JP7508883B2 - Method for manufacturing fiber-reinforced resin structure - Google Patents

Description

The present invention relates to a method for manufacturing a fiber-reinforced resin structure that includes a fiber body and a resin.

Composite materials consisting of reinforced fiber bodies such as CFRP and soft bodies such as foams have been proposed (see, for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 63-312136

The method described in Patent Document 1 had excellent strength due to the fiber reinforcement, even though some parts were curved, but it was only possible to produce fiber-reinforced resin structures of fixed shapes.

Therefore, the present invention aims to provide a method for manufacturing a novel fiber-reinforced resin structure that has a predetermined excellent strength while being capable of being formed into various shapes. Furthermore, the second aim of the present invention is to provide a novel fiber-reinforced resin structure that can be manufactured by the manufacturing method.

The invention (I) is
The present invention includes a method for preparing a laminate having a columnar foam and a fibrous body that is wound around a side portion of the foam one or more times, the fibrous body being impregnated with an uncured thermosetting resin, applying an external force to the laminate to deform a cross-sectional shape of the foam contained in the laminate, and thermally curing the thermosetting resin contained in the laminate,
The method for producing a fiber-reinforced resin structure (excluding a method using, as the foam, a foam capable of secondary foaming; and a covering body having bleed holes through which the uncured thermosetting resin and gas can seep out and covering the laminate), wherein a 25% compressive load of the foam measured in accordance with JIS K6400-2:2012 is 1 to 2000 kPa.
The invention (I) is
The foam may be an olefin-based resin foam.
The invention (I) is
The foam may have a density of 1 to 800 kg/ ^m3 .
The invention (I) is
The deformation of the cross-sectional shape of the foam may be carried out in a reduced pressure atmosphere.
The invention (I) is
cooling the laminate after the heat curing step to shrink the foam;
The method may further include a step of removing the foam contained in the laminate after the step of shrinking the foam.

Invention (II) is
The present invention includes a method for preparing a laminate having a columnar foam and a fibrous body covering at least a part of a side surface of the foam, the method including the steps of preparing a laminate in which the fibrous body is impregnated with an uncured thermosetting resin, curving the laminate so that the column axis of the foam is curved, and thermally curing the thermosetting resin contained in the laminate,
The method for producing a fiber-reinforced resin structure (excluding a method using, as the foam, a foam capable of secondary foaming; and a covering body having bleed holes through which the uncured thermosetting resin and gas can seep out and covering the laminate), wherein a 25% compressive load of the foam measured in accordance with JIS K6400-2:2012 is 1 to 2000 kPa.
The invention (II) is
In the laminate, the fibrous body may be wound around the side surface of the foam body one or more times.
The invention (II) is
The foam may be an olefin-based resin foam.
The invention (II) is
The foam may have a density of 1 to 800 kg/ ^m3 .
The invention (II) is
cooling the laminate after the heat curing step to shrink the foam;
The method may further include a step of removing the foam contained in the laminate after the step of shrinking the foam.

The invention (III) relates to
The method includes the steps of preparing an assembly having a columnar first foam body, a fibrous body that is wound around a side portion of the first foam body one or more times, and a columnar second foam body that is adjacent to the first foam body via the fibrous body, the assembly being impregnated with an uncured thermosetting resin, and thermally curing the thermosetting resin contained in the assembly,
The method for producing a fiber-reinforced resin structure (excluding a method using a foam capable of secondary foaming as the first foam; and a covering body having bleed holes through which the uncured thermosetting resin and gas can seep out and covering the assembly), wherein a 25% compressive load of the first foam and the second foam, measured in accordance with JIS K6400-2:2012, is 1 to 2000 kPa.
The invention (III) is
The process may include a deformation process in which an external force is applied to the assembly to deform the cross-sectional shapes of the first foam body and the second foam body before the thermosetting resin contained in the assembly is thermally cured.
The invention (III) is
The aggregate may include the first foam, the fibrous body wrapping around a side portion of the first foam at least one revolution, the second foam, and a fibrous body wrapping around a side portion of the second foam at least one revolution, and the fibrous body wrapping around the side portion of the first foam at least one revolution and the fibrous body wrapping around the side portion of the second foam at least one revolution may be in contact with each other.
The invention (III) is
The first foam and the second foam may be olefin-based resin foams.
The invention (III) is
The first foam and the second foam may have a density of 1 to 800 kg/ ^m3 .
The invention (III) is
The deformation process may be carried out in a reduced pressure atmosphere.
The invention (III) is
cooling the assembly after the heat curing step to cause the first foam and the second foam to shrink;
and removing the first foam and the second foam contained in the assembly after the step of shrinking the first foam and the second foam.

Invention (IV) is
The present invention relates to an assembly having a columnar first foam, a fibrous body covering at least a portion of a side surface of the first foam, and a columnar second foam adjacent to the first foam via the fibrous body, the assembly being impregnated with an uncured thermosetting resin, the assembly being curved so that the columnar axis of the foam is curved, and the thermosetting resin contained in the assembly is thermally cured,
The method for producing a fiber-reinforced resin structure (excluding a method using a foam capable of secondary foaming as the first foam; and a covering body having bleed holes through which the uncured thermosetting resin and gas can seep out and covering the assembly), wherein a 25% compressive load of the first foam and the second foam, measured in accordance with JIS K6400-2:2012, is 1 to 2000 kPa.
The invention (IV) is
The process may further include a deformation process of applying an external force to the assembly and deforming the cross-sectional shapes of the first foam body and the second foam body before thermally curing the thermosetting resin contained in the assembly.
The invention (IV) is
In the assembly, the fibrous body may be wound around the side surface of the first foam body one or more times.
The invention (IV) is
The aggregate may include the first foam, the fibrous body wrapping around a side portion of the first foam at least one revolution, the second foam, and a fibrous body wrapping around a side portion of the second foam at least one revolution, and the fibrous body wrapping around the side portion of the first foam at least one revolution and the fibrous body wrapping around the side portion of the first foam at least one revolution may be in contact with each other.
The invention (IV) is
The first foam and the second foam may be olefin-based resin foams.
The invention (IV) is
The first foam and the second foam may have a density of 1 to 800 kg/ ^m3 .
The invention (IV) is
The deformation process may be carried out in a reduced pressure atmosphere.
The invention (IV) is
cooling the assembly after the heat curing step to cause the first foam and the second foam to shrink;
The method may further include a removing step of removing the first foam and the second foam contained in the assembly after the step of shrinking the first foam and the second foam.

According to the present invention, it is possible to provide a method for producing a novel fiber-reinforced resin structure that has excellent strength and can be formed into various shapes. Furthermore, according to the present invention, it is possible to provide a novel fiber-reinforced resin structure.

FIG. 1 is a diagram illustrating the first embodiment, and in particular, FIG. 1(a) is a perspective view illustrating the state in which a fiber sheet and a flexible body are directly laminated, and FIG. 1(b) is a perspective view showing the first multilayer laminate. Figure 2 is a diagram illustrating the first embodiment, and in particular, Figure 2(a) is an oblique view illustrating a state in which a fiber sheet and a flexible body are directly laminated, Figure 2(b) is an oblique view illustrating a state in which a fiber sheet is wound around a core material, Figure 2(c) is an oblique view illustrating a state in which a fiber sheet is wound multiple times around a core material, Figure 2(d) is an oblique view showing an uncured vortex stack, and Figure 2(e) is an oblique view showing a hardened vortex stack after hardening. Figure 3 is a diagram illustrating the first embodiment, and in particular, Figure 3(a) is an oblique view illustrating a state in which a fiber sheet and a flexible body are directly laminated, Figure 3(b) is an oblique view illustrating a state in which a fiber sheet is wound around a core material, Figure 3(c) is an oblique view illustrating a state in which a fiber sheet is wound multiple times around a core material, Figure 3(d) is an oblique view showing a first cylindrical laminate in an uncured state, and Figure 2(e) is an oblique view showing a hardened first cylindrical laminate after hardening. Figure 4 is a diagram illustrating the first embodiment, and in particular, Figure 4(a) is an oblique view showing the first multilayer laminate, Figure 4(b) is an oblique view explaining the state in which the first multilayer laminate is being cut, Figure 4(c) is an oblique view for explaining the second multilayer laminate, Figure 4(d) is an oblique view explaining the state in which a fiber sheet is wound around a core material, Figure 4(e) is an oblique view explaining the state in which the fiber sheet is wound around the core material, Figure 4(f) is an oblique view showing the second cylindrical laminate in an uncured state, and Figure 4(e) is an oblique view showing the hardened second cylindrical laminate after hardening. Figure 5 is a diagram illustrating the first embodiment, and in particular, Figure 5(a) is a cross-sectional view illustrating the laminated state of a fiber sheet and a flexible body, Figure 5(b) is a cross-sectional view illustrating the state in which the energetic curable resin impregnated into the fiber sheet seeps into the flexible body, Figure 5(c) is a cross-sectional view illustrating the state in which the energetic curable resin impregnated into the fiber sheet seeps into the flexible body and hardens, and Figure 5(d) is a cross-sectional view illustrating the state in which the energetic curable resin that has seenp out into the flexible body has hardened. 6A and 6B are diagrams for explaining the first embodiment, and in particular, FIG. 6A is a perspective view for explaining a state in which a hardened vortex stack is cut to obtain a cut vortex stack, and FIG. 6B is a perspective view for explaining a state in which a hardened first cylindrical laminate is cut to obtain a cut first cylindrical laminate. Figure 7 is a diagram illustrating the first embodiment, and in particular, Figure 7(a) is an oblique view showing a hardened first multi-layer laminate, Figure 7(b) is an oblique view illustrating the state in which the hardened first multi-layer laminate is being cut, Figure 7(c) is an oblique view illustrating the state in which second cut laminates are arranged side by side on a plate member, and Figure 7(d) is an oblique view illustrating the state in which multiple second cut laminates are interposed between a pair of plate members. 8A and 8B are diagrams for explaining the first embodiment. In particular, FIG. 8A is a perspective view for explaining a state in which a plurality of cut vortex stacks are interposed between a pair of plate members, and FIG. 8B is a perspective view for explaining a state in which a plurality of cut first cylindrical stacks are interposed between a pair of plate members. Figure 9 is a diagram illustrating a modified example of the first embodiment, and in particular, Figure 9(a) is an oblique view showing a third multi-layer laminate, Figure 9(b) is an oblique view illustrating the state in which the third multi-layer laminate is cut, Figure 9(c) is an oblique view illustrating the state in which a fourth multi-layer laminate is obtained by directly laminating a fiber sheet on the third multi-layer laminate, and Figure 9(d) is an oblique view showing the hardened fourth laminate. FIG. 10 is a plan view showing a bent cylindrical laminate according to the second embodiment. 11A is a diagram for explaining the second embodiment, and in particular, FIG. 11(a) is an oblique view for explaining the state in which a fiber sheet is wound around a cylindrical foam body to obtain a cylindrical laminate, FIG. 11(b) is an oblique view for explaining the state in which a group of cylindrical laminates is obtained by arranging the cylindrical laminates in a row, FIG. 11(c) is an oblique view for explaining the state in which the group of cylindrical laminates is cut to obtain a first group of cut cylindrical laminates, FIG. 11(d) is an oblique view for explaining the state in which the first group of cut cylindrical laminates is sandwiched between a pair of fiber sheets, and FIG. 11(e) is an oblique view for explaining the state in which a hardening process is performed on the special flat laminate to obtain a hardened special flat laminate. Figure 13 is a diagram for explaining the second embodiment, and in particular, Figure 13(a) is an oblique view for explaining the state in which a fiber sheet is wound around a cylindrical foam to obtain a cylindrical laminate, Figure 13(b) is an oblique view for explaining the state in which cylindrical laminate groups are stacked on top of each other, Figure 13(c) is an oblique view for explaining the state in which a plurality of stacked cylindrical laminate groups are cut to obtain a second cut cylindrical laminate group, Figure 13(d) is an oblique view showing the second cut cylindrical laminate group, and Figure 13(e) is an oblique view for explaining the state in which a hardening process is performed on the special block laminate to obtain a hardened special block laminate. 15A and 15B are diagrams for explaining the second embodiment, and in particular, FIG. 15(a) is a perspective view for explaining a state in which a fiber sheet is wound around a cylindrical foam body to obtain a cylindrical laminate, FIG. 15(b) is a perspective view for explaining a state in which a group of cylindrical laminates is bundled into a bundle, FIG. 15(c) is a perspective view for explaining a state in which a bundle of cylindrical laminates is cut to obtain a cut cylindrical laminate bundle, FIG. 15(d) is a perspective view showing the cut cylindrical laminate bundle, and FIG. 15(e) is a perspective view for explaining a state in which a hardening process is performed on the special cylindrical laminate to obtain a hardened special cylindrical laminate. FIG. 14 is a perspective view showing a fiber-reinforced resin structure according to the first embodiment and a method for manufacturing the same. FIG. 15 is a perspective view showing a fiber-reinforced resin structure according to a modification of the first embodiment and a method for manufacturing the same. FIG. 16 is a perspective view showing a fiber-reinforced resin structure according to a modification of the first embodiment and a method for manufacturing the same. FIG. 17 is a perspective view showing a fiber-reinforced resin structure according to embodiment II and a method for manufacturing the same. FIG. 18 is a perspective view showing a fiber-reinforced resin structure according to a modified example of the second embodiment and a method for manufacturing the same. FIG. 19 is a perspective view showing a fiber-reinforced resin structure according to a modification of the second embodiment and a method for manufacturing the same. FIG. 20 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 21 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 22 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 23 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 24-1 is a perspective view showing a fiber-reinforced resin structure and a manufacturing method thereof according to embodiment III. FIG. 24-2 is a perspective view showing a fiber-reinforced resin structure and a manufacturing method thereof according to embodiment III. FIG. 25 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 26 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 27 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 28 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 29 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 30 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 31 is a perspective view showing a fiber-reinforced resin structure according to embodiment III and a method for manufacturing the same. FIG. 32-1 is a perspective view showing a fiber-reinforced resin structure according to embodiment IV and a method for manufacturing the same. FIG. 32-2 is a perspective view showing a fiber-reinforced resin structure according to embodiment IV and a method for manufacturing the same. FIG. 33-1 is a perspective view showing a fiber-reinforced resin structure according to embodiment IV and a method for manufacturing the same. FIG. 33-1 is a perspective view showing a fiber-reinforced resin structure according to embodiment IV and a method for manufacturing the same. FIG. 34 is a perspective view showing a fiber-reinforced resin structure according to embodiment IV and a method for manufacturing the same. FIG. 35 is a perspective view showing a fiber-reinforced resin structure according to the first modification. FIG. 36 is a perspective view showing a fiber-reinforced resin structure according to the second modification. FIG. 37 is a perspective view showing a fiber-reinforced resin structure according to the third modification. FIG. 38A is a perspective view showing a fiber-reinforced resin structure according to the fourth modification. FIG. 38B is a perspective view showing a fiber-reinforced resin structure according to the fourth modification. FIG. 39 is a perspective view showing a fiber-reinforced resin structure according to the fifth modification. FIG. 40 is a perspective view showing a fiber-reinforced resin structure according to the sixth modification. FIG. 41 is a perspective view showing a fiber-reinforced resin structure according to the seventh modification. FIG. 42 is a perspective view showing a fiber-reinforced resin structure according to the seventh modification. FIG. 43 is a perspective view showing a fiber-reinforced resin structure according to Modification 8. As shown in FIG. FIG. 44 is a perspective view showing a fiber-reinforced resin structure according to the ninth modification. FIG. 45 is a perspective view showing a fiber-reinforced resin structure according to Modifications 10-1 to 10-3.

