JP7003585B2 - Manufacturing method of fiber reinforced resin molded product and fiber reinforced resin molded product - Google Patents

Description

The present invention relates to a fiber-reinforced resin molded product and a method for manufacturing a fiber-reinforced resin molded product.

Resin molded products reinforced with reinforcing fibers such as carbon fiber and glass fiber are widely used. As an example of such a resin molded product, a laminate in which a sheet-shaped reinforcing fiber base material is laminated on the front and back surfaces of a core material made of foamed resin is hardened with a thermosetting resin (for example,). , Patent Document 1). This type of resin molded product is molded by using the RTM (Resin Transfer Molding) method. Specifically, the laminate is set in the cavity of the molding die and uncured in the cavity. The above-mentioned resin molded product is manufactured by injecting a thermosetting resin having fluidity in a state and heat-curing the resin in a state of being impregnated with a reinforcing fiber base material or the like of the laminate.

Japanese Unexamined Patent Publication No. 04-224915

If the thermosetting resin is supplied into the cavity of the molding die at a high pressure, the core material of the laminate may be crushed. Therefore, in the manufacturing process of this type of molded product, there is a circumstance that the injection pressure of the resin should be kept as low as possible. However, if the injection pressure of the resin is set low, it takes a long time for the resin to spread in the laminate or in every corner of the cavity, and the production efficiency is lowered. In particular, if the thermosetting resin has a high viscosity, it takes time for the resin to spread in the laminate or in every corner of the cavity.

An object of the present invention is to provide a fiber-reinforced resin molded product or the like having a structure in which an uncured resin is easily distributed at the time of manufacture.

The fiber-reinforced resin molded product according to the present invention comprises a laminated body having a plate-shaped core material made of foamed resin and a pair of sheet-shaped reinforcing fiber base materials laminated on the front surface and the back surface of the core material, respectively. A fiber-reinforced resin molded product including a resin portion obtained by curing an uncured resin impregnated in a laminate, wherein the core material of the laminate is formed on or inside the front surface and the back surface. The uncured resin is composed of a flow path through which the uncured resin flows along the surface direction and a hole portion connected to the flow path while penetrating in the thickness direction and is uncured from the outside through the reinforcing fiber base material. The resin portion has a flow path resin portion that fills the flow path and a supply port resin portion that fills the supply port.

In the fiber-reinforced resin molded product, the core material of the laminate has a pair of unit core materials each of which is laminated with each other so as to form a gap used as the flow path and has a plate shape. The resin portion may have a gap resin portion that fills the gap as the flow path resin portion.

In the fiber-reinforced resin molded product, it is preferable that the core material of the laminate is arranged between the pair of the unit core materials and has a spacer portion for securing the gap.

In the fiber-reinforced resin molded product, the core material of the laminate is formed at least on the back surface and has a groove used as the flow path, and the resin portion is the groove as the flow path resin portion. It may have a groove resin portion for filling.

In the fiber-reinforced resin molded product, the core material of the laminate has a cavity portion formed inside the laminate and used as the flow path, and the resin portion is the cavity as the flow path resin portion. It may have a hollow resin portion that fills the portion.

In the fiber-reinforced resin molded product, the core material of the laminate communicates the flow path with the surface side facing one of the reinforcing fiber base materials or the other reinforcing fiber base material, and is in an uncured state. It is preferable that the resin portion has a branch path for branching the flow of the resin, and the resin portion has a branch path resin portion for filling the branch path.

Further, the fiber-reinforced resin molded product according to the present invention is a laminate having a plate-shaped core material made of foamed resin and a pair of sheet-shaped reinforcing fiber base materials stacked on the front surface and the back surface of the core material, respectively. A fiber-reinforced resin molded product comprising a resin portion obtained by curing an uncured resin impregnated in the laminate, wherein the core material of the laminate is placed between adjacent end faces. The resin portion has a pair of divided core materials so as to form a longitudinal through-passage that extends along the plane direction and penetrates in the thickness direction, and the resin portion has the longitudinal through-passage. It has a through-passage resin part to be filled.

In the fiber-reinforced resin molded product, the core material of the laminate is composed of holes penetrating in the thickness direction, and faces the surface side facing the reinforcing fiber base material on one side and the surface side facing the reinforcing fiber base material on the other side. It is preferable to have a communication passage that communicates with the back surface side, and the resin portion has a communication passage resin portion that fills the communication passage.

Further, the method for manufacturing a fiber-reinforced resin molded product according to the present invention is the method for manufacturing a fiber-reinforced resin molded product according to any one of the above, and is not present in the cavity of the molding mold in which the laminate is housed from the outside. When the cured resin is supplied, the uncured resin is supplied to the supply port through the reinforcing fiber base material, and the resin is provided with a resin supply step in which the resin flows along the flow path.

Further, the method for manufacturing a fiber-reinforced resin molded product according to the present invention is the method for manufacturing a fiber-reinforced resin molded product according to any one of the above, and is not present in the cavity of the molding mold in which the laminate is housed from the outside. When the cured resin is supplied, the uncured resin is supplied to the through flow path through the reinforcing fiber base material, and the resin is provided with a resin supply step in which the resin flows along the through flow path.

