the painted surface. The design of the product is improved.

Next, an example of the method for manufacturing the fiber-reinforced resin molded product shown in FIG. 1A will be described with reference to the overall views of FIGS. 2A to 2F and the partially enlarged views of FIGS. 3A to 3D. 2A to 2F are top views showing the entire fiber woven fabric 1, and partially enlarged views of FIGS. 3A to 3D are an enlarged top view of the right side region (R) of FIG. 2A and a top view in the X-axis direction. It consists of a cross-sectional view along the line.

First, as shown in FIG. 2A, a sheet-shaped fiber woven fabric 1 is prepared in which a plurality of first fiber bundles 10 and a plurality of second fiber bundles 11 intersecting the plurality of first fiber bundles 10 are woven together. The fiber woven fabric 1 is cut in advance into a desired shape. Here, it is pre-processed into a square shape. The first fiber bundle 10 or the second fiber bundle 11 is arranged in parallel with respect to the four sides of the square. The second fiber bundle 11 is arranged parallel to the X-axis direction, and the first fiber bundle 10 is arranged parallel to the Y-axis direction. The first fiber bundle 10 and the second fiber bundle 11 are woven one by one. The right-hand side region R of FIG. 2A is a region including the right-hand side region of the outer peripheral portion 21 of FIG. 1A, and is a region corresponding to the partially enlarged view of FIGS. 3A to 3D.

Next, as shown in FIG. 2B, of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the fiber woven fabric 1, the angle formed by the outer peripheral direction (22a, 22b) of the fiber woven fabric 1 is small. Extract the fiber bundle (corresponding to the "other fiber bundle"). Specifically, of the second fiber bundle 11 parallel to the outer peripheral direction 22a (X direction) of the fiber woven fabric 1, two second fiber bundles located in the upper side region and the lower side region of the outer peripheral portion 21 of the fiber woven fabric 1. 11 is extracted from the fiber woven fabric 1. Similarly, of the first fiber bundles 10 parallel to the outer peripheral direction 22b (Y direction) of the fiber woven fabric 1, two first fiber bundles 10 located in the right side region and the left side region of the outer peripheral portion 21 of the fiber woven fabric 1 are , Extract from the fiber woven fabric 1. The fiber woven fabric 1 after being extracted is shown in FIG. 2C. Here, the case where each of the two fiber bundles located on the outer peripheral portion 21 is extracted is shown, but the number of fibers to be extracted is not limited to this. It is desirable to increase the number of fibers to be extracted as the thickness of the fiber woven fabric 1 after impregnating and curing the resin increases. As a result, it is possible to increase the area of the fiber woven fabric 1 that can be exposed while smoothing the step generated at the end of the fiber woven fabric 1 after the resin is impregnated and cured.

As shown in the top view of FIG. 3A, in the right side region (R) of FIG. 2A, the two second fibers located on the outer peripheral portion 21 of the fiber woven fabric 1 and having a small angle with the outer peripheral direction (Y direction) of the fiber woven fabric 1. 1 Extract the fiber bundle 10. As a result, as shown in the cross-sectional view of FIG. 3A, the thickness of the end portion of the fiber woven fabric 1 corresponding to the cross-sectional area 31 can be reduced. For example, the thickness of the cross-section region 31 is 0.11 mm, and the width of the cross-section region 31 is 4 mm. That is, the width of the cross-sectional region 31 corresponds to the width of two fiber bundles (10, 11).

Next, as shown in FIG. 2D, of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the fiber woven fabric 1, the angle formed with the outer peripheral direction (22a, 22b) of the fiber woven fabric 1 is large. The end of the fiber bundle (corresponding to "one fiber bundle") is cut into a cyclically repeating wavy shape 23. The fiber woven fabric 1 after cutting is shown in FIG. 2E. Here, as an example of the wave shape 23 that is periodically repeated, a wave shape (including an uneven shape) that is repeated with the width of two fiber bundles as one cycle is shown. Further, the cut surface when cutting the end portion of one fiber bundle is inclined with respect to the direction in which the one fiber bundle extends. As a result, the lengths of the fibers contained in one fiber bundle can be made uneven, so that the step at the end of the fiber bundle after opening can be made smooth. In the example of FIG. 2D, the cut surface of the fiber bundle forms a constant inclination angle with respect to the direction in which one of the fiber bundles extends. However, the shape of the cut surface is not limited to the shape forming a constant inclination angle, and may be, for example, a triangular wave (sine wave, cosine wave) in which the inclination angle changes.