The present invention is described in detail below, but is not limited to the following. The present invention also includes configurations obtained by combining the matters disclosed in one embodiment with the matters disclosed in another embodiment, to the extent that no contradiction occurs.

In addition, in the description of each embodiment, matters that have already been described in another embodiment may be omitted without special explanation. For example, parts showing similar materials may be given the same reference numerals, and their description may be omitted or simplified. In addition, in each figure, matters given the same reference numerals may be omitted or simplified. Note that when the same reference numerals are used in the first and second embodiments described below and the I to IV embodiments described below, it may be determined that different components are disclosed.

In this invention, "circle" includes ellipse.

In the present invention, when the term "polygon" is used, it is sufficient that the shape has some straight sides, has a structure different from a circle or an indeterminate shape, and can be judged to be a polygon or approximate a polygon as a whole. Therefore, shapes with some rounded sides and shapes with sides that are loosely connected are also included in the concept of "polygon." In addition, when the term "polygon" is used simply, it preferably refers to a regular polygon, but it also includes configurations other than regular polygons.

In this specification, the up, down, left and right directions when viewed in a figure are referred to as "up, down, left and right".

The present invention will be described below from two perspectives: the first and second embodiments, and the I to IV embodiments.

The first and second embodiments and the I to IV embodiments have some overlapping and different parts. Matters described in the description of the first and second embodiments but not described in the description of the I to IV embodiments can be incorporated into the I to IV embodiments as appropriate to the extent that no contradictions arise.

The manufacturing method of the fiber-reinforced resin structure described below may include a step of using a foam capable of secondary expansion as the foam and covering the laminate with a covering having bleed holes through which the uncured thermosetting resin and gas can seep out, but it is preferable not to include such a step. If a foam capable of secondary expansion is not used and a step of covering the laminate with a covering having bleed holes through which the uncured thermosetting resin and the like can seep out is not provided, the unnecessary step of controlling the secondary expansion of the foam can be omitted and the necessary thermosetting resin can be prevented from leaking out from the bleed holes, so that a fiber-reinforced resin structure with superior strength and appearance can be manufactured.

<<<<<<First and Second Embodiments>>>>>>
<<<<First embodiment>>>>
First, a first embodiment will be described. In the first embodiment, a lamination process is performed in which a fibrous body impregnated with an energy curable resin and a flexible body are directly laminated to obtain an uncured laminate, or a fibrous body is directly contacted with a flexible body, and then the fibrous body is impregnated with an energy curable resin to obtain an uncured laminate;
and a curing step of applying energy to the uncured laminate to cure the energy curable resin contained in the fibrous body constituting the uncured laminate. The method for producing a composite material containing a reinforced fiber body and a flexible body will be described below in the order of raw materials, process, and composite material.

<<1. Raw materials>>
(1-1. Fibrous body)
The fibrous body according to the present invention is not particularly limited in terms of shape, size, etc., and may be, for example, a sheet-like fibrous sheet. This fibrous sheet is not particularly limited as long as it is a sheet of assembled fibers, and examples thereof include woven fabrics (twill weave, double weave, triple weave, tatami weave, etc.) and nonwoven fabrics.

The thickness of the fiber sheet is not particularly limited and can be selected appropriately. If the fiber sheet is too thin, the mechanical properties such as the strength and elastic modulus of the fiber sheet may be reduced. Therefore, the thickness of the fiber sheet according to the present invention is preferably, for example, 20 μm to 500 μm, more preferably 30 μm to 300 μm, and particularly preferably 30 μm to 200 μm. Furthermore, multiple such fiber sheets may be laminated. Needless to say, fiber sheets having a thickness of several mm, such as chopped strand mats and core mats, may also be used.

The fibers forming the fiber sheet are not particularly limited and may be any known fibers, and may include at least one of metal fibers, inorganic fibers, and organic fibers. Examples of the fibers include metal fibers such as stainless steel fibers, nickel fibers, copper fibers, aluminum fibers, silver fibers, gold fibers, and titanium fibers; organic fibers such as polyolefin resins such as polyparaphenylene benzoxazole, polyethylene terephthalate (PET) resin, polyvinyl alcohol (PVA), polyethylene, and polypropylene, polyvinyl chloride resin, aramid resin, acrylic resin, polyimide resin, polyparaphenylene benzoxazole (PBO) fibers, cellulose, vinylon, nylon, rayon, aramid, phenolic fibers, fluorine fibers, pulp (fibers), kenaf, hemp, and bamboo fibers; inorganic fibers such as glass fibers, carbon fibers, silica fibers, rock wool, basalt fibers, slag wool, alumina fibers, and ceramic fibers; and the like. One or more of these may be used in combination. The fibers according to the present invention are preferably those having a higher Young's modulus than the resin or matrix resin used in the sealing material, and are more preferably metal or inorganic fibers. The higher the Young's modulus of the fiber, the higher the rigidity of the fiber sheet can be, and when embedded in the resin, the rigidity of the resin can be effectively improved. Therefore, it is possible to obtain a sealing material that is highly rigid and difficult to break.

(1-1-1. Manufacturing method of fiber sheet)
The fiber sheet can be manufactured by a known method. For example, suitable examples of methods for manufacturing nonwoven fabric include dry methods such as carding and airlaid, wet papermaking methods in which the fiber is formed by sifting like paper, fleece forming methods such as spunbonding and meltblowing, and fleece bonding methods such as thermal bonding, chemical bonding, needle punching, spunlace (hydroentanglement), stitch bonding, and steam jet. Among these, the manufacturing method using the wet papermaking method is suitable because it is possible to make the fiber sheet thin and is excellent in terms of uniformity.

(1-2. Thermosetting resin)
Examples of the thermosetting resin that can be used include epoxy resins, unsaturated polyester resins, polyvinyl ester resins, phenolic resins, polyurethane resins, acrylic resins, melamine resins, urea resins, benzoguanamine resins, rosin-modified maleic acid resins, rosin-modified fumaric acid resins, etc. These may be used alone or in combination of two or more.

The thermosetting resin may contain an energy ray curable resin as another curable resin. Examples of the energy ray curable resin include epoxy resin, acrylic resin, silicone resin, and polyester resin. These may be used alone or in combination of two or more.

The volume ratio of the thermosetting resin to the fiber sheet, assuming that the total volume of the thermosetting resin and the fiber sheet is 100 volume %, can be such that the volume fraction of the fiber sheet (fiber fraction) is 15 to 85 volume %, preferably 25 to 85 volume %, and more preferably 45 to 80 volume %. When the volume fraction of the fiber sheet (fiber fraction) is within this range, the fiber-reinforced resin structure after curing has few defects, is less susceptible to destruction such as buckling, and has excellent mechanical strength.

(1-3. Flexible body)
As the flexible body, a columnar foam is used. This foam may be a closed-cell foam, an open-cell foam, or a foam containing both closed and open cells. The closed-cell foam mentioned here does not only refer to foam in which all the cells are completely independent, but also means that some of the cells may be connected to adjacent cells, and it is sufficient that each cell is independent to the extent that it can be understood as a closed-cell foam as a whole.

Here, when the foam contains closed and open bubbles, the average ratio of the closed and open bubbles (hereinafter referred to as the closed bubble ratio) is not particularly limited, but for example, the closed bubble ratio can be 0.1 to 99.9%, preferably 10.0% to 99.9%, more preferably 30.0 to 99.9%, and even more preferably 50.0 to 99.9%. A foam containing only closed bubbles is most preferable. When the foam contains a large number of closed bubbles, there are many sealed air layers inside the foam, so when the foam is heated, in addition to the thermal expansion of the resin itself, the sealed air layers also thermally expand, and the force with which the foam presses the fibrous body can be strengthened. Therefore, when the foam is heated in the heat curing process described later, the thermal expansion occurs more strongly, and by pressing the fibrous body, it is possible to further improve the moldability (the shape can be formed into a desired shape without wrinkles or twists, etc.), and by shrinking when cooled after curing, the foam becomes easier to remove from the laminate.

The closed cell ratio of a foam is determined by observing the cross section of the foam using a microscope or scanning electron microscope, counting the number of closed and open cells per unit area in the photographed image, dividing the number of closed cells by the total number of cells (both closed and open cells) and multiplying the result by 100. This measurement of the closed cell ratio is repeated at 10 randomly selected cross sections of the same foam, and the average of the closed cell ratios found for each is taken as the closed cell ratio of the foam.

The resin constituting the foam is not particularly limited, and may be appropriately selected according to the application from olefin resins, urethane resins, styrene resins, phenolic resins, silicone resins, etc. In addition, other materials constituting the foam include natural rubber (NR), chloroprene rubber (CR), ethylene propylene diene rubber (EPDM), and nitrile rubber (NBR), and these may also be appropriately selected according to the application. Among these, olefin resins can be preferably used. With olefin resins, for example, it is easy to adjust the hardening temperature of the fiber body and the degree of thermal expansion of the foam at the hardening temperature of the fiber body by adjusting the blending ratio of polyethylene and polypropylene. That is, when the foam is heated and thermally expanded in the thermal hardening process described below, the foam presses the fiber body, so that the moldability (the shape is made into a desired shape without wrinkles or twists) can be excellent, but the degree of this pressing can be adjusted by changing the blending ratio of olefin resins, for example, polyethylene and polypropylene, and the moldability can be excellent according to the shape of the fiber body. In addition, by adjusting the blending ratio of polyethylene and polypropylene, the presence or absence of crosslinking, and the degree of crosslinking, it is easy to adjust the flexibility (hardness), thermal expansion, wettability (affinity), softening point, etc. of the foam.

The resin that constitutes the foam can be freely selected taking into consideration its affinity with the uncured resin contained in the fibrous body. If the resin that constitutes the foam and the uncured resin contained in the fibrous body have a high affinity, it becomes easier to wrap the laminate around the foam, but it may be difficult to remove the foam after it has been heated and cured. For this reason, it is preferable to adjust the affinity between the resin that constitutes the foam and the uncured resin contained in the fibrous body.

To adjust the affinity between the resin constituting the foam and the uncured resin contained in the fibrous body, it is sufficient to adjust the wettability (e.g., contact angle or surface energy) of the resin constituting the foam and the uncured resin contained in the fibrous body, and to increase the affinity, it is sufficient to select the contact angle (or surface energy) of the resin constituting the foam and the uncured resin contained in the fibrous body. To increase the affinity, it is sufficient to set the contact angle (or surface energy) of the resin constituting the foam and the uncured resin contained in the fibrous body to similar values, and to decrease the affinity, it is sufficient to set the contact angle and surface energy of the resin constituting the foam and the uncured resin contained in the fibrous body to different values.

The difference in contact angle between the resin constituting the foam and the uncured resin contained in the fibrous body is not particularly limited, but can be greater than 0° and less than ±90°. When the difference in contact angle between the resin constituting the foam and the uncured resin contained in the fibrous body is within this range, it is easy to wrap the fibrous body around the foam, and it is also easy to remove the foam after it has been heat-cured.

The softening point of the resin constituting the foam is not particularly limited and can be selected according to the curing temperature of the thermosetting resin used in the fibrous body. For example, the softening point of the resin constituting the foam can be 10°C or more higher than the curing temperature of the thermosetting resin used in the fibrous body. For example, when the thermosetting resin is an epoxy resin, the softening point of the resin constituting the foam can be 60 to 200°C, preferably 80 to 160°C, and more preferably 100 to 150°C. When the softening point of the resin constituting the foam is within this range, the foam has sufficient thermal expansion as a foam when heated and sufficient strength (e.g. tensile strength), so that excellent moldability (no wrinkles or twists, and the desired shape) can be achieved during molding.

The foam is preferably a solid body. The foam preferably does not have holes (through holes/hollow portions) with a diameter of 1/2 or more, 1/3 or more, 1/4 or more, 1/5 or more, 1/10 or more, 1/15 or more, or 1/20 or more of the outer diameter of the foam. In other words, the ratio of the inner diameter/outer diameter of the foam is preferably 1/2 or less, 1/3 or less, 1/4 or less, 1/5 or less, 1/10 or less, 1/15 or less, 1/20 or less, 1/50 or less, or 0/1 (i.e., the foam is a solid body). By configuring the foam in this way, buckling of the foam can be prevented when the foam is deformed/curved.

The foam may contain known additives such as thickeners, plasticizers, lubricants, fillers, flame retardants, colorants, antioxidants, reinforcing agents, and conductive materials.

The density of the foam is not particularly limited, but may be, for example, 1 kg/m ³ or more, 2 kg/m ³ or more, 3 kg/m ³ or more, 4 kg/m ³ or more, 5 kg/m ³ or more, 10 kg/m ³ or more, or 15 kg/m ³ or more, and may be 800 kg/m ³ or less, 700 kg/m ³ or less, 600 kg/m ³ or less, 500 kg/m ³ or less, 250 kg/m ³ or less, 100 kg/m ³ or less, or 50 kg/m ³ or less. The upper and lower limits can be arbitrarily combined to obtain a desired numerical range. For example, the density may be 5 to 800 kg/m ³ , preferably 5 to 500 kg/m ³ , and more preferably 10 to 250 kg/m ³ . When the density of the foam falls within this range, the foam has sufficient thermal expandability and sufficient strength (e.g., tensile strength) when heated, and therefore excellent moldability (no wrinkles or twists and the desired shape) is possible during molding. The density of the foam is the apparent density measured according to JIS K7222:2005 "Foamed plastics and rubber - Determination of apparent density". The reciprocal of the density of the foam may be expressed as the expansion ratio.

The tensile elongation at break of the foam at 25°C is more than 25% and less than 400%, preferably more than 50% and less than 350%, and more preferably more than 80% and less than 300%. If the tensile elongation at break of the foam at 25°C is within this range, the laminate can be sufficiently deformed in the deformation process described below, and the thermal expansion coefficient can be adjusted to an appropriate range. Therefore, when the foam is heated in the heat curing process described below, it is possible to strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The tensile elongation at break of the foam at 25°C is measured in accordance with JIS K6767 "Foamed plastics - Polyethylene - Test method" by processing the foam into a No. 3 dumbbell test piece.

The tensile strength of the foam at 25°C is not particularly limited, but can be, for example, 0.05 MPa or more, preferably 0.1 MPa or more, and more preferably 0.2 MPa or more. The upper limit of the tensile strength of the foam at 25°C is not particularly limited, but can be, for example, 20 MPa or less. When the tensile strength of the foam at 25°C is within this range, the foam has sufficient strength in the deformation process described below, and the foam can press the fibrous body uniformly. Therefore, when the foam is heated in the heat curing process, it can strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The tensile strength of the foam at 25°C can be measured by processing the foam into a No. 3 dumbbell test piece in accordance with JIS K6767 "Foamed plastics - Polyethylene - Test method".

The tear strength of the foam at 25°C is not particularly limited, but can be, for example, 0.5 N/mm or more, preferably 0.8 N/mm or more, and more preferably 1.0 N/mm or more. The upper limit of the tear strength of the foam at 25°C is not particularly limited, but can be, for example, 50 N/mm or less. If the tear strength of the foam at 25°C is within this range, the foam has sufficient strength in the deformation process described below, and the foam can press the fibrous body evenly. Therefore, when the foam is heated in the heat curing process, it can strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The tear strength of the foam at 25°C can be measured in accordance with JIS K6767 "Foamed plastics - Polyethylene - Test method."