According to the present invention, it is possible to provide a fiber-reinforced resin molded product or the like having a structure in which an uncured resin is easily distributed at the time of manufacture.

Explanatory drawing schematically showing the cross-sectional structure of the fiber reinforced resin molded product Explanatory drawing which shows the process of setting the laminate | Explanatory drawing showing how the movable mold approaches the fixed mold in the mold clamping process. Explanatory drawing showing a process of injecting an uncured resin into a cavity of a molded mold. Explanatory drawing showing how the resin supplied from the injection hole spreads over the laminated body in the cavity. Explanatory drawing which shows the process of demolding a molded product from a fixed mold Explanatory drawing schematically showing the cross-sectional structure of the molded article of Embodiment 2. Explanatory drawing which shows how the resin supplied from an injection hole is distributed to the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 2. Explanatory drawing schematically showing the cross-sectional structure of the molded article of Embodiment 3. Perspective view of the core material of the third embodiment Explanatory drawing which shows how the resin supplied from an injection hole is distributed to the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 3. Explanatory drawing schematically showing the cross-sectional structure of the molded article of Embodiment 4. Explanatory drawing which shows how the resin supplied from an injection hole is distributed to the laminated body in a cavity in the manufacturing process of the molded article of Embodiment 4. Explanatory drawing schematically showing the cross-sectional structure of the molded article of Embodiment 5. Top view of the core material of the fifth embodiment An explanatory view showing how the resin supplied from the injection hole is distributed to the laminated body in the cavity in the manufacturing process of the molded product of the fifth embodiment.

<Embodiment 1>
Hereinafter, Embodiment 1 of the present invention will be described with reference to FIGS. 1 to 6. In this embodiment, the fiber reinforced resin molded product 10 and the manufacturing method thereof will be exemplified. First, the fiber-reinforced resin molded product 10 will be described with reference to FIG.

[Fiber reinforced plastic molded product]
FIG. 1 is an explanatory diagram schematically showing a cross-sectional structure of a fiber-reinforced resin molded product (hereinafter, molded product) 10. The molded product 10 is lightweight and has high rigidity, and is used as a part of a vehicle seat (for example, a backboard). Such a molded product 10 is impregnated with the core material 11, a pair of sheet-shaped reinforcing fiber base materials 12a and 12b stacked on the front and back surfaces of the core material 11, and the reinforcing fiber base materials 12a and 12b, respectively. A resin portion 13 made of a thermosetting resin to be cured is provided. Of the pair of reinforcing fiber base materials 12a and 12b, the reinforcing fiber base material 12a is arranged on the front surface 11a1 side (upper side in FIG. 1), and the reinforcing fiber base material 12b is arranged on the back surface 11b1 side (lower side in FIG. 1). ).

The core material 11 is a member made of synthetic resin (so-called foamed resin) having a closed cell structure. The core material 11 of the present embodiment is formed by laminating a pair of unit core materials 11a and 11b, each of which has a plate shape. Of the pair of unit core materials 11a and 11b, the unit core material 11a is arranged on the front side (upper side in FIG. 1), and the unit core material 11b is arranged on the back side (lower side in FIG. 1). The core material 11 has a plate-like shape (layered shape) having a thickness larger than that of the reinforcing fiber base materials 12a and 12b as a whole. Examples of the synthetic resin used for the core material 11 (unit core materials 11a and 11b) include acrylic resin. Since the unit core materials 11a and 11b are relatively thin, they can be manufactured by extrusion molding using a predetermined die, and are excellent in terms of cost.

A very small gap 110 is formed between the unit core materials 11a and 11b stacked in the thickness direction. As will be described later, this gap 110 is used as a flow path 110 for flowing the uncured resin R along the plane direction in the manufacturing process of the molded product 10. The gap (flow path) 110 is formed by a part of the resin portion 13 (gap resin portion which is an example of the flow path resin portion) 130 which is cured in a state of being thinly spread in a plane shape in the state of the molded product 10. It will be buried.

Further, the unit core material 11a on the front side is provided with a supply port 111 formed of a hole portion 111 that penetrates in the thickness direction and connects to the flow path (gap) 110. As will be described later, the supply port 111 is a portion where the uncured resin R is supplied from the outside through one of the reinforcing fiber base materials 12a on the front side in the manufacturing process of the molded product 10. The supply port 111 is filled with a filler 121 made of the same material as the reinforcing fiber base materials 12a and 12b. Such a supply port (hole portion) 111 is filled with a part (supply port resin portion) 131 of the resin portion 13 that has been cured while being impregnated with the filler 121 in the state of the molded product 10. Become.