As shown in the top view of FIG. 3B, in the right side region (R), the end portion of the second fiber bundle 11 in the outer peripheral portion 21 is cut into a wavy shape 23. The wave shape 23 is repeated with the width (4 mm) of the two fiber bundles as one cycle, and the cut surface is inclined with respect to the direction in which the second fiber bundle 11 extends (X-axis direction). By cutting and opening the end portion of the second fiber bundle 11, the thickness of the end portion of the fiber woven fabric 1 corresponding to the cross-sectional area 32 in the outer peripheral portion 21 is reduced as shown in the cross-sectional view of FIG. 3B. be able to. Since the positions (X coordinates) of the ends of the second fiber bundle 11 are not uniform, the cross-sectional region 32 can be removed and the steps at the ends of the second fiber bundle 11 can be smoothed.

Next, as shown in FIG. 2F, the other uncut fiber bundle is opened. Specifically, the entire fiber bundle of the other fiber bundle closest to the end of the fiber woven fabric 1 and having a small angle formed in the outer peripheral direction (22a, 22b) of the fiber woven fabric 1 is opened. In the upper side region and the lower side region of the fiber woven fabric 1 whose outer peripheral direction is along the X direction, the entire second fiber bundle 11 closest to the end portion of the fiber woven fabric 1 is opened. In the left side region and the right side region of the fiber woven fabric 1 whose outer peripheral direction is along the Y direction, the entire first fiber bundle 10 closest to the end portion of the fiber woven fabric 1 is opened.

As shown in the top view of FIG. 3C, in the right side region (R), the entire first fiber bundle 10 closest to the end of the fiber woven fabric 1 is opened. The first fiber bundle 10 after opening is shown in the top view of FIG. 3D. As a result, as shown in the cross-sectional view of FIG. 3C, the thickness of the end portion of the fiber woven fabric 1 corresponding to the cross-sectional area 33 can be reduced. The cross-sectional area 33 corresponds to the position of the opened first fiber bundle 10. For example, the height (thickness) of the cross-sectional area 33 is 0.11 mm, and the width of the cross-sectional area 31 is 4 mm. That is, the width of the cross-sectional region 33 corresponds to the width of one spread fiber bundle (10, 11). The height (thickness) and width of the cross-sectional areas (31 to 33) are substantially equal to each other. Therefore, the thickness of the fiber woven fabric 1 is 0.22 mm.

Further, as shown in FIG. 2F, the end portion of one of the cut fiber bundles is opened. Specifically, of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the fiber woven fabric 1, the end of one of the fiber bundles having a large angle in the outer peripheral direction (22a, 22b) of the fiber woven fabric 1. Open the part. It is desirable to open the end of one fiber bundle after cutting the end of one fiber bundle into a wavy shape. As a result, fibers having different lengths can be uniformly distributed in the plane at the end of the fiber bundle.

As shown in the top view of FIG. 3D, the end portion of the cut second fiber bundle 11 is opened in the right side region (R). At this time, it is desirable to collectively open the ends of two or more second fiber bundles 11 arranged in the outer peripheral direction of the fiber woven fabric 1. For example, as shown in the top view of FIG. 3C, the second fiber bundle 10 (the other fiber bundle) that is closest to the end of the fiber woven fabric 1 and has a small angle forming with the outer peripheral direction of the fiber woven fabric 1 is passed. The end of the fiber bundle 11b (one fiber bundle) and the end of the second fiber bundle 11a (one fiber bundle) passing under the first fiber bundle 10 described above are collectively opened. Since the period of the wave shape 23 in FIG. 3B is the width of two fiber bundles, a second fiber bundle 11b having a long fiber length and a second fiber bundle 11a having a short fiber length are generated. When the second fiber bundle 11b and the second fiber bundle 11a are individually opened, the length distribution of the second fiber bundle 11 becomes non-uniform in the top view. Therefore, by opening the second fiber bundle 11b and the second fiber bundle 11a together, the length distribution of the second fiber bundle 11 can be made uniform. Therefore, the step at the end of the fiber bundle can be made gentle.

By the manufacturing method described above, as shown in the cross-sectional view of FIG. 3D, a gentle inclined surface can be formed in the second outer peripheral region 22 of the fiber woven fabric 1. The second outer peripheral region 22 is a region including the outer peripheral portion 21 and the opened first fiber bundle 10 (the other fiber bundle) located inside the outer peripheral portion 21. The width of the second outer peripheral region 22 is approximately 8 mm.

As a specific method for opening the fiber bundle, a known method may be used. For example, the portion to be opened is sandwiched between the plate members from both the front and back surfaces of the fiber woven fabric 1, and the plate member is vibrated while applying pressure. By appropriately adjusting the magnitude of pressure and vibration, the processing time, etc., the end of one fiber bundle in the outer peripheral portion 21 of the fiber woven fabric 1 or the entire other fiber bundle in the second outer peripheral portion 24 is opened. Can be woven. Of course, the above method is an example, and the fiber may be opened by another method.