The 25% compression load (hardness) of the foam at 25°C is not particularly limited, but can be, for example, 1 to 2000 kPa, preferably 5 to 1000 kPa, more preferably 10 to 500 kPa, and even more preferably 10 to 200 kPa. When the 25% compression load of the foam is within this range, it is easy to wrap the fibrous body around the foam, sufficient deformation is possible when deforming the laminate in the deformation process described below, and furthermore, in the heat curing process described below, the repulsive force of the foam itself can act in addition to thermal expansion. Therefore, when the foam is heated in the heat curing process, it is possible to strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists, etc.) can be further improved.

The 25% compressive load of the foam at 25°C can be determined by the D method described in JIS K6400-2:2012 "Flexible foam materials - Physical properties - Part 2: Determination of hardness and compressive stress-strain characteristics".

The thermal conductivity of the foam is not particularly limited, but can be, for example, 0.01 W/m·K or more, preferably 0.02 W/m·K or more, and more preferably 0.03 W/m·K or more. The upper limit of the thermal conductivity of the foam is not particularly limited, but can be, for example, 0.2 W/m·K or less. When the thermal conductivity of the foam is within this range, the foam can be heated uniformly in a short time when heated in the thermal curing process described below, and the foam can be thermally expanded uniformly. This reduces the variation in the force with which the foam presses the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The thermal conductivity of the foam can be measured using the method described in JIS A1412-1:2016 "Methods for measuring thermal resistance and thermal conductivity of thermal insulation materials - Part 1: Guarded hot plate method (GHP method)."

The linear thermal expansion coefficient of the foam is not particularly limited, but can be, for example, 0.01% or more, preferably 0.05% or more, more preferably 0.10% or more, and even more preferably 1.00% or more. The upper limit of the linear thermal expansion coefficient of the foam is not particularly limited, but can be 10.00% or less. When the linear thermal expansion coefficient of the foam is within this range, the foam can strongly press against the fibrous body when heated in the heat curing process described below, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The linear thermal expansion coefficient of the foam can be measured by processing the foam into a size of 3 mm width x 25 mm length x 2 mm thickness, and using a thermomechanical analyzer (TMA) in tension mode with a chuck distance of 10 mm and a load of 5 g in a nitrogen atmosphere, heating from 25 to 85°C at 1°C/min, then lowering the temperature from 85°C to 25°C at 1°C/min, and again heating from 25°C to 85°C at 1°C/min, and measuring the linear thermal expansion coefficient at 85°C during the second heating.

Such a foam can be manufactured by a known method. Examples of the manufacturing method of a foam include a raw material preparation step in which a liquid raw material mixture containing at least an aqueous liquid dispersion medium and a water-dispersible resin is obtained, a foaming step in which the liquid raw material mixture is foamed to obtain a foamed mixture, and a drying step in which the dispersion medium in the foamed mixture is evaporated. In addition, before or after the foaming step, the liquid raw material mixture or the foamed mixture may be coated using a doctor knife or a doctor roll, or the liquid raw material mixture or the foamed mixture may be extrusion-molded or injection-molded to form the foamed mixture into a sheet. In addition, rubber sponge or the like may be molded into a desired shape, or a foam molded into a block shape may be slicing, cutting, grinding, or the like to form a desired shape such as a sheet, string, or cylinder. Note that some or all of these steps may be performed simultaneously.

Examples of foaming methods used in the foaming process include a method of forming bubbles by mixing a foaming agent that generates gas through a chemical reaction into the liquid raw material mixture, a method of dissolving an appropriate gas in the liquid raw material mixture under high pressure and then reducing the pressure or heating to form bubbles, a method of removing soluble substances mixed into the liquid raw material mixture to form voids and forming bubbles, and a method of mechanically stirring the liquid raw material mixture so that air or an appropriate gas is incorporated (mechanical froth).

The foaming conditions (temperature, time, etc.) in the foaming process and the drying conditions (temperature, time, etc.) in the drying process can be changed as appropriate depending on the raw materials of the foam and the foaming means used.

The shape, size, etc. of the flexible body are not particularly limited, and in addition to sheet-like flexible bodies and cylindrical flexible bodies, flexible bodies having a cylindrical, square prism, hexagonal prism, or a cross-sectional shape that is star-shaped or semicircular can be appropriately selected, and the same applies when a foam is used as the flexible body.

<<2. Process>>
(2-1. Lamination process)
In this lamination process, generally, a fiber sheet and a flexible body are directly laminated. In this lamination process, fiber bodies and flexible bodies of various shapes and thicknesses can be used. The pattern of this lamination process is not particularly limited, but various patterns listed below can be mentioned.

(2-1-1. Lamination process pattern 1)
In this pattern 1, as shown in FIG. 1, a fiber sheet 1 in an uncured state in which an energy curable resin has been previously impregnated and a plate-shaped flexible body 3 are used. Examples of a method for previously impregnating the fiber sheet 1 with the energy curable resin include, for example, dipping in which the fiber sheet 1 is immersed in an uncured viscous liquid raw material of the energy curable resin, roll coating in which the fiber sheet 1 is passed between multiple horizontally placed hard rolls to apply the above-mentioned uncured viscous liquid raw material, or the so-called hand lay-up molding method and RIMP (resin infusion) molding method, but are not limited thereto. Note that the fiber sheet 1 may be a single sheet or may be a stack of multiple sheets, and is not particularly limited. This will also be the case hereinafter.

In this pattern 1, as shown in FIG. 1(a), the lower surface of the flexible body 3 is directly superimposed on the upper surface of the fiber sheet 1 placed on a flat surface, the lower surface of another fiber sheet 1 is directly superimposed on the upper surface of this flexible body 3, and then the upper surface of the other fiber sheet 1 is directly superimposed on the lower surface of the other flexible body 3, and this process is repeated. As a result, each fiber sheet 1 and each flexible body 3 are in surface contact with each other, and the flexible body 3 is temporarily bonded to the fiber sheet 1 by the uncured energy-curable resin impregnated in the fiber sheet 1. By this lamination process pattern 1, a block-shaped first multilayer laminate 5 is obtained in which fiber sheets 1 and flexible bodies 3 are stacked in multiple layers, as shown in FIG. 1(b).

(2-1-2. Lamination process pattern 2)
In this pattern 2, the fiber sheet 1 and flexible body 3 described in the above-mentioned pattern 1 are used. As shown in Fig. 2(a) and Fig. 3(a), fiber sheets 1, 1 are directly laminated on the upper and lower surfaces (both surfaces of the flexible body 3), respectively, to obtain a single-layer laminate 7 in which the flexible body 3 is interposed between a pair of fiber sheets 1, 1. Note that the single-layer laminate 7 may be one in which the fiber sheet 1 is directly laminated on only one surface of the flexible body 3.

(2-1-3. Lamination process pattern 3)
In this pattern 3, a first cut laminate 5a obtained by subjecting the above-mentioned first multilayer laminate 5 shown in Fig. 4(a) to a cutting step shown in Fig. 4(b) (described later) is used. As shown in Fig. 4(c), other fiber sheets 1A and 1B similar to the above-mentioned fiber sheet 1 are directly laminated on both sides of the first cut laminate 5a along the cutting direction, respectively, to obtain a second multilayer laminate 8 shown in Fig. 4(d).

The lamination process patterns 1 to 3 described above have been explained using an example in which the fiber sheet is impregnated with the energy-curable resin in advance. However, it goes without saying that instead, the fiber sheet 1 and the flexible body 3 may be directly laminated together, and then the fiber sheet 1 may be impregnated with the energy-curable resin in the same manner as the impregnation method described for pattern 1 above.

(2-2. Winding process)
This winding process is a process of winding the laminates 7, 8 obtained by the above-mentioned patterns 2, 3. Since these laminates 7, 8 are made of the fiber sheet 1 and the flexible body 3, they are flexible even in this state and can be easily deformed by bending, twisting, etc. In this embodiment, the winding process, which is a type of bending process, is used as an example of these deformation processes and will be listed and described below, but it goes without saying that the present invention is not limited to this.

(2-2-1. Winding process pattern 1)
In this pattern 1, the single layer laminate 7 obtained in the pattern 2 of the lamination process described above is used (see FIG. 2(a)). As shown in FIG. 2(b) and FIG. 2(c), the single layer laminate 7 is wound multiple times around a core S made of, for example, a metal pipe, a resin tube, or a foam formed into a cylindrical shape. For this reason, the length of the single layer laminate 7 in this pattern 1 is set to about several times the outer circumferential length of the core S (to an extent corresponding to the number of windings). After the single layer laminate 7 is wound multiple times around the core S, the core S is pulled out (removed), thereby obtaining a spirally wound spiral laminate 9 in which multiple single layer laminates 7 are stacked, as shown in FIG. 2(d).

(2-2-2. Winding process pattern 2)
In this pattern 2, the single layer laminate 7 obtained in the lamination process pattern 2 described above is also used (see FIG. 3(a)). In this pattern 2, as shown in FIG. 3(b) and FIG. 3(c), the single layer laminate 7 is wound multiple times around the core S. That is, a single layer laminate 7 having a length substantially the same as the outer circumferential length of the core S is wound so that both end faces are joined together, and another single layer laminate 7 slightly longer than the above-mentioned single layer laminate 7 is wound around the outside of the single layer laminate 7 so that both end faces are joined together. This process is repeated multiple times. Thereafter, the core S is pulled out to obtain a cylindrical first cylindrical laminate 11 in which multiple single layer laminates 7 are stacked, as shown in FIG. 3(d).

(2-2-3. Winding process pattern 3)
In this pattern 3, the second multilayer laminate 8 obtained in the lamination step pattern 3 described above is used, and the length of the second multilayer laminate 8 is set to be approximately the same as the outer circumferential length of the core S. As shown in Figures 4(d) and 4(e), the second multilayer laminate 8 is wound around the core S. That is, the second multilayer laminate 8 is wound so that both end faces in the winding direction are joined together, and then the core S is pulled out to obtain a cylindrical second cylindrical laminate 13 shown in Figure 4(f).

In this second cylindrical laminate 13, the outer peripheral surface of the other fiber sheet 1A laminated directly on one side of the second multilayer laminate 8 forms the outer peripheral surface of the second cylindrical laminate 13, and the outer peripheral surface of the other fiber sheet 1B laminated directly on the other side of the second multilayer laminate 6 forms the inner peripheral surface of the second cylindrical laminate 13. Between these fiber sheets 1A and 1B, the fiber sheet 1 and the soft body 3 of the first cut laminate 5a extend along the longitudinal direction of the second cylindrical laminate 13 and are in a positional relationship that intersects with the other fiber sheets 1A and 1B. In other words, the fiber sheet 1 and the soft body 3 each form a rib structure that stands upright relative to the other fiber sheets 1A and 1B and extends along the longitudinal direction of the second cylindrical laminate 13.

It goes without saying that the inner diameter of the hollow portion along the central axis of each of the above-mentioned vortex stack 9, first cylindrical laminate 11, and second cylindrical laminate 13 can be appropriately adjusted by using cores S of different diameters. In addition, in the above-mentioned winding process patterns 1 to 3, the core S is used to wind the various laminates 7 and 8, but this is not limited to this. The vortex stack 9 can be obtained by directly winding the various laminates 7 and 8 in a spiral shape from their ends without using the core S, or the first cylindrical laminate 11 and the second cylindrical laminate 13 can be obtained by directly bending the various laminates 7 and 8 as they are wound and temporarily bonding both ends in the winding direction with the uncured energy-curable resin impregnated in the fiber sheet 1.

(2-3. Curing process)
In this curing step, energy is applied to the first multilayer laminate 5, the single layer laminate 7, the second multilayer laminate 8 obtained in the patterns 1 to 3 of the lamination step, the spiral laminate 9 obtained in the patterns 1 to 3 of the winding step, the first cylindrical laminate 11, and the second cylindrical laminate 13 (hereinafter collectively referred to as the "laminate 5, etc."). The energy applied is by heating the laminate 5, etc., and may further include energy applied by irradiating it with energy rays. As shown in Figures 5(a) to 5(c), by applying energy to the laminate 5, etc., the energy curable resin impregnated in the fiber sheet 1 of the laminate 5, etc. in the temporarily bonded state by lamination, seeps out (penetrates) into each flexible body 3 and cures.

This cured energy curable resin becomes the adhesive part G that bonds (anchor effect) the fiber sheet 1 and the flexible body 3, and the fiber sheet 1 and the flexibility value 3 are integrated. In addition, the fiber sheet 1 becomes a cured fiber sheet 1X by the energy curable resin impregnated in it curing. As a result, the first multilayer laminate 5 becomes a cured first multilayer laminate 5A (see FIG. 7(a)), the single layer laminate 7 becomes a cured single layer laminate (not shown), the second multilayer laminate 8 becomes a cured second multilayer laminate (not shown), the vortex laminate 9 becomes a cured vortex laminate 9A (see FIG. 2(e)), the first cylindrical laminate 11 becomes a cured first cylindrical laminate 11A (see FIG. 3(e)), and the second cylindrical laminate 13 becomes a cured second cylindrical laminate 13A (see FIG. 4(g)) (hereinafter, these are collectively referred to as "cured laminate 5A, etc."). By going through the curing process in this way, a cured laminate 5A, etc. as a composite material is obtained. The hardened laminate 5A obtained in this manner does not use adhesives to bond the fiber sheet 1 and the flexible body 3, so damage caused by deterioration of the adhesives can be prevented.

Next, the configuration of a certain cured laminate 5A among the cured laminates 5A and others will be described with reference to the drawings. That is, the cured first multilayer laminate 5A shown in FIG. 7(a) has multiple layers of cured fiber sheets 1X in which impregnated energy curable resin has been cured and flexible bodies 3, and these cured fiber sheets 1X and flexible bodies 3 are integrated with adhesive parts G.

The cured vortex laminate 9A shown in FIG. 2(e) also has a cured fiber sheet 1X, which is made by curing the impregnated energy-curable resin, and a flexible body 3, which are wound around the central axis line multiple times and form multiple layers that expand in the radial direction relative to the central axis line, and the cured fiber sheets 1X and 3 in these layers are integrated by adhesive parts G.

The first cured cylindrical laminate 11A shown in FIG. 3(e) also has a cylindrically shaped cured fiber sheet 1X obtained by curing the impregnated energy curable resin, and a cylindrical flexible body 3 bonded to at least one of the inner and outer circumferential surfaces of the fiber body, and the cured fiber sheet 1X and the flexible body 3 are integrated by an adhesive part G.

As shown in FIG. 4(g), the cured second cylindrical laminate 13A is a cylindrical laminate consisting of a first cylindrical fiber body 1Y that is formed by curing the impregnated energy curable resin, and a second cylindrical fiber body 1Z that is formed by curing the impregnated energy curable resin and that is arranged in the hollow portion of the first cylindrical fiber body 1Y so as to be concentric with the first cylindrical fiber body 1Y, and is interposed between the first and second cylindrical fiber bodies 1Y and 1Z, and is arranged in the longitudinal direction of the first and second cylindrical fiber bodies 1Y and 1Z. It is provided with an intervening fiber body 1K, which is an elongated plate-like intervening fiber body made of hardened impregnated energy-curable resin, extending in the direction perpendicular to the axis of the cylindrical fiber body 1Y and in contact with the inner peripheral surface of the first cylindrical fiber body 1Y and the outer peripheral surface of the second cylindrical fiber body 1Z, respectively, and a flexible body 3, which is disposed in an internal space formed by the pair of intervening fiber bodies 1K, 1K that face each other with the first and second cylindrical fiber bodies 1Y, 1Z, and which is in contact with the inner peripheral surface of the first cylindrical fiber body 1Y, the outer peripheral surface of the second cylindrical fiber body 1Z, and the opposing surfaces of the intervening fiber bodies 1K, 1K.