Further, the unit core material 11a on the front side includes a branch path 112a connecting the gap (flow path) 110 and the surface 11a1 side facing one of the reinforcing fiber base materials 12a on the front side. The branch paths 112a are provided at a plurality of locations on the unit core material 11a, and each of them is composed of a small-diameter hole portion that penetrates the unit core material 11a in the thickness direction. On the other hand, the unit core material 11b on the back side includes a branch path 112b connecting the gap (flow path) 110 and the back surface 11b side facing the other reinforcing fiber base material 12b on the back side. The branch paths 112b are provided at a plurality of locations on the unit core material 11b, and each of them is composed of a small-diameter hole portion that penetrates the unit core material 11b in the thickness direction. In the present specification, when the branch roads 112a and 112b are collectively expressed, it is referred to as "branch road 112". The branch path 112 is in a state of being filled with a part of the resin portion 13 (branch path resin portion 132) that has been cured in a state of being elongated along the thickness direction in the state of the molded product 10.

The reinforcing fiber base material 12 is made of a woven fabric of carbon fibers (carbon fibers) processed into a sheet shape. As the reinforcing fiber base material 12, other fibers such as glass fiber may be used in addition to the carbon fiber, but the reinforcing fiber base material 12 made of carbon fiber is most preferable from the viewpoint of having high strength and the like. In the case of the present embodiment, the reinforcing fiber base material 12a on the front side and the reinforcing fiber base material 12b on the back side are made of carbon fiber woven fabric having the same thickness. In the present specification, when the reinforcing fiber base material 12a on the front side and the reinforcing fiber base material 12b on the back side are collectively expressed, it is referred to as “reinforcing fiber base material 12”.

As shown in FIG. 1, the core material 11 is sandwiched from the front and back sides by a pair of reinforcing fiber base materials 12a and 12b, which have a so-called sandwich structure.

As the thermosetting resin used for the resin portion 13, a resin generally used in the RTM method (for example, a two-component mixed type epoxy resin) is used. As the thermosetting resin, a colorless and transparent resin may be used, or a resin to which a colorant is added may be used.

In the molded product 10, the cured product of the thermosetting resin constituting the resin portion 13 is formed so as to cover not only the inside of the reinforcing fiber base material 12 but also the surface of the reinforcing fiber base material 12. Therefore, in the molded product 10, the resin portion 13 is formed so as to wrap the entire laminate composed of the core material 11 and the pair of reinforcing fiber base materials 12a and 12b.

Since such a molded product 10 contains the core material 11, the amount of the reinforcing fiber base material 12 (particularly made of carbon fiber), which is relatively expensive, can be reduced while maintaining light weight and high rigidity. Can be done. Further, since the core material 11 includes the flow path 110, the supply port 111, and the branch path 112, even when the resin supply pressure (injection pressure) is relatively low in the manufacturing process of the molded product 10, even if the resin supply pressure (injection pressure) is relatively low. It is easy to spread the uncured resin in the details of the molded product 10.

[Manufacturing method of fiber reinforced resin molded product]
Next, a method of manufacturing the molded product 10 using the molding apparatus 20 will be described with reference to FIGS. 2 to 6. FIG. 2 shows a process in which a laminate X made of a pair of unit core materials 11a and 11b and a pair of reinforcing fiber base materials 12a and 12b is set in a fixed mold 31 of the molding apparatus 20. It is explanatory drawing.

The molding apparatus 20 includes a molding die 30 having a fixed die 31 which is one split die and a movable die 32 (see FIG. 3) which is the other split die. The fixed mold 31 includes a molding surface 31a that forms the back side of the molded product 10. The molded surface 31a has a concave shape on the center side. FIG. 2 shows a molding die 30 in an open state, and the fixed mold 31 is arranged on a horizontal floor surface so that the molding surface 31a faces upward. In the mold open state, the movable mold 32 stands by above the fixed mold 31, but is omitted in FIG. 2. On the molding surface 31a of the fixed mold 31 in such a mold-opened state, a laminate X made of a pair of unit core materials 11a and 11b and a pair of reinforcing fiber base materials 12a and 12b is placed ( Setting process). The laminated body X is set in the fixed mold 31 in a state of following the shape of the molding surface 31a. In the case of the present embodiment, the laminated body X is placed on the molding surface 31a of the fixed mold 31 with the peripheral edge raised. The laminate X may be previously molded (preformed) into a shape that follows the shape of the molding surface 31a. A binder (for example, a powdery adhesive) is previously applied to the reinforcing fiber base materials 12a and 12b constituting the laminate X, and the laminate X is kept in a predetermined shape by the action of the binder. .. The laminated body X may be shaped by using the molded surface 31a by pressing the laminated body X against the molded surface 31a.

As shown in FIG. 2, the core material 11 of the laminated body X is composed of a stack of relatively small unit core materials 11a and 11b. Further, the core material 11 is smaller than the reinforcing fiber base materials 12a and 12b in a plan view, and the peripheral edges of the reinforcing fiber base materials 12a and 12b are arranged on the outside of the peripheral edge of the core material 11. The peripheral edges of the reinforcing fiber base materials 12a and 12b are in a state of directly overlapping each other without the core material 11.