Then, the fiber woven fabric 1 is superposed on the surface of the fiber assembly 2, and the resin is impregnated and cured. Any method may be used as the resin impregnation curing method. In the embodiment, a case where a resin transfer molding method (including an RTM method and a resin injection method) is used will be described as an example. In the RTM method, the dry fiber woven fabric 1 and the dry fiber aggregate 2 not impregnated with the resin are placed on top of each other in the same mold, and after the mold is sealed, the resin is injected and pressure impregnated. As a result, the dry fiber woven fabric 1 not impregnated with the resin can be easily subjected to the fiber bundle extraction treatment, cutting treatment, and fiber opening treatment shown in FIGS. 2A to 2F and 3A to 3D. it can. Through the above steps, the fiber-reinforced resin molded product shown in FIG. 1A is completed. In the embodiment, the RTM method has been described as an example, but another method capable of carrying out the above treatment on the dry fiber woven fabric 1 not impregnated with the resin may be used.

(Modification example)
2A to 2F and FIGS. 3A to 3A to FIG. 2A to FIG. 2F and FIGS. 3A to 3A to FIG. It is also possible to carry out a fiber bundle extraction treatment, a cutting treatment, and a fiber opening treatment shown in 3D. The manufacturing method in this case is as follows.

First, a wet fiber woven fabric 1 (prepreg) impregnated with a resin is prepared. Then, of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the prepreg, the end portion of one of the fiber bundles having a large angle formed with the outer peripheral direction (22a, 22b) of the prepreg is periodically squeezed. It cuts into a repeating wave shape 23. The cutting treatment can be performed by the same method as in the case of the dry fiber woven fabric 1. Then, the end of one of the cut fiber bundles and the other fiber bundle closest to the end of the prepreg are opened. In the case of prepreg, before opening the fiber bundle, the portion to be opened is heated to soften the resin. The fiber bundle in which the resin is softened is opened.

Then, the prepreg is joined to the surface of the sheet-shaped fiber assembly 2. Specifically, the fiber assembly 2 and the prepreg impregnated with the resin are cured and molded in the same manner as in the fiber woven fabric 1. Any method may be used as the method for curing and molding the resin. In the modified example, the sheet molding compound method (SMC method) is used as an example. In the SMC method, a prepreg (fiber assembly 2 and fiber woven fabric 1) is sandwiched between films, passed through a roller to form a continuous sheet, cut and stacked in a mold, and heated and pressed by a press to produce the prepreg. In the modified example, the SMC method has been taken as an example, but another method capable of carrying out the above treatment on the wet fiber woven fabric 1 impregnated with the resin may be used.

As described above, according to the embodiment and the modified example, the following effects can be obtained.

At the outer peripheral portion 21 of the fiber woven fabric 1 or its prepreg, the end portion of the fiber bundle having a large angle formed in the outer peripheral direction (22a, 22b) is cut into a wavy shape 23 and opened. As a result, the step between the end of the fiber woven fabric 1 or its prepreg and the fiber assembly 2 becomes gentle, and sanding (polishing treatment) after resin curing is reduced or unnecessary.

The cut surface when cutting the end of one fiber bundle is inclined with respect to the direction in which the one fiber bundle extends. As a result, the lengths of the fibers contained in one fiber bundle can be made uneven, so that the step at the end of the fiber woven fabric 1 or its prepreg becomes gentle.

The ends of two adjacent fiber bundles are put together and opened. As a result, even when the end of one fiber bundle is cut by the wave shape 23 repeated with the lengths of the two fiber bundles, the distribution of the length of the fibers at the end of the fiber woven fabric 1 or its prepreg. Can be made uniform. Therefore, the step at the end of the fiber woven fabric 1 or its prepreg becomes gentle.

Of the first fiber bundle 10 and the second fiber bundle 11 located on the outer peripheral portion 21 of the fiber woven fabric 1, the fiber woven fabric 1 is used before the end of one of the fiber bundles is cut into a wavy shape 23 that is periodically repeated. The other fiber bundle having a small angle in the outer peripheral direction (22a, 22b) is extracted. As a result, the step at the end of the fiber woven fabric 1 or its prepreg can be smoothed.

The fiber woven fabric 1 or the other fiber bundle closest to the end of the prepreg is opened after the fiber woven fabric 1 or the other fiber bundle having a small angle forming with the outer peripheral direction of the prepreg is extracted. As a result, the step at the end of the fiber woven fabric 1 or its prepreg can be smoothed.

Although the contents of the present invention have been described above according to the embodiments, it is obvious to those skilled in the art that the present invention is not limited to these descriptions and various modifications and improvements can be made.