In addition, the hardened second cylindrical laminate 13A is integrated by the adhesive G at the contact portions between the first and second cylindrical fiber bodies 1Y, 1Z and the intervening fiber bodies 1K, 1K in the flexible body 3. The contact portions between the first and second cylindrical fiber bodies 1Y, 1Z and the intervening fiber bodies 1K are also integrated by the adhesive G. In this example, no adhesive is used to join the fiber sheet 1 to the flexible body 3 and to bond the fiber sheets 1, 1A, 1B, so damage due to deterioration of the adhesive can be prevented. In addition, since the intervening fibers 1K are arranged like ribs standing on each of the fiber bodies 1Y, 1Z between the first cylindrical fiber body 1Y on the inside and the second cylindrical fiber body 1Z on the outside, a hardened second cylindrical laminate 13A can be obtained that is stronger and less likely to deform than a simple cylindrical shape.

(2-4. Cutting process)
In this cutting step, the laminate 5 etc. before curing obtained in the lamination step or winding step and the cured laminate 5A etc. after curing obtained in the curing step are cut into smaller pieces. In this cutting step, the laminate 5 etc. or the cured laminate 5A etc. may be cut into any shape or size, and the pattern is not particularly limited, but some examples are described below.

(2-4-1. Cutting process pattern 1)
In this pattern 1, the first multilayer laminate 5 obtained in pattern 1 of the lamination step before curing is cut. As shown in Fig. 4(b), the first multilayer laminate 5 is placed on a flat surface so that the fiber sheet 1 and the flexible sheet 3 are horizontal, and then thinly cut vertically to obtain a first cut laminate 5a before curing to be used in pattern 3 of the lamination step. As described above, this first cut laminate 5a is made into the second multilayer laminate 8 in pattern 3 of the lamination step, and into the second cylindrical laminate 13 in pattern 3 of the winding step, and then goes through the curing step to become the hardened second cylindrical laminate 13A as a composite material.

(2-4-2. Cutting process pattern 2)
In this pattern 2, the cured first multilayer laminate 5A that has been subjected to the curing step shown in Fig. 7(a) is cut. As shown in Fig. 7(b), the cured first multilayer laminate 5A is placed on a flat surface so that its fiber sheet 1 and flexible sheet 3 are horizontal, and then thinly cut vertically to obtain a cured second cut laminate 5B.

(2-4-3. Cutting process pattern 3)
In this pattern 3, the hardened vortex stack 9A and the hardened first cylindrical laminate 11A are cut after the hardening process. As shown in Fig. 6(a) and Fig. 6(b), the hardened vortex stack 9A and the hardened first cylindrical laminate 11 are sliced into rings of a predetermined width in the longitudinal direction to obtain the hardened cut vortex stack 9B and the hardened cut first cylindrical laminate 11B as a composite material. Although not shown, it goes without saying that the hardened second cylindrical laminate 13A may be similarly cut to obtain the hardened cut second cylindrical laminate as a composite material.

<<3. Composite Materials>>
Here, the composite material obtained through the above-mentioned steps will be described.
(3-1. Composite material pattern 1)
As shown in FIG. 7, this pattern 1 is an example in which the hardened second cut laminates 5B, 5C, and 5D are used as the composite material obtained in the cutting step pattern 2 (note that in FIG. 7, the complicated diagram is omitted). 7, in order to avoid confusion, the reference numerals 5B, 5C, and 5D are used to refer to the hardened second cut laminates, and the entire mass consisting of these is referred to as a hardened second laminate group 5Z. The second cut laminates 5B, 5C, and 5D are placed on the upper surface of the lower first plate member 15 of the first plate members 15 and 17, which are made of resin or the like. , 5C, and 5D in which the hardened fiber sheet 1X and the flexible body 3 stand up like ribs (in other words, the hardened fiber sheet 1X and the flexible body 3 are in contact with the plate surfaces of the plate members 15 and 17). The electrodes are placed so that they extend in a crossing direction (vertical direction in FIG. 7C).

In addition, when placing, one hardened second cut laminate 5C and another hardened second cut laminate 5D are placed so that the extension direction of the hardened fiber sheet 1X and the flexible body 3 of the hardened second cut laminate 5B and the extension direction of the hardened fiber sheet 1X and the flexible body 3 of the other hardened second cut laminates 5C and 5D adjacent to this hardened second cut laminate 5B intersect with each other (perpendicular in FIG. 7(c)). This is repeated to obtain a hardened second laminate group 5Z in which the hardened second cut laminates 5B, 5C, and 5D are spread over almost the entire upper surface of the first plate member 15. Then, with the upper surface of the first plate member 15 and the lower surface of the hardened second laminate group 5Z bonded, the lower surface of the upper second plate member 17 and the upper surface of the hardened second laminate group 5Z are bonded to each other, thereby reinforcing the plate members 15 and 17. In addition, in this pattern 1, a pair of plate members 15 and 17 is used, but it goes without saying that this is not limited to this, and it is also possible to use only one of the plate members 15 and 17.

(3-2. Composite material pattern 2)
In this pattern 2, as shown in Fig. 8(a) and Fig. 8(b), a plurality of hardened cut vortex stacks 9B or a plurality of hardened cut first cylindrical laminates 11B are arranged adjacent to each other between plate members 15 and 17 similar to the composite material pattern 1. Then, the upper surface of the plate member 15 is bonded to the lower surface of each of the hardened cut vortex stacks 9B or the hardened cut first cylindrical laminates 11B, and the lower surface of the plate member 17 is bonded to the upper surface of each of the hardened cut vortex stacks 9B or the hardened cut first cylindrical laminates 11B. This allows the plate members 15 and 17 to be reinforced.

In addition, in this pattern 2, the cut laminate 9B or the cut first cylindrical laminate 11B is bonded to the plate members 15 and 17, but the present invention is not limited to this. For example, a through hole may be formed in the plate members 15 and 17, and the cut laminate 9B or the cut first cylindrical laminate 11B may be fitted into the through hole to reinforce the plate members. In addition, a foam similar to the flexible body 3 may be used as the plate members 15 and 17, and after forming a through hole similar to that described above in the plate members 15 and 17, the uncured vortex laminate 9, the first cylindrical laminate 11, and the second cylindrical laminate 13 may be fitted into the through hole, and then a curing process may be performed to obtain a hardened plate member. In this case, if a plate member without a through hole is desired, for example, the various laminates 7 and 8 may be directly wound from their ends in a spiral shape without using a core S to provide a vortex laminate 9 without a hollow portion, and this may be fitted into the through hole of the plate member.

The present invention is not limited to the first embodiment described above, and various modifications are possible without departing from the gist of the invention. In this modified example, the same parts as those in the first embodiment described above are designated by the same reference numerals, and the description thereof will be omitted or simplified.

In the first embodiment described above, in pattern 1 of the lamination process, flexible bodies 3 of the same width (thickness) are used as shown in FIG. 1(b) and other figures, but this is not limited to this, and flexible bodies of different widths, hardness, density, etc. may be used. An example of this specific example is shown in FIG. 9, which will be described below while interweaving the various processes described above.

In the example shown in Figure 9, a lamination process is carried out using a fiber sheet 1, a flexible body 3a of a given width, and a flexible body 3b of a smaller width. As shown in Figure 9(a), a block-shaped third multilayer laminate 19 is obtained in which the fiber sheet 1 and the flexible bodies 3a and 3b are stacked in multiple layers. That is, the central part of the third multilayer laminate 19, which extends vertically, is made up of relatively thin flexible bodies 3b and the fiber sheet 1 stacked alternately, and the upper and lower parts of the third multilayer laminate 19 are made up of relatively thick flexible bodies 3a and the fiber sheet 1 stacked alternately.

Next, as shown in FIG. 9(b), a cutting process is performed in which the third multilayer laminate 19 is thinly cut vertically to obtain a third cut laminate 23. Then, as shown in FIG. 9(c), a lamination process is performed in which another fiber sheet 24 is directly laminated on one side of the third cut laminate 23 to obtain a fourth multilayer laminate 25. Since the fourth multilayer laminate 25 is made of an uncured fiber sheet 1 and a flexible body 3, it is flexible even in this state and can be easily deformed by bending, twisting, etc. Therefore, a bending process can be performed in which the fourth multilayer laminate 25 is lightly bent around its center (see FIG. 9(d)). Then, the above-mentioned curing process is performed on the bent fourth multilayer laminate 25.

Here, in the fourth multilayer laminate 25, as shown in FIG. 9(c), each fiber sheet 1 extends in a state of standing up almost perpendicularly to the fiber sheet 24 like a rib. In addition, the flexible body 3, which stands up from the fiber sheet 24 and is interposed between the adjacent fiber sheets 1, 1, is in surface contact with these fiber sheets 1, 1, 24 and is in a temporary adhesive state. Therefore, as shown in an enlarged view in FIG. 9(e), when the curing process is performed, the energetic curable resin that has exuded from each of the fiber sheets 1, 1, 24 seeps into the flexible body 3 and hardens, as described above. That is, the curing process causes the fiber sheets 1, 1, 24 to become hardened fiber sheets 1X, 1X, 24X, respectively, and the energetic curable resin that has exuded into the flexible body 3 and hardened becomes the adhesive part G between the flexible body 3 and the hardened fiber sheets 1X, 1X, 24X, integrating them. Similarly, the contacting portions of the fiber sheets 1, 1, 24 are bonded together by adhesive G made of the seeped and cured energy curable resin. This allows a cured fourth multilayer laminate 25A to be obtained as a composite material. Note that instead of the uncured fiber sheets 1, 1, 24, at least one of these may be a cured fiber sheet 1X, 1X, 24X, and in this case, the same effect is achieved.

In other words, the cured fourth multilayer laminate 25A comprises a cured fiber sheet 24X, which is a first fiber body obtained by curing the impregnated energy curable resin, a plurality of cured fiber sheets 1X, 1X, which are second fiber bodies obtained by curing the impregnated energy curable resin and are arranged in an upright state relative to the cured fiber sheet 24X, and a flexible body 3 in contact with the cured fiber sheet 24X and the adjacent cured fiber sheets 1X, 1X, respectively, and the contact portion of the flexible body 3 with the cured fiber sheets 1X, 1X, 24X is provided with an adhesive portion G made of energy curable resin that seeps out and hardens when the energy curable resin impregnated in the cured fiber sheets 1X, 1X, 24X is hardened by applying energy to the energy curable resin.

The cured fourth multilayer laminate 25A obtained in this manner has a cured fiber sheet 24C and multiple cured fiber sheets 1C standing upright on the cured fiber sheet 24C, and therefore has a higher strength than a simple plate-shaped cured fiber sheet. Also, as described above, in the pre-cured state, deformation processing such as bending and twisting can be easily performed, making it easy to obtain a composite material of the desired shape. It goes without saying that the same effect can be achieved even if the curing process is performed using a fiber sheet 1 impregnated with an energetic curable resin instead of the plate members 15 and 17 in the above-mentioned composite material pattern 1.

In the example shown in FIG. 9, the width of the central flexible body 3a is greater than the width of the upper and lower flexible bodies 3b, but this is not limited to the above. For example, the width of the central flexible body 3a may be greater than the width of the upper and lower flexible bodies 3b, and the bendable angle can be adjusted to some extent depending on these widths. In short, a flexible body 3 with a width appropriate to the application can be used, and the width, etc. can be set appropriately.

In the example shown in FIG. 9, the fourth multilayer laminate 25 is subjected to a curing process to obtain a hardened fourth multilayer laminate as a composite material, but the present invention is not limited to this. For example, the third multilayer laminate 19 shown in FIG. 9(a) may be subjected to a curing process to obtain a hardened third multilayer laminate as a composite material, or the third cut laminate 23 shown in FIG. 9(b) may be subjected to a curing process to obtain a hardened third cut laminate as a composite material. In this case, for example, a composite material can be obtained by stacking a fiber sheet 24 on a releasable mold having a curved surface and arranging the hardened third cut laminate thereon to fit the laminate. In addition, this hardened third cut laminate may be used in place of the multiple second laminates 5b, 5c, and 5d (see FIG. 7) described in the above-mentioned composite material pattern 1.

In the first embodiment described above, the lamination process alternately laminates the horizontal fiber sheet 1 and the flexible body 3, but for example, a cylindrical laminate may be obtained by winding the fiber sheet 1 once or multiple times around the core S shown in FIG. 2, winding the flexible body 3 on the outside of the fiber sheet 1, and then winding the fiber sheet 1 once or multiple times on the outside of the flexible body 3, and repeating this process. Also, the fiber sheet 1 may be laminated on at least one of the sides of the first multilayer laminate 5. In short, there is no particular limitation as long as the fiber sheet 1 and the flexible body 3 are directly laminated. Also, the fiber sheet 1 may be laminated on at least one of the upper surface, lower surface, and each side surface of the cured second laminate group 5Z shown in FIG. 7, and then the fiber sheet 1 may be cured, or the cured laminate may be appropriately combined with an uncured fiber sheet.

<<<<Second embodiment>>>>
Next, a second embodiment will be described.
In the second embodiment,
a lamination step in which a fibrous body impregnated with an energy curable resin and a flexible body are directly laminated together to obtain an uncured laminate, or a fibrous body is directly contacted with a flexible body, and then the fibrous body is impregnated with an energy curable resin to obtain an uncured laminate;
a deformation step of deforming the uncured laminate;
a curing step of applying energy to the uncured laminate deformed in the deformation step to cure the energy curable resin contained in the fibrous body constituting the uncured laminate;
The method for producing a reinforcing fiber body includes the steps of:
Hereinafter, the raw materials and the process will be described in that order. In the description, the same parts as those in the first embodiment described above will be denoted by the same reference numerals, and the description thereof will be omitted or simplified.

<<1. Raw materials>>
The raw materials in this second embodiment are the same as those in the first embodiment described above, and therefore the description thereof will be omitted.

<<2. Process>>
(2-1. Lamination process)
In this lamination process, the fiber body and the flexible body are directly laminated. In this lamination process, fiber bodies and flexible bodies of various shapes and thicknesses can be used. Specifically, as shown in Fig. 11(a), Fig. 12(a), and Fig. 13(a), respectively, a fiber sheet 1 in an uncured state in which an energy curable resin has been impregnated in advance, and a cylindrical flexible body 31 serving as a core material are used. The fiber sheet 1 is directly wound around the flexible body 31 to obtain a cylindrical laminate 33 in which the fiber sheet 1 and the flexible body 31 are directly laminated. In this cylindrical laminate 33, the length of the flexible body 31 is longer than the vertical width of the fiber sheet 1, and both ends of the flexible body 31 protrude from both ends in the longitudinal direction of the fiber sheet 1 wound around the flexible body 31 to form a cylinder. It goes without saying that, as in the first embodiment, the fiber sheet 1 may be directly laminated around the flexible body 31, and then the fiber sheet 1 may be impregnated with the energy curable resin.

(2-2. Deformation process)
In this deformation process, the uncured cylindrical laminate 33, which is easily deformed, is deformed in various ways. There are no particular limitations on the deformation, but examples of the deformation include the following patterns.