FIG. 3 is an explanatory diagram showing how the movable mold 32 approaches the fixed mold 31 in the mold clamping step. As shown in FIG. 3, the movable mold 32 that has been waiting above the fixed mold 31 descends so as to approach the fixed mold 31 side, whereby the mold 30 is clamped. (Molding process). The movable mold 32 is driven up and down by using a known elevating mechanism (reciprocating mechanism) (not shown) provided with a hydraulic cylinder or the like. Such a movable mold 32 is provided with a molding surface 32a that forms the front side of the molded product 10. The molded surface 32a has a shape in which the central side is raised in a convex shape. The molding surface 32a is provided on the inside (inner surface side) of the movable mold 32 facing the fixed mold 31 side. As will be described later, in the molding die 30 in the mold-clamped state, the space surrounded by the molding surface 32a of the movable mold 32 and the molding surface 31a of the fixed mold 31 is the cavity C of the molding die 30.

The movable mold 32 has a lid shape as a whole so as to cover the concave molding surface 31a of the fixed mold 31. An injection hole (sprue) 33 for injecting resin into the molding die 30 is provided in the central portion of such a movable mold 32. The injection hole 33 is provided so as to penetrate the movable mold 32 and communicates with the cavity C of the molding mold 30. The nozzle 41 of the resin supply device 40 is connected to such an injection hole 33.

The resin supply device 40 is a device that supplies a thermosetting resin in an uncured state to the cavity C of the molding die 30. The resin supply device 40 of the present embodiment supplies a two-component mixed type epoxy resin (resin R) composed of a main agent and a curing agent into the molding mold 30. The resin supply device 40 includes a mixing head that discharges the main agent and the curing agent to the molding die 30 side while colliding and mixing them. The main agent and the curing agent are each housed in a predetermined tank, and are delivered to the mixing head in an accurate mixing ratio by each pressure pump. Then, the main agent and the curing agent collide with each other in the mixing head and mix with each other, and the uncured epoxy resin composed of the mixture thereof is discharged from the nozzle 41 at the tip of the mixing head. The resin discharged from the nozzle 41 is injected into the cavity C through the injection hole 33.

Further, a seal member 34 surrounding the peripheral edge of the cavity C is provided on the peripheral edge side of the inside (inner surface side) of the movable mold 32. When such a sealing member 34 is sandwiched between the fixed mold 31 and the movable mold 32 at the time of mold clamping, the gap between the movable mold 32 and the fixed mold 31 around the cavity C is sealed. Will be done.

FIG. 4 is an explanatory diagram showing a step of injecting the uncured resin R into the cavity C of the molded mold 30. As shown in FIG. 4, when the molding die 30 is molded, a space surrounded by the molding surface 31a of the fixed mold 31 and the molding surface 32a of the movable mold 32 is formed as one cavity C. To. The laminated body X is housed in the cavity C of the molded mold 30 that has been molded.

After molding, the gas in the cavity C is discharged to the outside by using the negative pressure applying mechanism (not shown) provided in the molding apparatus 20, and the inside of the cavity C is put into a negative pressure state (negative pressure applying step). The movable mold 32 of the molding die 30 is provided with an exhaust hole (not shown) having a through hole shape, and the gas in the cavity C is discharged to the outside through the exhaust hole.

When the negative pressure in the cavity C reaches a predetermined value, a predetermined valve device (not shown) is activated and the exhaust of gas from the exhaust hole is stopped. The inside of the cavity C is kept in an airtight state. After that, the uncured resin (epoxy resin) is injected into the cavity C in such a state by using the resin supply device 40. In the case of the present embodiment, the injection pressure of the resin supply device 40 is a relatively low pressure (for example, 0.3 MPa to 5 MPa, preferably 1 MPa or less) in order to suppress the core material 11 of the laminate X from being crushed. ) Is set.

The resin supply device 40 injects a two-component mixed type epoxy resin (resin R) composed of a main agent and a curing agent into the cavity C while colliding and mixing (resin supply step). FIG. 5 is an explanatory diagram showing how the resin R supplied from the injection hole 33 spreads over the laminated body X in the cavity C. As shown in FIG. 5, the laminated body X is set in the cavity C so that the injection hole 33 is arranged directly above the supply port 111. The supply port 111 is formed of a hole portion penetrating the unit core material 11a on the front side, and has a circular shape smaller than the injection hole 33 in a plan view. The supply port 111 is filled with a filler 121 made of a woven carbon fiber, and the formation of large voids in the unit core material 11a is suppressed.

The resin R supplied from the injection hole 33 is supplied to the supply port 111 of the core material 11 in the cavity C through the reinforcing fiber base material 12a on the front side. Since the reinforcing fiber base material 12a is made of a carbon fiber woven fabric, it is porous and easily impregnated with the uncured resin R, and is easily passed through the resin R. A part of the resin R supplied from the injection hole 33 moves along the surface of the core material 11 so as to spread in the surface direction inside the reinforcing fiber base material 11 on the front side.