As described above, the fiber-reinforced resin molded product according to the embodiment can be applied to automobile exterior parts such as hoods, front fenders, doors, rear fenders, trunk lids, and loops. In the exterior of automobiles, there is a demand for designability (designability) in which a cloth material is exposed to a part of exterior parts to give an accent. For example, in the case of a hood, the fiber woven fabric 1 (cloth material) is exposed on the air intake (raised portion) and the outer portion of the character line. In this case, the fiber woven fabric 1 is joined to the outer portion of the air intake or the character line on the surface of the hood. Then, as shown in FIG. 1B, the paint 3 is applied to the outer peripheral portion 21 of the fiber woven fabric 1 and the region where the fiber aggregate 2 is exposed, and the paint is applied to the central portion of the fiber woven fabric 1 excluding the outer peripheral portion 21. Do not apply. The central portion of the fiber woven fabric 1 may be located on the outer portion of the air intake or the character line.

In addition, the fiber woven fabric 1 (cloth material) is pasted on the entire surface of the hood. However, it is assumed that there is a problem or a desire to reduce the cost of the fiber woven fabric 1 (cloth material) to be attached to the entire surface. Unless the embodiment of the present invention is applied, the step generated at the end of the fiber woven fabric 1 cannot be reduced. For this reason, shadows are generated by the steps appearing on the painted surface, so sanding after resin curing is required. The fiber-reinforced resin molded product and the method for producing the same according to the embodiment of the present invention are effective solutions to such demands and problems.

1 Fiber woven fabric 2 Fiber aggregate 10, 10a First fiber bundle 11, 11a, 11b Second fiber bundle 21 Outer peripheral portion 22a, 22b of fiber woven fabric 23 Wave shape in outer circumference direction of fiber woven fabric

Claims (7)

A fiber woven fabric in which a plurality of first fiber bundles and a plurality of second fiber bundles are woven together is prepared.
An outer circumference of any one of the first fiber bundle and the second fiber bundle located on the side of the fiber woven fabric, in which the direction in which the fiber bundle extends is the direction along the side of the fiber woven fabric. The end of one fiber bundle having a large angle with the direction is cut into a wave shape that repeats periodically.
The end of the one of the cut fiber bundles is opened and the fiber is opened.
The fiber woven fabric is layered on the surface of the sheet-shaped fiber aggregate,
A method for producing a fiber-reinforced resin molded product, which comprises impregnating the fiber aggregate and the fiber woven fabric with a resin. A fiber woven fabric in which a plurality of first fiber bundles and a plurality of second fiber bundles are woven and pre-impregnated with a resin is prepared.
An outer circumference of any one of the first fiber bundle and the second fiber bundle located on the side of the fiber woven fabric, in which the direction in which the fiber bundle extends is the direction along the side of the fiber woven fabric. The end of one fiber bundle having a large angle with the direction is cut into a wave shape that repeats periodically.
The end of the one of the cut fiber bundles is opened and the fiber is opened.
A method for producing a fiber-reinforced resin molded product, which comprises joining the fiber woven fabric to the surface of a sheet-shaped fiber aggregate. The fiber-reinforced resin molded product according to claim 1 or 2, wherein the cut surface when cutting the end portion of the one fiber bundle is inclined with respect to the extending direction of the one fiber bundle. Manufacturing method. When the end of one of the cut fiber bundles is opened, the angle formed by the direction in which the fiber bundle extends closest to the end of the fiber woven fabric and the outer peripheral direction, which is the direction along the side of the fiber woven fabric, is formed. Claims 1 to 1, wherein the end of one fiber bundle passing over the other small fiber bundle and the end of one fiber bundle passing under the other fiber bundle are collectively opened. The method for producing a fiber-reinforced resin molded product according to any one of 3. Before cutting the end of the one fiber bundle periodically corrugated repeated, either in the fiber bundle of said first fiber bundle and the second fiber bundle located sides of the textile fabric According to any one of claims 1 to 4, the direction in which the fiber bundle extends is the direction along the side of the fiber woven fabric, which is the outer peripheral direction, and the other fiber bundle having a small angle is extracted. The method for producing a fiber-reinforced resin molded product according to the description. The method for producing a fiber-reinforced resin molded product according to claim 5, wherein the other fiber bundle closest to the end of the fiber woven fabric, which is left after the other fiber bundle is pulled out, is opened. .. Sheet-shaped fiber aggregates and
A fiber woven fabric that is laminated and bonded to the surface of the fiber aggregate,
The fiber aggregate and the resin impregnated in the fiber woven fabric are provided.
The fiber woven fabric is formed by interweaving a plurality of first fiber bundles and a plurality of second fiber bundles.
An outer circumference of any one of the first fiber bundle and the second fiber bundle located on the side of the fiber woven fabric, in which the direction in which the fiber bundle extends is the direction along the side of the fiber woven fabric. The end of one of the fiber bundles, which forms a large angle with the direction, is cut into a cyclically repeating wavy shape.
A fiber-reinforced resin molded product characterized in that the end of one of the fiber bundles is opened.

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