(2-2-1. Deformation process pattern 1)
In this pattern 1, as shown in Fig. 10, a single cylindrical laminate 33 is bent as it is into a curved shape. Here, it goes without saying that there is no particular limitation on the curvature. In addition to bending into a curved shape such as an L-shape, a U-shape, an S-shape, etc., deformation by bending at a predetermined angle (30 degrees, 90 degrees, etc.) according to the application, etc. can be performed. In this way, bent cylindrical laminates 35 of special shapes bent into various shapes are obtained.

(2-2-2. Deformation process pattern 2)
In this pattern 2, as shown in Fig. 11(b), a plurality of cylindrical laminates 33 are arranged in a row to form a cylindrical laminate group 33a, and then, as shown in Fig. 11(c), a cutting process is performed to cut the vicinity of both ends of the flexible body 3 protruding from the fiber sheet 1, thereby obtaining a first cut cylindrical laminate group 33b in which both end faces of each cylindrical laminate 33 are made flush with each other. The cutting process shown in Fig. 11(c) may be omitted. This also applies to the subsequent cutting processes.

Then, as shown in FIG. 11(d), the cut cylinder laminate group 33b is sandwiched between another pair of fiber sheets 35, 37 and pressure is applied. As a result, as shown in FIG. 11(e), the cross-sectional shape of each fiber sheet 1 of the first cut cylinder laminate group 33b is deformed into a hollow quadrangular column shape, and the cross-sectional shape of each flexible body 31 located in each of these hollow parts is deformed into a quadrangular column shape, and as a whole, a special flat plate laminate 39 with a special shape is obtained that is deformed into a flat plate shape. Note that the method of applying pressure is not particularly limited, and may be performed by directly applying a load, or by reducing the pressure by sealing the first cut cylinder laminate group 33b. This also applies to the subsequent deformation processes.

In addition, in this pattern 2, the cylindrical laminates are formed in a rectangular column shape, but this is not limited to this. By adjusting the direction in which pressure is applied to the cylindrical laminate group 33a, etc., a special flat laminate 39 with a pentagonal or hexagonal cross section may be obtained. In addition, without using the other pair of fiber sheets 35, 37, pressure may be applied directly to the first cut cylindrical laminate group 33b, or directly to the cylindrical laminate group 33a, and in this case, the same effect is achieved.

(2-2-3. Deformation process pattern 3)
In this pattern 3, as shown in Figure 12(b), a plurality of cylindrical laminate groups 33a described in pattern 2 of the above-mentioned deformation process are prepared, and these cylindrical laminate groups 33a are stacked on top of each other in a parallel state. After that, as shown in Figure 12(c), a cutting process is performed to cut the vicinity of both ends of the flexible body 3 protruding from the fiber sheet 1, thereby obtaining a second cut cylindrical laminate group 33c in which both end surfaces of the cylindrical laminate group 33a are made flush, as shown in Figure 12(d).

As shown in FIG. 12(e), by applying pressure to the second cut cylindrical laminate group 33c, the cross-sectional shape of the fiber sheet 1 of the second cut cylindrical laminate group 33c is deformed into a hollow hexagonal column shape, and the cross-sectional shape of each of the flexible bodies 33 located in each of these hollows is also deformed into a hexagonal column shape, resulting in a block-shaped special block laminate 41 as a whole. It goes without saying that in this pattern 3 as well, as in the above-mentioned pattern 2, special block laminates 41 of various cross-sectional shapes can be obtained by adjusting the direction in which pressure is applied, etc.

(2-2-4. Deformation process pattern 4)
In this pattern 4, as shown in FIG. 13(b), a cylindrical laminate bundle 43 is formed by bundling a plurality of cylindrical laminates 33 into a bundle, and as shown in FIG. 13(c), a cutting process is carried out to cut the vicinity of both ends of the flexible body 3 protruding from the fiber sheet 1, thereby obtaining a cut cylindrical laminate bundle 43a consisting of a bundle of cut cylindrical laminates 33d, each of which has both end surfaces flush with each other, as shown in FIG. 13(d).

As shown in FIG. 13(e), by applying pressure to the cut cylinder laminate bundle 43a, the fiber sheets 1 of the surrounding cut cylinder laminates 33d surrounding the central cut cylinder laminate 33d of the cut cylinder laminate bundle 43a are deformed into a hollow pentagonal column shape. Accordingly, the flexible bodies 33 located in the hollow of these cut cylinder laminates 33d are deformed into a pentagonal column shape. In addition, the central cut cylinder laminate 33d is deformed into a hollow hexagonal column shape, and the flexible bodies 33 located in this hollow are deformed into a hexagonal column shape. As a result, a special cylinder laminate 45 with a special shape deformed into a cylindrical shape is obtained as a whole. It goes without saying that in this pattern 4 as well, as in the above-mentioned pattern 2, a special block laminate 45 with various cross-sectional shapes can be obtained by adjusting the direction of pressure application, etc. In addition, in FIG. 13(e), in order to clearly show that the fiber sheet 1 of the central cut cylindrical laminate 33d has a hexagonal cross-sectional shape, the flexible body 33 in the hollow part of the central cut cylindrical laminate 33d is purposely removed, but in reality the hollow part is filled with the flexible body 33.

(2-3. Curing process)
In this curing step, the energy curing resin impregnated in the sheet fibers is cured by applying energy to the bent cylindrical laminate 35, the special flat plate laminate 39, the special block laminate 41, and the second cylindrical laminate 41, which are uncured laminates deformed in the above-mentioned deformation steps, in the same manner as in the first embodiment. As a result, the bent cylindrical laminate 35 becomes the first reinforcing fiber body (not shown), the special flat plate laminate 39 becomes the second reinforcing fiber body 39A (see FIG. 11(e)), the special block laminate 41 becomes the third reinforcing fiber body 41A (see FIG. 12(e)), and the special cylindrical laminate 45 becomes the fourth reinforcing fiber body 45A (see FIG. 13(e)). In addition, a removal step may be performed in which the soft body 33 is removed from each of the reinforcing fiber bodies 39A, 41A, and 45A by, for example, drilling out or dissolving the soft body 33.

As explained above, in the second embodiment, the uncured laminate obtained in the lamination process is easily deformed, and reinforcing fibers of the desired special shape can be obtained by a very simple method of deforming it in this state into the desired special shape and then performing the curing process.

The present invention is not limited to the second embodiment described above, and various modifications are possible within the scope of the present invention. For example, the cutting steps shown in Figs. 11(c), 12(c), and 13(c) were performed after the cylindrical laminate 33 was formed into a cylindrical laminate group 33a or a cylindrical laminate bundle 43 as shown in Figs. 11(b), 12(b), and 13(b), respectively. However, the present invention is not limited to this, and the cutting steps may be performed after the cylindrical laminate group 33a or the cylindrical laminate bundle 43 is formed and pressure is applied to the cylindrical laminate group 33a or the cylindrical laminate bundle 43 to deform them. There is no particular limit to the timing of the cutting step as long as it is performed before the hardening step.

<<<<<Summary of First and Second Embodiments>>>>
The above-described first and second embodiments can be summarized as follows.

The invention (1-1) is
a lamination step in which a fibrous body impregnated with an energy curable resin and a flexible body are directly laminated together to obtain an uncured laminate, or a fibrous body is directly contacted with a flexible body, and then the fibrous body is impregnated with an energy curable resin to obtain an uncured laminate;
and a curing step of applying energy to the uncured laminate to cure the energy-curable resin contained in the fibrous body that constitutes the uncured laminate.
The invention (1-2) is
The method for producing the method according to claim 1-1, wherein the flexible body is a foam.
The invention (1-3) is
The method according to the invention (1-1) or (1-2), further comprising a winding step of winding the uncured laminate after the laminating step.
Invention (1-4) is the method according to any one of Inventions (1-1) to (1-3), further comprising a step of cutting the uncured laminate or the cured laminate cured by the curing step into pieces smaller than the cured laminate.

The above invention makes it possible to prevent damage to composite materials (composite materials of reinforced fiber bodies and flexible bodies) due to deterioration of adhesives, glues, etc., and also makes it easy to manufacture composite materials of desired shapes.

The invention (2-1) is
a lamination step in which a fibrous body impregnated with an energy curable resin and a flexible body are directly laminated together to obtain an uncured laminate, or a fibrous body is directly contacted with a flexible body, and then the fibrous body is impregnated with an energy curable resin to obtain an uncured laminate;
a deformation step of deforming the uncured laminate;
a curing step of applying energy to the uncured laminate deformed in the deformation step to cure the energy curable resin contained in the fibrous body constituting the uncured laminate;
The method for producing a reinforcing fiber body includes the steps of:
The invention (2-2) is
The method for producing the method according to claim 2-1, wherein the flexible body is a foam.

The above invention makes it possible to easily manufacture reinforced fiber bodies with special shapes.

The invention (3-1) is
a first fibrous body obtained by curing the energy curable resin impregnated therein;
a second fibrous body that is arranged in an upright state relative to the first fibrous body and that has been impregnated with an energy curable resin and cured;
a flexible body in contact with the first fibrous body and the adjacent second fibrous bodies,
This composite material is characterized in that the contact portion of the flexible body with the first and second fibrous bodies is provided with an adhesive portion made of energy-curable resin that seeps out and hardens when energy is applied to the energy-curable resin impregnated in at least one of the first and second fibrous bodies to harden the resin.

The above invention makes it possible to prevent damage to composite materials caused by deterioration of adhesives, glues, etc.

The invention (4-1) is
a first cylindrical fiber body formed in a cylindrical shape and impregnated with an energy curable resin and cured;
a second cylindrical fiber body formed in a cylindrical shape having a diameter smaller than that of the first cylindrical fiber body, arranged in a hollow portion of the first cylindrical fiber body so as to be concentric with the first cylindrical fiber body, and having an energy curable resin impregnated therein and cured;
an intervening fiber body which is interposed between the first and second cylindrical fiber bodies, extends along the longitudinal direction of the first and second cylindrical fiber bodies, contacts the inner peripheral surface of the first cylindrical fiber body and the outer peripheral surface of the second cylindrical fiber body, respectively, and is impregnated with an energy curable resin and cured;
a flexible body that is disposed in an internal space formed by the first and second cylindrical fiber bodies and a pair of the intervening fiber bodies facing each other, and that is in contact with an inner circumferential surface of the first cylindrical fiber body, an outer circumferential surface of the second cylindrical fiber body, and one surface of the intervening fiber body,
This composite material is characterized in that the contact portions of the first and second cylindrical fibrous bodies and the intervening fibrous body in the foam have adhesive portions made of energy-curable resin that seeps out and hardens when energy is applied to the energy-curable resin impregnated in at least one of the first and second fibrous bodies and the intervening fibrous body to harden the resin.

The above invention makes it possible to prevent damage to composite materials caused by deterioration of adhesives, glues, etc.

<<<<<<Embodiments I to IV>>>>>
Next, embodiments I to IV will be described from a different perspective than embodiments 1 and 2. Note that embodiments I to IV can be considered as arrangements of fiber-reinforced resin structures and their manufacturing methods obtained by utilizing, applying, modifying, etc. the concept described in embodiment 2.

In the embodiments I to IV, the member corresponding to the flexible body described in the first and second embodiments is specifically described as a foam, but this does not exclude the use of flexible bodies other than foam.

The size of the fiber-reinforced resin structure described below, the thickness of the thick wall portion of the fiber-reinforced resin structure, the diameter of the communicating hole H of the fiber-reinforced resin structure, etc. are not limited in any way and can be adjusted appropriately depending on the application.

<<<<First Embodiment>>>>
<<<<Structure>>>
The fiber-reinforced resin structure 100-1 according to the first embodiment is a cylindrical fiber-reinforced resin structure including at least a fiber body 10 and a resin 20 impregnated in the fiber body 10 (see FIG. 14(c)).

More specifically, the resin 20 impregnated into the cylindrical fiber body 10 becomes the thick portion, and as a whole, a cylindrical fiber-reinforced resin structure 100-1 is formed.

The fiber-reinforced resin structure 100-1 may have a foam 30 inserted inside the tube. In each of the following embodiments and modifications, each fiber-reinforced resin structure may or may not include a foam 30.

<<<Ingredients>>>
<<Fiber body 10>>
The fibrous body 10 is not particularly limited in terms of shape, size, etc., but is preferably, for example, a sheet-like fibrous sheet. This fibrous sheet is not particularly limited as long as it is a sheet of assembled fibers, and examples thereof include woven fabrics (plain weave, twill weave, double weave, triple weave, tatami weave, etc.), nonwoven fabrics, unidirectional reinforcement materials (UD materials), etc.

The thickness of the fiber sheet is not particularly limited and can be selected appropriately. If the fiber sheet is too thin, the mechanical properties such as the strength and elastic modulus of the fiber sheet may be reduced. Therefore, the thickness of the fiber sheet according to the present invention is preferably, for example, 20 μm to 500 μm, and more preferably 30 μm to 200 μm. It goes without saying that fiber sheets with a thickness of several mm, such as chopped strand mats and core mats, may also be used.

The fibers forming the fiber sheet are not particularly limited and may be any known fibers, including at least one of metal fibers, inorganic fibers, and organic fibers.

Examples of the fibers constituting the fibrous body 10 include:
Metal fibers such as stainless steel fibers, nickel fibers, copper fibers, aluminum fibers, silver fibers, gold fibers, and titanium fibers;
Polyparaphenylenebenzoxazole, polyethylene terephthalate (PET) resin, polyvinyl alcohol (PVA), polyolefin resins such as polyethylene and polypropylene, polyvinyl chloride resin, aramid resin, acrylic resin, polyimide resin, polyparaphenylenebenzoxazole (PBO) fiber, cellulose, vinylon, nylon, rayon, aramid, phenolic fiber, fluorine fiber, pulp (fiber), kenaf, hemp, bamboo fiber, and other organic fibers;
Inorganic fibers such as glass fibers, carbon fibers, silica fibers, rock wool, slag wool, alumina fibers, and ceramic fibers;
etc. can be mentioned.
As the fiber, one or a combination of a plurality of these can be used. For example, a non-crimp fiber (NCF) having a two-layer structure including a carbon fiber and a polyester fiber can be used.

The fibers are preferably ones that have a higher Young's modulus than the resin or matrix resin used in the sealing material, and metal fibers and inorganic fibers are more preferable. The higher the Young's modulus of the fibers, the higher the rigidity of the fiber sheet can be, and when embedded in the resin, the rigidity of the resin can be effectively improved. Therefore, it is possible to obtain a sealing material that is highly rigid and difficult to break.

The fiber sheet may be made of fibers woven into a tubular shape.

The fiber sheet may be partially punched or otherwise voided to the extent that the effect of the present invention is not impaired.

The fibrous sheet may be a bias cut sheet.

<Method of manufacturing fiber sheet>
The fiber sheet can be manufactured by a known method. For example, suitable examples of methods for manufacturing nonwoven fabric include dry methods such as carding and airlaid, wet papermaking methods in which the fiber is formed by sifting like paper, fleece forming methods such as spunbonding and meltblowing, and fleece bonding methods such as thermal bonding, chemical bonding, needle punching, spunlace (hydroentanglement), stitch bonding, and steam jet. Among these, the manufacturing method using the wet papermaking method is suitable because it is possible to make the fiber sheet thin and is excellent in terms of uniformity.

When the fiber sheet is cylindrical, it can be manufactured in the same manner as braided cords, for example.

The method for manufacturing a fiber sheet may include a bias cutting step.