The resin R supplied to the supply port 111 is supplied to the gap (flow path) 110 between the unit core materials 11a and 11b connected to the supply port 111. The resin R supplied to the gap 110 moves in the gap 110 so as to spread in a plane shape. When moving in the gap 110, a part of the resin R infiltrates into the branch paths 112 (112a, 112b) provided in the unit core materials 11a and 11b, and the front side reinforcing fiber base material 12a and the back side. It is supplied to each of the reinforcing fiber base materials 12a of. When the resin R was continuously supplied to the injection hole 33 and the inside of the cavity C was filled with the resin, the reinforcing fiber base material 12a on the front side and the reinforcing fiber base material 12b on the back side of the laminate X were each impregnated with the resin R. It becomes a state. Further, the gap 110, the supply port 111, and the branch path 112 of the core material 11, which are used as a flow path for spreading the resin R in the laminated body X, are all filled with the resin R. ..

Since the core material 11 of the laminate X is made of a foamed resin having a closed cell structure, the core material 11 cannot be positively impregnated with the uncured resin R, but the core material 11 is provided with a supply port 111 as described above. By providing the gap (flow path) 110 and the branch path 112, the resin R can be efficiently distributed between the core material 11 and the reinforcing fiber base materials 12a and 12b.

Since the uncured liquid resin R (epoxy resin) has a low viscosity (for example, about several mPa · s to several 100 mPa · s), it is easily impregnated into the laminate X even if the resin injection pressure is low. .. That is, the epoxy resin can move even in a small space such as a gap 110 or a branch path 112.

After the inside of the cavity C of the molding die 30 is filled with the resin R, the discharge of the resin R is stopped, and then the inside of the cavity C is held in pressure (pressure holding step). Then, the resin R in the molding die 30 is cured while the inside of the cavity C is held in pressure (curing step). The molding die 30 is provided with a heating device (heater or the like) (not shown), and the molding die 30 is heated by the heating device to cure the resin R in the cavity C.

When the resin R in the gap 110 is cured, it becomes the gap resin portion 130 (an example of the flow path resin portion, see FIG. 1), and when the resin R in the supply port 111 is cured, it becomes the supply port resin portion 131 (see FIG. 1). When the resin R in the branch path 112 is cured, it becomes the branch path resin portion 132 (see FIG. 1). After that, the molding die 30 is opened (mold opening step). When the mold is opened, the movable mold 32 rises away from the fixed mold 31.

FIG. 6 is an explanatory diagram showing a step (demolding step) in which the molded product 10 is demolded from the fixed mold 31. After opening the mold, the molded product 10 left on the molding surface 31a of the fixed mold 31 is removed from the molding surface 31a. In this way, the molded product 10 is manufactured using the molding device 20.

As described above, by forming a flow path (gap 110) through which the uncured resin R passes in the plane direction inside the core material 11, the inside of the cavity C does not affect the appearance of the molded product 10. And the resin R can be distributed in the laminated body X. Even when the injection pressure of the resin R is low or the viscosity of the resin R is high, the resin R can be spread to every corner in the cavity C of the molding mold in a short time.

<Embodiment 2>
Next, Embodiment 2 of the present invention will be described with reference to FIGS. 7 and 8. FIG. 7 is an explanatory view schematically showing the cross-sectional configuration of the molded product 10A of the second embodiment, and FIG. 8 shows the laminated body XA in the cavity C in the manufacturing process of the molded product 10A of the second embodiment. It is explanatory drawing which shows the state that the resin R supplied from the injection hole 33 spreads. In each of the embodiments after the second embodiment, the same components as those of the molded article 10 of the first embodiment are designated by the same reference numerals as those of the first embodiment, and detailed description thereof will be omitted as appropriate.

As shown in FIG. 7, the molded product 10A of the present embodiment includes a core material 11A, a pair of reinforcing fiber base materials 12a and 12b superposed on the front surface 11Aa1 and the back surface 11Ab1 of the core material 11A, and a reinforcing fiber base material 12a. , 12b and the like are impregnated with a resin portion 13A made of a thermosetting resin (epoxy resin) that is cured. The core material 11A is formed by stacking a pair of unit core members 11Aa and 11Ab, and the gap 110A between them is a flow path through which the uncured resin R passes.

In the case of the present embodiment, a plurality of spacer portions 113A are provided on the inner surface side (the surface side facing the reinforcing fiber base material 12b on the back side) of the unit core member 11Aa on the front side. The spacer portion 113A has a shape that is convexly raised from the inner surface of the unit core member 11a, and such a spacer portion 113A facilitates the formation of a gap 110A between the unit core members 11Aa and 11Ab. .. Such a gap 110A is filled with a gap resin portion (an example of a flow path resin portion) 130A which is a part of the resin portion 13A.

Similar to the first embodiment, the unit core member 11Aa on the front side constituting the core material 11A is formed with a supply port 111A filled with the filler 121A. The supply port 111A is filled with a supply port resin portion 131A which is a part of the resin portion 13A. Further, as in the first embodiment, a plurality of branch paths 112A are formed in the unit core members 11Aa and 11Ab. Each branch path 112A is filled with a branch path resin portion 132A which is a part of the resin portion 13A.