<<Resin 20>>
As the resin 20, a known resin used as a fiber reinforced resin can be used, and a thermoplastic resin or the like can also be used, but in order to improve workability, it is preferable to use an energy curable resin.

<Energy curable resin>
The energy curable resin is a thermosetting resin, and may further include an energy ray curable resin and the like.

Examples of thermosetting resins that can be used include epoxy resins, unsaturated polyester resins, polyvinyl ester resins, phenolic resins, polyurethane resins, acrylic resins, melamine resins, urea resins, benzoguanamine resins, rosin-modified maleic acid resins, and rosin-modified fumaric acid resins. These may be used alone or in combination of two or more.

Examples of energy ray curable resins include epoxy resins, acrylic resins, silicone resins, and polyester resins. These may be used alone or in combination of two or more.

In the following explanation, resin 20 will be described as a thermosetting resin, but to the extent that there is no particular contradiction, "thermosetting" can be interpreted as "curing" in the following explanation.

<<Foam 30>>
The foam may be a closed-cell foam, an open-cell foam, or a foam containing both closed and open cells. The closed-cell foam mentioned here does not mean only foam in which all the cells are completely independent, but some of the cells may be connected to adjacent cells, and it is sufficient that each cell is independent to the extent that it is understood as a closed-cell foam as a whole.

Here, when the foam contains closed and open bubbles, the average ratio of the closed and open bubbles (hereinafter referred to as the closed bubble ratio) is not particularly limited, but for example, the closed bubble ratio can be 0.1 to 99.9%, preferably 10.0% to 99.9%, more preferably 30.0 to 99.9%, and even more preferably 50.0 to 99.9%. A foam containing only closed bubbles is most preferable. When the foam contains a large number of closed bubbles, there are many sealed air layers inside the foam, so when the foam is heated, in addition to the thermal expansion of the resin itself, the sealed air layers also thermally expand, and the force with which the foam presses the fibrous body can be strengthened. Therefore, when the foam is heated in the heat curing process described later, the thermal expansion occurs more strongly, and by pressing the fibrous body, it is possible to further improve the moldability (the shape can be formed into a desired shape without wrinkles or twists, etc.), and by shrinking when cooled after curing, the foam becomes easier to remove from the laminate.

The closed cell ratio of a foam is determined by observing the cross section of the foam using a microscope or scanning electron microscope, counting the number of closed and open cells per unit area in the photographed image, dividing the number of closed cells by the total number of cells (both closed and open cells) and multiplying the result by 100. This measurement of the closed cell ratio is repeated at 10 randomly selected cross sections of the same foam, and the average of the closed cell ratios found for each is taken as the closed cell ratio of the foam.

The resin constituting the foam is not particularly limited, and may be selected appropriately according to the application from olefin resins, urethane resins, styrene resins, phenolic resins, silicone resins, etc. In addition, other materials constituting the foam include natural rubber (NR), chloroprene rubber (CR), ethylene propylene diene rubber (EPDM), and nitrile rubber (NBR), and these may also be selected appropriately according to the application. Among these, olefin resins can be preferably used. With olefin resins, for example, it is easy to adjust the hardening temperature of the fiber body and the degree of thermal expansion of the foam at the hardening temperature of the fiber body by adjusting the blending ratio of polyethylene and polypropylene. That is, when the foam is heated and thermally expanded in the thermal hardening process described below, the foam presses the fiber body, so that the moldability (the shape is made into a desired shape without wrinkles or twists) can be excellent, but the degree of this pressing can be adjusted by changing the blending ratio of olefin resins, for example, polyethylene and polypropylene, and the moldability can be excellent according to the shape of the fiber body. In addition, by adjusting the blending ratio of polyethylene and polypropylene, the presence or absence of crosslinking, and the degree of crosslinking, it is easy to adjust the flexibility (hardness), thermal expansion, wettability (affinity), softening point, etc. of the foam.

The resin that constitutes the foam can be freely selected taking into consideration its affinity with the uncured resin contained in the fibrous body. If the resin that constitutes the foam and the uncured resin contained in the fibrous body have a high affinity, it becomes easier to wrap the laminate around the foam, but it may be difficult to remove the foam after it has been heated and cured. For this reason, it is preferable to adjust the affinity between the resin that constitutes the foam and the uncured resin contained in the fibrous body.

To adjust the affinity between the resin constituting the foam and the uncured resin contained in the fibrous body, it is sufficient to adjust the wettability (e.g., contact angle or surface energy) of the resin constituting the foam and the uncured resin contained in the fibrous body, and to increase the affinity, it is sufficient to select the contact angle (or surface energy) of the resin constituting the foam and the uncured resin contained in the fibrous body. To increase the affinity, it is sufficient to set the contact angle (or surface energy) of the resin constituting the foam and the uncured resin contained in the fibrous body to similar values, and to decrease the affinity, it is sufficient to set the contact angle and surface energy of the resin constituting the foam and the uncured resin contained in the fibrous body to different values.

The difference in contact angle between the resin constituting the foam and the uncured resin contained in the fibrous body is not particularly limited, but can be greater than 0° and less than ±90°. When the difference in contact angle between the resin constituting the foam and the uncured resin contained in the fibrous body is within this range, it is easy to wrap the fibrous body around the foam, and it is also possible to remove the foam after heat curing.

The softening point of the resin constituting the foam is not particularly limited and can be selected according to the curing temperature of the thermosetting resin used in the fibrous body. For example, the softening point of the resin constituting the foam can be 10°C or more higher than the curing temperature of the thermosetting resin used in the fibrous body. For example, when the thermosetting resin is an epoxy resin, the softening point of the resin constituting the foam can be 60 to 200°C, preferably 80 to 160°C, and more preferably 100 to 150°C. When the softening point of the resin constituting the foam is within this range, the foam has sufficient thermal expansion as a foam when heated and sufficient strength (e.g. tensile strength), so that excellent moldability (no wrinkles or twists, and the desired shape) can be achieved during molding.

The foam is preferably solid. It is also preferable that the foam does not have holes (through holes/hollow portions) with a diameter of 1/2 or more, 1/3 or more, 1/4 or more, 1/5 or more, 1/10 or more, 1/15 or more, or 1/20 or more of the outer diameter of the foam. In other words, the foam is solid, or if the foam is hollow, the ratio of the inner diameter/outer diameter of the foam is preferably 1/2 or less, 1/3 or less, 1/4 or less, 1/5 or less, 1/10 or less, 1/15 or less, or 1/20 or less. By configuring the foam in this way, it is possible to prevent the foam from buckling when it is deformed/curved.

The foam may contain known additives such as thickeners, plasticizers, lubricants, fillers, flame retardants, colorants, antioxidants, reinforcing agents, and conductive materials.

The density of the foam is not particularly limited, but may be, for example, 1 kg/m ³ or more, 2 kg/m ³ or more, 3 kg/m ³ or more, 4 kg/m ³ or more, 5 kg/m ³ or more, 10 kg/m ³ or more, or 15 kg/m ³ or more, and may be 800 kg/m ³ or less, 700 kg/m ³ or less, 600 kg/m ³ or less, 500 kg/m ³ or less, 250 kg/m ³ or less, 100 kg/m ³ or less, or 50 kg/m ³ or less. The upper and lower limits can be arbitrarily combined to obtain a desired numerical range. For example, the density may be 5 to 800 kg/m ³ , preferably 5 to 500 kg/m ³ , and more preferably 10 to 250 kg/m ³ . When the density of the foam falls within this range, the foam has sufficient thermal expandability and sufficient strength (e.g., tensile strength) when heated, and therefore excellent moldability (no wrinkles or twists and the desired shape) is possible during molding. The density of the foam is the apparent density measured according to JIS K7222:2005 "Foamed plastics and rubber - Determination of apparent density". The reciprocal of the density of the foam may be expressed as the expansion ratio.

The tensile elongation at break of the foam at 25°C is more than 25% and less than 400%, preferably more than 50% and less than 350%, and more preferably more than 80% and less than 300%. If the tensile elongation at break of the foam at 25°C is within this range, the laminate can be sufficiently deformed in the deformation process described below, and the thermal expansion coefficient can be adjusted to an appropriate range. Therefore, when the foam is heated in the heat curing process described below, it is possible to strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The tensile elongation at break of the foam at 25°C is measured in accordance with JIS K6767 "Foamed plastics - Polyethylene - Test method" by processing the foam into a No. 3 dumbbell test piece.

The tensile strength of the foam at 25°C is not particularly limited, but can be, for example, 0.05 MPa or more, preferably 0.1 MPa or more, and more preferably 0.2 MPa or more. The upper limit of the tensile strength of the foam at 25°C is not particularly limited, but can be, for example, 20 MPa or less. When the tensile strength of the foam at 25°C is within this range, the foam has sufficient strength in the deformation process described below, and the foam can press the fibrous body uniformly. Therefore, when the foam is heated in the heat curing process, it can strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The tensile strength of the foam at 25°C can be measured by processing the foam into a No. 3 dumbbell test piece in accordance with JIS K6767 "Foamed plastics - Polyethylene - Test method".

The tear strength of the foam at 25°C is not particularly limited, but can be, for example, 0.5 N/mm or more, preferably 0.8 N/mm or more, and more preferably 1.0 N/mm or more. The upper limit of the tear strength of the foam at 25°C is not particularly limited, but can be, for example, 50 N/mm or less. If the tear strength of the foam at 25°C is within this range, the foam has sufficient strength in the deformation process described below, and the foam can press the fibrous body evenly. Therefore, when the foam is heated in the heat curing process, it can strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The tear strength of the foam at 25°C can be measured in accordance with JIS K6767 "Foamed plastics - Polyethylene - Test method."

The 25% compression load (hardness) of the foam at 25°C is not particularly limited, but can be, for example, 1 to 2000 kPa, preferably 5 to 1000 kPa, more preferably 10 to 500 kPa, and even more preferably 10 to 200 kPa. When the 25% compression load of the foam is within this range, it is easy to wrap the fibrous body around the foam, sufficient deformation is possible when deforming the laminate in the deformation process described below, and furthermore, in the heat curing process described below, the repulsive force of the foam itself can act in addition to thermal expansion. Therefore, when the foam is heated in the heat curing process, it is possible to strongly press the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The 25% compressive load of the foam at 25°C can be determined by the D method described in JIS K6400-2:2012 "Flexible foam materials - Physical properties - Part 2: Determination of hardness and compressive stress-strain characteristics".

The thermal conductivity of the foam is not particularly limited, but can be, for example, 0.01 W/m·K or more, preferably 0.02 W/m·K or more, and more preferably 0.03 W/m·K or more. The upper limit of the thermal conductivity of the foam is not particularly limited, but can be, for example, 0.2 W/m·K or less. When the thermal conductivity of the foam is within this range, the foam can be heated uniformly in a short time when heated in the thermal curing process described below, and the foam can be thermally expanded uniformly. This reduces the variation in the force with which the foam presses the fibrous body, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The thermal conductivity of the foam can be measured using the method described in JIS A1412-1:2016 "Methods for measuring thermal resistance and thermal conductivity of thermal insulation materials - Part 1: Guarded hot plate method (GHP method)."

The linear thermal expansion coefficient of the foam is not particularly limited, but can be, for example, 0.01% or more, preferably 0.05% or more, more preferably 0.10% or more, and even more preferably 1.00% or more. The upper limit of the linear thermal expansion coefficient of the foam is not particularly limited, but can be 10.00% or less. When the linear thermal expansion coefficient of the foam is within this range, the foam can strongly press against the fibrous body when heated in the heat curing process described below, and the moldability (the ability to form the desired shape without wrinkles or twists) can be further improved.

The linear thermal expansion coefficient of the foam can be measured by processing the foam into a size of 3 mm width x 25 mm length x 2 mm thickness, and using a thermomechanical analyzer (TMA) in tension mode with a chuck distance of 10 mm and a load of 5 g in a nitrogen atmosphere, heating from 25 to 85°C at 1°C/min, then lowering the temperature from 85°C to 25°C at 1°C/min, and again heating from 25°C to 85°C at 1°C/min, and measuring the linear thermal expansion coefficient at 85°C during the second heating.

<Method of manufacturing foam>
The foam can be manufactured by a known method. Examples of the manufacturing method of the foam include a raw material preparation step of obtaining a liquid raw material mixture containing at least an aqueous liquid dispersion medium and a water-dispersible resin, a foaming step of foaming the liquid raw material mixture to obtain a foamed mixture, and a drying step of evaporating the dispersion medium in the foamed mixture. In addition, before or after the foaming step, the liquid raw material mixture or the foamed mixture may be coated using a doctor knife or a doctor roll, or the liquid raw material mixture or the foamed mixture may be extrusion molded or injection molded to form the foamed mixture into a sheet. In addition, a rubber sponge or the like may be molded into a desired shape, or a foam molded into a block shape may be sliced into a desired shape such as a sheet, a string, or a cylinder. Note that some or all of these steps may be performed simultaneously.

Examples of foaming methods used in the foaming process include a method of forming bubbles by mixing a foaming agent that generates gas through a chemical reaction into the liquid raw material mixture, a method of dissolving an appropriate gas in the liquid raw material mixture under high pressure and then reducing the pressure or heating to form bubbles, a method of removing soluble substances mixed into the liquid raw material mixture to form voids and forming bubbles, and a method of mechanically stirring the liquid raw material mixture so that air or an appropriate gas is incorporated (mechanical froth).

The foaming conditions (temperature, time, etc.) in the foaming process and the drying conditions (temperature, time, etc.) in the drying process can be changed as appropriate depending on the raw materials of the foam and the foaming means used.

The shape and size of the foam are not particularly limited, and in addition to cylindrical foam, cylindrical, square prism, hexagonal prism, or foam with a star-shaped or semicircular cross section can be appropriately selected. In addition, the foam may be foam molded into the desired shape, or may be molded by cutting or carving a block-shaped foam, or may be a rolled-up sheet-shaped foam.

<<<Production Method>>>
The manufacturing method of the fiber reinforced resin structure 100-1 may be, for example,
A preparation step of preparing a laminate 50 having a columnar foam 30 and a fibrous body 10 covering at least a part of a side surface of the foam 30, the fibrous body 10 being impregnated with an uncured thermosetting resin (uncured resin 25);
and a curing step of thermally curing the resin (uncured resin 25 ) impregnated into the fibrous body 10 to obtain the resin 20 .

The manufacturing method of the fiber-reinforced resin structure 100-1 may include a cutting process for cutting the foam 30, a cooling process for cooling the foam 30 and the resin 20 after the curing process, and a removal process for pulling out the foam 30 after the curing process.

Although not specifically described, the manufacturing method of the fiber-reinforced resin structure 100-1 may include a scraping or polishing process for treating the surface of the fiber-reinforced resin structure 100-1 after the curing process.

<<Preparation process>>
The preparation process is a process for preparing a laminate 50 having a columnar foam 30 and a fibrous body 10 covering at least a portion of the side surface of the foam 30, in which the fibrous body 10 is impregnated with an uncured thermosetting resin (uncured resin 25).

The preparation process may be carried out by, for example, purchasing the laminate 50 from an outside source.

The preparation process may also include an impregnation process and a lamination process.

<Impregnation process>
In the impregnation step, the uncured resin 25 is brought into contact with the fibrous body 10 to impregnate the fibrous body 10 with the uncured resin 25 .

The impregnation method is not particularly limited, and may be, for example, roll coating, hand lay-up molding, infusion molding, VaRTM molding, RTM molding, or a method of submerging the fibrous body 10 in a tank containing uncured resin 25 (dipping).

The impregnation conditions can be adjusted depending on the type of fibrous body 10 and uncured resin 25. If it is difficult to impregnate the fibrous body 10 with the uncured resin 25, the impregnation time may be extended or pressure may be applied while the resin is impregnated.

When the volume of the laminate 50 is taken as 100 volume %, the volume fraction of the fiber body 10 (fiber fraction) can be 15 to 85 volume %, preferably 25 to 85 volume %, and more preferably 45 to 80 volume %. When the volume fraction of the fiber body 10 (fiber fraction) is within this range, the fiber-reinforced resin structure after curing has few defects, is less susceptible to destruction such as buckling, and has excellent mechanical strength.

<Lamination process>
In the lamination step, at least a portion of the side surface of the foam body 30 is covered with the fibrous body 10 (see Figs. 14(a) and 14(c)).

There is no particular limitation on the method for covering the sides of the foam 30 with the fibrous body 10. For example, when the fibrous body 10 is a fiber sheet, the fibrous body 10 may be wrapped around the foam 30. The number of times that the fibrous body 10 is wrapped is preferably one or more times, and may be two or more times.

In addition, in the lamination process, the fibrous body 10 may be temporarily fixed after covering the foam body 30. For example, if the fibrous body 10 is impregnated with uncured resin 25, the fibrous body 10 can be temporarily adhered to the side of the foam body 30 by the adhesiveness of the uncured resin 25.

In the lamination process, as shown in FIG. 14, it is not necessary to cover the entire side surface of the foam 30 from the top to the bottom with the fibrous body 10, but it is also possible to cover the entire side surface of the foam 30 with the fibrous body 10.

In the lamination process, the thickness of the fiber body 10 can be adjusted. For example, when the fiber body 10 is a fiber sheet, the thickness of the fiber body 10 can be increased by increasing the number of times the fiber body 10 is wrapped around. In addition, the fiber sheet may be a single sheet or a stack of multiple sheets, and is not particularly limited. The fiber body 10 may be used in combination of two or more types. In addition, when the fiber body 10 is a woven fabric or UD material, the fiber orientation (bias, etc.) may be adjusted and the winding may be performed in consideration of the thermal expansion of the foam, or in consideration of the deformation process, bending process, etc. in another embodiment. Furthermore, when a fiber body 10 with an adjusted fiber orientation is used, the fiber body 10 may be configured so that the fiber orientation is adjusted throughout the entire fiber body 10, or the fiber orientation is adjusted only in a portion of the fiber body 10 (for example, the fiber orientation is adjusted only in an easily deformed area).

When the fibrous body 10 is long, the lamination process can be performed by winding the fibrous body 10 around the side of the foam body 30 while moving the fibrous body 10 in the axial direction of the foam body 30. For example, the lamination process can be performed based on a filament winding method, a braiding method, or the like.

Alternatively, the fibrous body 10 may be prefabricated into a cylindrical shape, and the foam body 30 may be inserted into the inside of the cylinder.

In the lamination process, the sides of the foam body 30 are covered with the fibrous body 10, but the foam body 30 also flexibly deforms when the fibrous body 10 is placed on the sides of the foam body 30. Therefore, for example, when the fibrous body 10 is a fiber sheet and the fibrous body 10 is wrapped around the foam body 30, distortions that may occur in the fibrous body 10 are absorbed by the deformation of the foam body 30, and the fibrous body 10 can be maintained in a relatively natural state.

Here, the impregnation step may be performed before, simultaneously with, or after the lamination step. When the fibrous body 10 is a fibrous sheet, in order to ensure impregnation into the fibrous body 10, it is preferable to impregnate the fibrous body 10 with resin (uncured resin 25) before the lamination step, and perform the lamination step in a state in which the fibrous body 10 is impregnated with the uncured resin 25. In the explanation of each embodiment, the preparation step is explained as a step in which the lamination step is performed after the impregnation step, but is not limited to this.

<<Curing process>>
By carrying out the curing step, the uncured resin 25 impregnated in the fibrous body 10 is cured, and the resin 20 is obtained (see FIG. 14(c)).

In the curing process, the curing method and conditions can be selected according to the type of resin (uncured resin 25) used so that the uncured resin 25 is sufficiently cured. For example, in the case of a thermosetting resin, heat can be applied to the uncured resin 25 to cause it to cure.

To improve the shape retention of the laminate 50 (foam 30), the curing process may be carried out in a state in which the laminate 50 is fitted into a formwork or shrink tape is placed around the laminate 50.

<<Cooling process>>
The cooling step is a step of cooling the resin 20 and the foam 30 obtained by thermal curing before carrying out a foam removal step or the like.

It is believed that the thermal curing in the curing process causes the foam 30 to thermally expand, generating a force that pushes the fibrous body 10 apart. It is believed that the foam 30 contracts as the uncured resin 25 is thermally cured and then cooled, promoting separation of the resin 20 and the foam 30, making it easier to carry out the removal process described below.

The cooling method is not particularly limited, and any method may be used, such as natural cooling, ventilation, or leaving in a cool air atmosphere. The temperature after cooling may be set to any of room temperature or higher, room temperature, and room temperature or lower. As an example, the cooling process may be performed by cooling the material to a temperature 10°C or higher, 20°C or higher, 30°C or higher, 40°C or higher, or 50°C or higher than the temperature at the time of thermal curing.

<<Cutting process>>
The cutting step may be a step of cutting only the foam 30 protruding from the fibrous body 10, or may be a step of simultaneously cutting the foam 30 and the fibrous body 10. For example, the cutting step may be used to adjust the laminate 50 to a desired length.

The cutting process may be performed before or after the hardening process.

<<Removal process>>
By removing the foam 30 contained in the laminate 50, a hollow fiber reinforced resin structure 100-1 containing no foam 30 can be obtained (see FIG. 14(c)).

By carrying out the preparation process (e.g., lamination process, impregnation process) and the curing process, the uncured resin 25 is cured in a state where the foam 30 and the uncured resin 25 are in contact with each other. If the foam 30 is a foam, the uncured resin 25 may penetrate into the air bubbles present on the surface of the foam. By carrying out the curing process in this state, the foam and the resin 20 may be fixed together. Therefore, when carrying out the removal process, the material of the foam or the density of the foam (foaming ratio) may be adjusted so that the foam and the resin 20 are less likely to be fixed together, or the foam may be easily removed even if the foam and the resin 20 are fixed together.

The removal process may be performed by physically removing the foam 30 or by dissolving the foam 30.

<<<Modification of the First Embodiment>>>
The fiber-reinforced resin structure 100-1 is not limited to a cylindrical one. A fiber-reinforced resin structure 100-1 having a shape other than a cylindrical shape will be described below as a modified example of the first embodiment.

<<Structure>>
The fiber-reinforced resin structure 100-1 may have a polygonal tubular structure (a tubular structure in which the cross section perpendicular to the tubular axis is polygonal) instead of the cylindrical structure shown in Fig. 14. For example, the fiber-reinforced resin structure 100-1 may have a square tubular shape as shown in Fig. 15(c) or a hexagonal tubular shape as shown in Fig. 16(c). The polygonal tubular shape of the fibrous body 10 may be a triangular tubular shape or a tubular shape with more than 100 sides.

Furthermore, the outer shape (shape of the outer surface of the tube) and the inner shape (shape of the inner surface of the tube) of the fiber-reinforced resin structure 100-1 do not need to be the same. For example, the fiber-reinforced resin structure 100-1 may have an outer shape that is prismatic and an inner shape that is cylindrical.

<<Production method>>
The manufacturing method of the fiber reinforced resin structure 100-1 according to the modified example is, for example,
A preparation step of preparing a laminate 50 having a columnar foam 30 and a fibrous body 10 covering at least a part of a side surface of the foam 30, the fibrous body 10 being impregnated with an uncured thermosetting resin (uncured resin 25);
a deformation step of applying an external force to the laminate 50 to deform the cross-sectional shape of the foam 30;
and a curing step of thermally curing the resin (uncured resin 25 ) impregnated into the fibrous body 10 to obtain the resin 20 .

The preparation process, hardening process, etc. are as described above. In addition, the cooling process, cutting process, and removal process may be performed as described above.

<Deformation process>
In the deformation step, an external force is applied to the laminate 50 to deform the cross-sectional shape of the foam 30 (see Figs. 15(a), 15(b), 16(a), and 16(b)). More specifically, for example, by applying an external force to the side surface of the laminate 50, the laminate 50 can be deformed into a prismatic shape.

When an external force is applied to the side of the laminate 50, the foam 30 and the fibrous body 10 are deformed, but the foam 30 prevents the fibrous body 10 from being crushed, and the desired shape (e.g., cylindrical) can be maintained.

The deformation process can be carried out, for example, by fitting the laminate 50 into a formwork having a predetermined shape.

In the deformation process, the shape of the laminate 50 can be freely changed by adjusting the direction and position at which the external force is applied.

For example, as shown in FIG. 15(a), when external force is applied evenly from four directions to the side of the laminate 50 (foam 30), the laminate 50 can be formed into a rectangular tube, and as shown in FIG. 16(a), when external force is applied evenly from six directions to the side of the laminate 50 (foam 30), the laminate 50 can be formed into a hexagonal tube.

In addition, by applying different external forces to one side of the laminate 50 and the other side, or by changing the direction or strength of the external forces applied to the upper side of the laminate 50 and the lower side of the laminate 50, it is possible to make the laminate 50 asymmetric in the up-down direction (axial direction) of the laminate 50 or in the left-right and front-rear directions (directions perpendicular to the axis) of the laminate 50.

The fiber-reinforced resin structure 100-1 can be made into a fiber-reinforced resin structure 100-1 of a different shape by changing the outer diameter of the foam 30 along the axial direction (for example, by providing a taper).

It is also possible to obtain a polygonal cylindrical fiber-reinforced resin structure 100-1 by first forming the foam 30 into a rectangular column shape and then carrying out a manufacturing method similar to that of embodiment I. However, in this case, the fibers are more likely to be subjected to stress, and the resulting structure may have inferior strength.

<<<<<Second embodiment>>>>
<<<<Structure>>>
As shown in FIG. 17( d ), the fiber-reinforced resin structure 100-2 according to the second embodiment has the following features:
The present invention includes at least a fibrous body 10 and a resin 20 impregnated in the fibrous body 10,
The fibrous body 10 is a fiber-reinforced resin structure having a curved cylindrical shape (or a cylindrical axis B is curved).

In other words, the fiber reinforced resin structure 100-2 has a curved portion 60 in which at least a portion of the structure of the fiber reinforced resin structure 100-2 is curved. Furthermore, the fiber reinforced resin structure 100-2 maintains a cylindrical structure at the curved portion 60. Furthermore, when the fiber reinforced resin structure 100-2 has a curved portion 60 and a non-curved portion, the curved portion 60 and the non-curved portion are smoothly connected. Furthermore, the fiber reinforced resin structure 100-2 may have the same shape at the curved portion 60 and the non-curved portion when observing a cross section perpendicular to the cylindrical axis B.

The fiber-reinforced resin structure 100-2 may have multiple curved portions 60. In this case, the direction of curvature, the degree of curvature, etc. can be designed for each curved portion 60.

There is no particular limitation on the degree of curvature of the cylindrical axis B or the curvature of the curved portion 60. The degree of curvature of the cylindrical axis B or the curvature of the curved portion 60 may be curved in a curved shape such as an L-shape, U-shape, S-shape, or bow shape, or may be curved at a specified angle (30 degrees, 45 degrees, 90 degrees, etc.) depending on the application, etc.

The fibrous body 10 is not limited to a cylindrical shape, but may be a polygonal tube.

The structure related to fiber-reinforced resin structure 100-2 can be described as fiber-reinforced resin structure 100-1 curved in a predetermined direction while maintaining the cross-sectional shape along the axis.

<<<Production Method>>>
The manufacturing method of the fiber reinforced resin structure 100-2 is, for example,
A preparation step of preparing a laminate 50 having a columnar foam 30 and a fibrous body 10 covering at least a part of a side surface of the foam 30, the fibrous body 10 being impregnated with an uncured thermosetting resin (uncured resin 25);
a bending step of bending the laminate 50 so that the column axis A of the foam is curved;
and a curing step of curing the resin (uncured resin 25 ) impregnated into the fibrous body 10 to obtain the resin 20 .

The preparation process, hardening process, etc. are as described above. In addition, the cutting process, cooling process, and removal process may be performed as described above.

<< Curving process >>
In the bending process, an external force is applied to the laminate 50 so as to bend the column axis A of the foam 30. As a result, the column axis A of the foam 30 is bent, and the axis of the entire laminate 50 is bent, so that when the laminate 50 includes a cylindrical fibrous body 10, the cylindrical axis B of the fibrous body 10 is similarly bent.

When an external force is applied to the side of the laminate 50, the foam 30 and the fibrous body 10 are deformed, but the foam 30 prevents the fibrous body 10 from being crushed, and the desired shape (e.g., cylindrical) can be maintained.

The method of bending the laminate 50 can be achieved by applying an external force to the laminate 50 from a predetermined direction (see Figs. 17(b) and 17(c)). The magnitude of the external force can be set appropriately taking into account the material of the laminate 50, the degree of bending, etc.

The bending process can be carried out, for example, by fitting the laminate 50 into a predetermined mold having a curved structure. If a complex curved shape is desired, the mold can be made separable.

The laminate 50 includes a fiber body 10 and a foam body 30. Therefore, the laminate 50 is unlikely to break even if it is curved. In particular, when the fiber body 10 is a fiber sheet and the foam body 30 is a foam, the fiber sheet and the foam body 30 can flexibly deform, resulting in a smoothly curved laminate 50 (less likely to have buckling).

During bending, the density of the fiber body 10 becomes dense in the compressed portion and sparse in the stretched portion. Taking this into consideration, the thickness of the fiber body 10 at the portion where the curved portion 60 can be formed may be adjusted in advance during the lamination process.

When making a fiber-reinforced resin structure 100-2 having multiple curved portions, a formwork having a shape with multiple curves may be used, or the curving process may be carried out multiple times.

<<<Modification of the second embodiment>>>
In the second embodiment, as shown in FIG. 17, a fiber-reinforced resin structure 100-2 having an overall cylindrical shape has been described. However, the fiber-reinforced resin structure 100-2 may be configured to have an overall polygonal cylindrical shape as shown in FIG. 18.

The structure according to the modified example of fiber-reinforced resin structure 100-2 can also be described as a structure according to the modified example of fiber-reinforced resin structure 100-1 that is curved in a predetermined direction while maintaining the cross-sectional shape along the axis.

The fiber-reinforced resin structure 100-2 according to the modified example of the second embodiment can be manufactured by carrying out the above-mentioned deformation process and the above-mentioned bending process on the laminate 50 (see FIG. 18). Note that in FIG. 18, the foam 30 is not shown for simplicity.

The deformation process changes the cross-sectional shape of the laminate 50 (foam 30) into a rectangular column shape, and the bending process bends the column axis A of the laminate 50.

In these processes, an external force is applied to the side of the laminate 50, causing the foam 30 and the fibrous body 10 to deform, but the foam 30 prevents the fibrous body 10 from being crushed, allowing it to maintain a predetermined shape (e.g., cylindrical).

The deformation process and the bending process may be performed while the laminate 50 contains the foam 30 and before the resin is cured (in other words, while it contains the uncured resin 25), and may be performed in any of the following ways: the deformation process is performed after the bending process, the deformation process is performed after the bending process, or the deformation process and the bending process are performed simultaneously.