As shown in FIG. 8, when the uncured (liquid) resin R is supplied from the injection hole 33 into the cavity C of the molding mold in which the laminated body XA is set, the resin R is used in the first embodiment. Similarly, it is supplied into the laminated body XA through the reinforcing fiber base material 12a on the front side. Then, the resin R supplied to the supply port 111A through the reinforcing fiber base material 12a moves so as to spread in a plane in the gap 110A, and is distributed to each branch path 112A on the way. In particular, in the case of the present embodiment, since the gap 110A is surely secured by the spacer portion 113A, the resin R can easily move so as to spread in the gap 110A in a planar manner. Therefore, in the present embodiment, the uncured resin R can be efficiently distributed in the cavity C and in the laminated body XA (particularly, the reinforcing fiber base materials 12a, 12b, etc.).

<Embodiment 3>
Next, Embodiment 3 of the present invention will be described with reference to FIGS. 9 to 11. 9 is an explanatory view schematically showing the cross-sectional structure of the molded product 10B of the third embodiment, FIG. 10 is a perspective view of the core material 11B of the third embodiment, and FIG. 11 is a perspective view of the third embodiment. It is explanatory drawing which shows the mode that the resin R supplied from the injection hole 33 spreads to the laminated body XB in a cavity C in the manufacturing process of a molded product 10B.

As shown in FIG. 9, the molded product 10B of the present embodiment includes a core material 11B, a pair of reinforcing fiber base materials 12a and 12b laminated on the front surface 11B1 and the back surface 11B2 of the core material 11B, and a reinforcing fiber base material 12a. , 12b and the like are impregnated with a resin portion 13B made of a thermosetting resin (epoxy resin) that is cured. The core material 11B is made of a single foamed resin plate material. The core material 11B is provided with a through-hole-shaped supply port 111B to which the uncured resin R is supplied through the reinforcing fiber base material 12a on the front side. As shown in FIG. 9, the supply port 111B is filled with a filler 121B made of a carbon fiber woven fabric, as in the first embodiment. Then, in the state of the molded product 10B, the inside of the supply port 111B filled with the filler 121B is filled with the supply port resin portion 131B which is a part of the resin portion 13B. Further, the back surface 11B2 of the core material 11B is provided with a plurality of grooves 110B extending along the surface direction while being connected to the supply port 11B. The groove 110B is a flow path through which the uncured resin R passes, and is particularly provided on the back surface 11B2 of the core material 11B so that the resin R can be easily distributed.

Further, in the state of the molded product 10B, the groove 110B is filled with the groove resin portion 130B which is a part of the resin portion 13B. Further, the core material 11B is provided with a plurality of branch paths 112B provided so as to penetrate in the thickness direction. Each branch path 112B communicates between the groove 110B on the back surface 11B2 side and the front surface 11B1 side. Then, in the state of the molded product 10B, each branch path 112B is filled with the branch path resin portion 132B which is a part of the resin portion 13B.

As shown in FIG. 11, when the uncured (liquid) resin R is supplied from the injection hole 33 into the cavity C of the molding mold in which the laminated body XB is set, the resin R is used in the first embodiment. Similarly, it is supplied into the laminated body XB through the reinforcing fiber base material 12a on the front side. Then, the resin R supplied to the supply port 111B through the reinforcing fiber base material 12a is impregnated into the reinforcing fiber base material 12b on the back side and guided to the groove 110B so as to cover the back surface 11B2 of the core material 11B. Spreads in a plane. Further, a part of the resin R supplied from the injection hole 33 spreads in a plane shape while being impregnated with the reinforcing fiber base material 12a on the front side along the surface 11B1 of the core material 11B.

By providing the supply port 111B, the groove 110B, and the branch path 112B in the core material 11B as in the present embodiment, the resin R in the uncured state can be introduced into the cavity C and the laminated body XB (in particular, each reinforcing fiber group). Materials 12a, 12b, etc.) can be efficiently distributed.

<Embodiment 4>
Next, Embodiment 4 of the present invention will be described with reference to FIGS. 12 and 13. FIG. 12 is an explanatory view schematically showing the cross-sectional configuration of the molded product 10C of the fourth embodiment, and FIG. 13 shows the laminated body XC in the cavity C in the manufacturing process of the molded product 10C of the fourth embodiment. It is explanatory drawing which shows the state that the resin R supplied from the injection hole 33 spreads.

As shown in FIG. 12, the molded product 10C of the present embodiment includes a core material 11C, a pair of reinforcing fiber base materials 12a and 12b stacked on the front surface 11C1 and the back surface 11C2 of the core material 11C, and the reinforcing fiber base material 12a. , 12b and the like are impregnated with a resin portion 13C made of a thermosetting resin (epoxy resin) that is cured. The core material 11C is made of a single foamed resin plate material, and the core material 11C is provided with a through-hole-shaped supply port 111C to which the uncured resin is supplied through the reinforcing fiber base material 12a on the front side. ing. As shown in FIG. 12, the supply port 111C is filled with a filler 121C made of a carbon fiber woven fabric, as in the first embodiment. The inside of the supply port 111C filled with the filler 121C is filled with the supply port resin portion 131C which is a part of the resin portion 13C.

Inside the core material 11C, a cavity portion 110C extending along the surface direction while being connected to the supply port 11B is provided. The cavity 110C is a flow path through which the uncured resin R passes, and a plurality of the cavities 110C are provided in the core material 11C. Further, the core material 11C is provided with a plurality of branch paths 112C that connect the cavity 110C to the front surface 11C1 side or the back surface 11C2 side of the core material 11C and branch the flow of the resin R flowing in the cavity 10C. There is. In the state of the molded product 10C, the inside of the cavity portion 110C is filled with the cavity resin portion 130C which is a part of the resin portion 13C, and the inside of each branch path 112C is a branch path resin portion which is a part of the resin portion 13C. It is filled with 132C.

As shown in FIG. 13, when the uncured (liquid) resin R is supplied from the injection hole 33 into the cavity C of the molding mold in which the laminated body XC is set, the resin R is used in the first embodiment. Similarly, it is supplied to the supply port 111C in the laminated body XC through the reinforcing fiber base material 12a on the front side. Then, a part of the resin R supplied to the supply port 111C through the reinforcing fiber base material 12a penetrates into the cavity 130C and further moves in the plane direction along the cavity 130C. Since the resin R flowing in the cavity 130C is appropriately branched at the branch path 112C, the resin R is distributed on the front surface 11C1 side and the back surface 11C2 side of the core material 11C, respectively. Further, the resin R supplied from the supply port 111C to the reinforcing fiber base material 11b on the back side spreads in a plane shape while being impregnated in the reinforcing fiber base material 12b on the back side along the back surface 11C2 of the core material 11C. Further, a part of the resin R supplied from the injection hole 33 spreads in a plane shape along the surface 11C1 of the core material 11C while being impregnated into the reinforcing fiber base material 12a on the front side.

By providing the supply port 11C, the cavity portion 110C, and the branch path 112C in the core material 11C as in the present embodiment, the resin R in the uncured state can be introduced into the cavity C and the laminated body XC (particularly, each reinforcing fiber). It can be efficiently distributed to the base materials 12a, 12b, etc.).

<Embodiment 5>
Next, Embodiment 5 of the present invention will be described with reference to FIGS. 14 to 16. 14 is an explanatory view schematically showing the cross-sectional structure of the molded product 10D of the fifth embodiment, FIG. 15 is a plan view of the core material 14D of the fifth embodiment, and FIG. 16 is a plan view of the fifth embodiment. It is explanatory drawing which shows the mode that the resin R supplied from the injection hole 33 spreads to the laminated body XD in a cavity C in the manufacturing process of a molded product 10D.

As shown in FIG. 14, the molded product 10D of the present embodiment includes a core material 11D, a pair of reinforcing fiber base materials 12a and 12b superposed on the front surface 11D1 and the back surface 11D2 of the core material 11D, and the reinforcing fiber base material 12a. , 12b and the like are impregnated with a resin portion 13D made of a thermosetting resin (epoxy resin) that is cured. The core material 11D is composed of a pair of divided core materials 11Da and 11Db divided in the plane direction. The divided core materials 11Da and 11Db are each made of a foamed resin plate material, and they are elongated through flow paths extending along the surface direction and penetrating in the thickness direction between the end faces 11D3 and 11D4 adjacent to each other. 113D is formed. The through flow path 113D is a flow path through which the uncured resin R is passed along the plane direction in the manufacturing process. The end faces 11D3 and 11D4 each have a longitudinal shape, and convex portions 115D protruding from the end faces 11D3 and 11D4 are provided at both ends thereof. The through flow path 113D is composed of a portion surrounded by each end face 11D3, 11D4 and each convex portion 114D.

As shown in FIGS. 14 and 15, the through-flow path 113D is filled with a filler 123D made of a woven carbon fiber. The inside of the through-flow path 113D filled with the filler 123D is filled with the through-flow path resin portion 133D which is a part of the resin portion 13D. Further, the core material 11D (divided core material 11Da, 11Db) is formed of a hole portion penetrating in the thickness direction, and a communication passage 114D communicating the front surface 11D1 side and the back surface 11D2 side is formed. A plurality of communication passages 114D are provided in each of the divided core materials 11Da and 11Db, respectively. In the state of the molded product 10D, the divided core materials 11Da and 11Db are filled with the continuous passage resin portion 134D which is a part of the resin portion 13D.

As shown in FIG. 16, when the uncured (liquid) resin R is supplied from the injection hole 33 into the cavity C of the molding mold in which the laminated body XD is set, the resin R is reinforced on the front side. It is supplied to the through flow path 113D in the laminated body XD through the fiber base material 12a. Then, the resin R supplied to the through flow path 113D moves along the longitudinal direction of the through flow path 113D and the like. A part of the resin R that has penetrated into the through flow path 113D spreads in a plane shape along the back surface 11D2 of the core material 11D while being impregnated with the reinforcing fiber base material 12b on the back side. A part of the resin R supplied from the injection hole 33 spreads in a plane along the surface 11D1 of the core material 11D while being impregnated with the reinforcing fiber base material 12a on the front side. Further, a part of the resin R on the front surface 11D1 side of the core material 11D moves to the back surface side 11D2 side via the communication passage 114D. In some cases, a part of the resin R on the back surface 11D2 side moves to the front surface 11D1 side.

By forming the through-flow path 113D in the core material 11D by combining the divided core materials 11Da and 11Db as in the present embodiment, the resin R in the uncured state can be introduced into the cavity C and the laminated body XD (particularly, respectively). It can be efficiently distributed to the reinforcing fiber base materials 12a, 12b, etc.). In particular, by forming a plurality of communication passages 114D in the core material 11D (divided core material 11Da, 11Db), the resin R can be further efficiently distributed.

<Other embodiments>
The present invention is not limited to the embodiments described above and the drawings, and for example, the following embodiments are also included in the technical scope of the present invention.

(1) In the first embodiment, a pair (two) of unit core materials are stacked, but the present invention is not limited to this, and for example, three or more unit core materials are used. The stacked materials may be used as a core material.

(2) In the first embodiment, unit core materials having the same thickness are used, but unit core materials having different thicknesses may be used as long as the object of the present invention is not impaired.

(3) In the second embodiment, the spacer portion is formed from a part of the unit core material on the front side, but in other embodiments, a part of the unit core material on the back side may be used as the spacer portion. Alternatively, a part of both unit core materials may be used as a spacer portion. Further, depending on the case, a member different from the unit core material may be used as the spacer portion.

(4) In the third embodiment, the groove is provided on the back surface side of the core material, but in other embodiments, the groove may be further provided on the front surface side of the core material. It is preferable that the groove is formed at least on the back surface of the core material.

(5) In the above embodiment 5, the convex portion for forming the through-passage may be formed only on one of the pair of adjacent split core materials, and the through-passage is formed. If so, there are no particular restrictions.

(6) In another embodiment, a molded product may be manufactured by using a thermosetting resin such as a urethane resin or a phenol resin.

10 ... Fiber reinforced resin molded product (molded product), 11 ... Core material, 110 ... Flow path (gap), 111 ... Supply port, 112 ... Branch path, 12a, 12b ... Reinforcing fiber base material, 13 ... Resin part, 130 ... Flow path resin part (gap resin part), 131 ... Supply port resin part, 132 ... Branch path resin part, 20 ... Molding device, 30 ... Molding mold, 31 ... Fixed mold (split mold), 31a ... Molding surface , 32 ... Movable mold (split mold), 32a ... Molded surface, 40 ... Resin supply device, C ... Cavity, R ... Uncured resin, X ... Laminated body

Claims (5)

A laminate having a plate-shaped core material made of foamed resin and a pair of sheet-shaped reinforcing fiber base materials to be laminated on the front surface and the back surface of the core material, respectively.
A fiber-reinforced resin molded product including a resin portion obtained by curing an uncured resin impregnated in the laminate.
The core material of the laminate is formed on or inside the front surface and the back surface, and is connected to the flow path through which the uncured resin flows along the surface direction and through the flow path in the thickness direction. It is composed of holes and has a supply port for supplying the uncured resin from the outside through the reinforcing fiber base material.
The resin portion has a flow path resin portion that fills the flow path and a supply port resin portion that fills the supply port .
The core materials of the laminated body are overlapped with each other so as to form a gap used as the flow path, and each has a pair of plate-shaped unit core materials.
The resin portion is a fiber-reinforced resin molded product having a gap resin portion that fills the gap as the flow path resin portion . The fiber-reinforced resin molded product according to claim 1 , wherein the core material of the laminate is arranged between a pair of the unit core materials and has a spacer portion for securing the gap. A laminate having a plate-shaped core material made of foamed resin and a pair of sheet-shaped reinforcing fiber base materials to be laminated on the front surface and the back surface of the core material, respectively.
A fiber-reinforced resin molded product including a resin portion obtained by curing an uncured resin impregnated in the laminate.
The core material of the laminate is formed on or inside the front surface and the back surface, and is connected to the flow path through which the uncured resin flows along the surface direction and through the flow path in the thickness direction. It is composed of holes and has a supply port for supplying the uncured resin from the outside through the reinforcing fiber base material.
The resin portion has a flow path resin portion that fills the flow path and a supply port resin portion that fills the supply port.
The core material of the laminate has a cavity formed inside the laminate and used as the flow path.
The resin portion is a fiber-reinforced resin molded product having a cavity resin portion that fills the cavity portion as the flow path resin portion. The core material of the laminate communicates the flow path with the surface side facing the reinforcing fiber base material on one side or the reinforcing fiber base material on the other side, and branches the flow of the resin in an uncured state. Has a fork,
The fiber-reinforced resin molded product according to any one of claims 1 to 3 , wherein the resin portion has a branch path resin portion that fills the branch path. The method for manufacturing a fiber-reinforced resin molded product according to any one of claims 1 to 4 .
When the uncured resin is supplied from the outside to the mold cavity in which the laminate is housed, the uncured resin is supplied to the supply port through the reinforcing fiber base material, and the resin is supplied. A method for manufacturing a fiber-reinforced resin molded product, comprising a resin supply step of flowing along the flow path.

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