When the deformation process and the bending process are performed simultaneously, they can be performed, for example, by fitting the laminate 50 into a mold having a predetermined curved structure and a predetermined cross-sectional shape.

In addition, when manufacturing the fiber-reinforced resin structure 100-2, as shown in FIG. 19, a step of bringing multiple laminates 50 into contact with each other before the resin is cured (when the laminates 50 contain uncured resin 25) may be further included (see FIG. 19(b)).

For example, in the manufacturing method shown in FIG. 19, first, a plurality of laminates 50 having a curved structure obtained by carrying out a bending process are prepared (see FIG. 19(a)), and these laminates 50 are arranged so that they are in contact with each other. In this state, a deformation process is carried out (see FIG. 19(b)), and finally, the laminates are cured to produce a fiber-reinforced resin structure 100-2 having a plurality of communicating holes, which are not parallel to each other.

Note that in Figures 19(a) and 19(b), the foam 30 has been omitted for simplicity.

The contacting, deforming, and curving steps may be performed in any order, and some or all of them may be performed simultaneously.

When the contact process, deformation process, and bending process are performed simultaneously, they can be performed, for example, by fitting multiple laminates 50 into a formwork that has a predetermined curved structure, a predetermined cross-sectional shape, and is capable of arranging multiple laminates 50 in predetermined positions.

In this way, it is possible to obtain a structure integrated with the resin 20 by contacting multiple laminates 50 with other members containing uncured resin 25 before the resin is cured (when the laminates 50 contain uncured resin 25) and then curing the resin. The concept of integrating multiple laminates 50 by contacting them before the resin is cured can be applied to all embodiments in the same way. In other words, for combinations of all structures described in each embodiment, and combinations of all structures described in each embodiment with known structures, structures in which each structure is integrated through resin are understood to be within the scope of the present invention.

<<<<<Embodiment III>>>>
<<<<Structure>>>
The fiber reinforced resin structure 100-3 according to the third embodiment has, for example,
The present invention includes at least a fibrous body 10 and a resin 20 impregnated in the fibrous body 10,
The fuel cell includes at least a first communication hole H, a second communication hole H parallel to the first communication hole H, and a wall portion defining the first communication hole H and the second communication hole H;
The wall portion includes a fibrous body 10.
It is a fiber-reinforced resin structure.

The fiber-reinforced resin structure 100-3 includes a plurality of communicating holes H arranged parallel to each other so that the hole axes C are aligned perpendicular to a predetermined direction (e.g., a certain straight line). The number of communicating holes H in the fiber-reinforced resin structure 100-3 may be two or more. For example, FIG. 20(f) shows a structure having four communicating holes H, FIG. 21(f) shows a structure having thirteen communicating holes H, FIG. 22(f) shows a structure having twelve communicating holes H, and FIG. 23(f) shows a structure having seven communicating holes H.

The first communication hole H and the second communication hole H are arranged so as to be parallel to each other. The first communication hole H and the second communication hole H being parallel means that they are regularly arranged to such an extent that the hole axis C of the communication hole H on one side and the hole axis C of the communication hole H on the other side are considered to be parallel when viewed as a whole.

The wall portion (e.g., thick resin 20) that defines each communication hole H includes a fibrous body 10. It is preferable that the fibrous body 10 is present in the entire wall portion surrounding each communication hole H, in other words, that the fibrous body 10 is provided so as to continuously surround the communication hole H for at least one revolution.

In this embodiment, the fiber body 10 is included in a wall portion that separates one communication hole H from another communication hole H (a wall portion that exists between one communication hole H and another communication hole H). By configuring in this way, it is possible to increase the strength of the fiber reinforced resin structure 100-3 in the thickness direction (the direction perpendicular to the direction in which the communication holes H are arranged).

The fiber-reinforced resin structure 100-3 may have foam 30 inserted into some or all of the communicating holes (see FIG. 20(e) etc.).

The fiber-reinforced resin structure 100-3 may have a structure as shown in FIG. 20(c), in which a plurality of cylindrical fibrous bodies 10 are arranged and cured in a state in which they are in close proximity to each other via resin. On the other hand, the fiber-reinforced resin structure 100-3 may have a structure as shown in FIG. 21(f), in which a plurality of polygonal tubular fibrous bodies 10 are arranged and cured in a state in which they are in close proximity to each other via resin. The fiber-reinforced resin structure 100-3 may also be obtained by combining a cylindrical fibrous body 10 and a polygonal tubular fibrous body 10.

In other words, the fiber reinforced resin structure 100-3 according to the third embodiment is
The present invention includes at least a fibrous body 10 and a resin 20 impregnated in the fibrous body 10,
The fibrous body 10 includes at least a first tubular fibrous body 10 and a second tubular fibrous body 10, which are polygonal tubular fibrous bodies;
This is a fiber-reinforced resin structure in which a planar portion constituting the outer surface of the first tubular fibrous body and a planar portion constituting the outer surface of the second tubular fibrous body are in contact with or close to each other.

From this perspective, the fiber-reinforced resin structure 100-3 includes a plurality of polygonal tubular fiber bodies 10. Furthermore, the plurality of fiber bodies 10 are regularly arranged so that the sides of the plurality of fiber bodies 10 are in contact with or close to each other.

The number of polygonal cylindrical fibrous bodies 10 contained in the fiber-reinforced resin structure 100-3 is not particularly limited, and may be two or more.

The fiber-reinforced resin structure 100-3 may have foam 30 inserted into the inside of all of the tubes of each tubular fiber body (e.g., the first tubular fiber body and the second tubular fiber body), may not have foam 30 inserted into the inside of all of the tubes, or may have foam 30 inserted into the inside of some of the tubes while not having foam 30 inserted into the inside of the remaining tubes.

Methods of arranging the communicating holes H (or the fibrous bodies 10) include a method of arranging multiple communicating holes H (or multiple fibrous bodies 10) in a single layer as shown in FIG. 20, a method of arranging multiple layers in which multiple communicating holes H (or multiple fibrous bodies 10) are arranged in a honeycomb shape as shown in FIG. 21, a method of arranging multiple layers in which multiple communicating holes H (or multiple fibrous bodies 10) are arranged in a lattice shape as shown in FIG. 22, and a method of arranging multiple communicating holes H (or multiple fibrous bodies 10) in a circular shape as shown in FIG. 23.

As shown in FIG. 24, the fiber-reinforced resin structure 100-3 may have multiple layers in which multiple communication holes H (or multiple fiber bodies 10) are arranged, and the communication holes H may be arranged such that the direction of the hole axis C (or the cylindrical axis direction of the fiber bodies 10) differs between one layer and another.

The wall portion (or the cylindrical shape of the fibrous body 10) that defines the communication hole H is not particularly limited, and may be a square cylindrical shape, a pentagonal or greater cylindrical shape, or a combination of multiple shapes (for example, a combination of a pentagonal cylindrical shape and a hexagonal cylindrical shape, as shown in FIG. 21).

As shown in FIG. 25(1), the fiber-reinforced resin structure 100-3 may have multiple communicating holes H (or multiple fiber bodies 10) arranged parallel to each other so that the hole axes are aligned perpendicular to a certain curve.

As shown in FIG. 25(2), the fiber-reinforced resin structure 100-3 may have the ends (opening faces) of the communication holes H sealed (or crushed). For example, the fiber-reinforced resin structure 100-3 may have a crushed shape at its upper end and/or lower end. The ends crushed in this way can be used, for example, as a surface for installing a fixing member such as a screw.

In the fiber-reinforced resin structure 100-3, only one end (opening surface) of the communication hole H may be sealed (or crushed), or both ends (opening surfaces) of the communication hole H may be sealed (or crushed).

In this case, the fiber-reinforced resin structure 100-3 may or may not include the foam 30.

Furthermore, the fiber-reinforced resin structures described in each embodiment can also be structured so that the ends of the communication holes H are sealed (or crushed).

As shown in Figures 26(f) and 31(f), the fiber-reinforced resin structure 100-3 may have voids in locations where multiple communication holes H (or multiple fiber bodies 10) are close to each other.

As shown in FIG. 27(f), the fiber-reinforced resin structure 100-3 may have a reinforcing member 15. This reinforcing member 15 is impregnated with resin (resin 20) and is integrated into the fiber-reinforced resin structure 100-3. By having the reinforcing member 15, it is possible to reinforce areas where the fiber body 10 is insufficient, and improve the strength of the fiber-reinforced resin structure 100-3.

The location where the reinforcing member 15 is placed is not particularly limited, and it can be placed appropriately in a location where strength may be insufficient due to a lack of fibrous bodies 10. For example, the reinforcing member 15 can be placed in a location where multiple communication holes H (or multiple fibrous bodies 10) are close to each other as shown in FIG. 27, or at the end of the fiber-reinforced resin structure 100-3.

The material of the reinforcing member 15 is not particularly limited, but can be the same material as the fibers that make up the fibrous body 10. In other words, the reinforcing member 15 may be made of fibers. The shape of the reinforcing member 15 is not limited, and it may be of any appropriate shape. For example, the reinforcing member 15 may be a unidirectional reinforcing material (UD material) or a twisted material thereof, or may be in the form of a sheet or a rod made by rolling a sheet, and can be changed according to the shape of the area to be reinforced. The content of the reinforcing member 15 can be appropriately used according to the desired strength of the fiber-reinforced resin structure 100-3.

As shown in FIG. 28(f), the fiber-reinforced resin structure 100-3 may have a plurality of communicating holes H each having a different hole diameter (or a plurality of fibrous bodies 10 each having a different cylindrical inner diameter).

As shown in Figures 29(e) and 30(e), in the fiber-reinforced resin structure 100-3, the thickness of the wall surrounding the communicating hole H (or the thickness of the cylindrical fiber body 10 and resin 20), in particular the fiber thickness of the fiber body 10 (or the cylindrical fiber body 10), may be different for each communicating hole H. Furthermore, in this case, as shown in Figures 29(e) and 30(e), the hole diameters of the multiple communicating holes H (or the cylindrical inner diameters of the multiple fiber bodies 10) may be different for each communicating hole H.

The structure according to fiber-reinforced resin structure 100-3 can also be described as having a structure in which the structure according to fiber-reinforced resin structure 100-1 and/or structures according to modified examples of fiber-reinforced resin structure 100-1 are regularly arranged and integrated through resin.

<<<Production Method>>>
The manufacturing method of the fiber reinforced resin structure 100-3 is, for example,
a preparation step of preparing an assembly 55 having at least a columnar first foam body 30, a fibrous body 10 covering at least a portion of the side surface of the first foam body 30, and a columnar second foam body 30 adjacent to the first foam body 30 via the fibrous body 10, the assembly 55 being impregnated with an uncured thermosetting resin (uncured resin 25);
and a curing step of thermally curing the thermosetting resin (uncured resin 25) contained in the assembly 55.

The curing process and the like are as described above. As shown in FIG. 20(e), by carrying out the curing process, the multiple fibrous bodies 10 and the like included in the aggregate 55 are integrated via the thermosetting resin.

As described above, the cooling process, cutting process and removal process may also be performed.

Furthermore, the manufacturing method of the fiber-reinforced resin structure 100-3 may include a sealing process (crushing process) in which the end (opening surface) of the assembly 55 is crushed before the curing process.

When performing the sealing process (crushing process), the length of the fibrous body 10 may be made longer than the length of the foam body 30 (configured so that the fibrous body 10 protrudes from the foam body 30).

The sealing process (crushing process) may be performed on only one end (opening surface) of the assembly 55, or on both ends (opening surfaces) of the assembly 55.

When the sealing process (crushing process) is performed, the removal process may or may not be performed. It is preferable to perform the sealing process (crushing process) when the assembly 55 contains the foam 30.

The sealing process (crushing process) may be performed so that the end (opening surface) of the assembly 55 is completely closed, or may be performed to the extent that the end of the assembly 55 has an opening.

<<Preparation process>>
In the preparation process, an aggregate 55 is prepared which has at least a fibrous body 10 covering at least a portion of the side portion of a first foam body 30 and a columnar second foam body 30 adjacent to the first foam body 30 via the fibrous body 10, and in which the fibrous body 10 is impregnated with an uncured thermosetting resin (uncured resin 25).

More specifically, in the preparation step, an assembly 55 is prepared in which a plurality of laminates 50 are arranged so as to be in contact with or in close proximity to each other (see, for example, Figures 20(a) to 20(c)). In other words, the foam bodies 30 contained in the laminates 50 are arranged so as to be in close proximity to each other via the fibrous bodies 10.

The number of laminates 50 included in the assembly 55 and the arrangement of the laminates 50 are not particularly limited, and may be adjusted according to the desired structure of the fiber-reinforced resin structure 100-3.

The assembly 55 may, for example, be one in which a plurality of laminates 50 are arranged in a single layer as shown in FIG. 20, one in which a plurality of laminates 50 are arranged in layers in a honeycomb shape as shown in FIG. 21, one in which a plurality of laminates 50 are arranged in layers in a lattice shape as shown in FIG. 22, or one in which a plurality of laminates 50 are arranged in a circle as shown in FIG. 23.

As shown in FIG. 24, the assembly 55 may be a structure in which a plurality of laminates 50 are arranged to have a layer in which the hole axes C of the communicating holes H (or the plurality of fibrous bodies 10) face in a certain direction, and another layer in which the plurality of laminates 50 are arranged in which the hole axes C of the communicating holes H (or the plurality of fibrous bodies 10) face in another direction.

Here, the assembly 55 may have a plate-shaped outer peripheral body 70 arranged to contact the side of the stack 50, as shown in FIG. 20(d).

The outer periphery 70 includes, for example, fibers similar to those constituting the fibrous body 10 and uncured resin 25. By using such an outer periphery 70, the strength of the fiber-reinforced resin structure can be improved.

The thickness of the outer body 70 can be adjusted as needed to suit the desired strength of the fiber-reinforced resin structure 100-3.

The shape of the outer periphery 70 is not particularly limited, but can be, for example, flat.

The outer periphery 70 may also be configured to wrap around the entire side surface of the assembly 55 one or more times. When configured in this way, the outer periphery 70 becomes the outer wall of the fiber-reinforced resin structure 100-3 after hardening, making it easier to improve the strength of the fiber-reinforced resin structure 100-3.

The outer circumferential body 70 may be provided so as to come into contact with the plurality of laminates 50. The outer circumferential body 70 comes into contact with the plurality of laminates 50, so that the laminates 50 are arranged along the outer circumferential body 70.

There may be other members between the laminates 50, or there may be no other members. For example, as shown in FIG. 27, the assembly 55 may include a reinforcing member 15. In the fiber-reinforced resin structure 100-3, the reinforcing member 15 is integrated with the fiber body 10, etc., via the resin 20. Therefore, it is preferable to impregnate the reinforcing member 15 with the uncured resin 25 at any timing. The uncured resin 25 contained in the laminate 50 may be transferred to the reinforcing member 15 by contacting the laminate 50 containing the uncured resin 25 with the reinforcing member 15 not containing the uncured resin 25, or the assembly 55 may be subjected to an impregnation process after forming the assembly 55 containing the laminate 50 and the reinforcing member 15 not containing the uncured resin 25, but it is preferable to impregnate the reinforcing member 15 with the uncured resin 25 in advance.

The shape and material of the foam 30 and the fibrous body 10 may be different between one laminate 50 and another laminate 50. For example, as shown in FIG. 28, an aggregate 55 may include multiple foams 30 (laminates 50) having different diameters.

Furthermore, as shown in Figures 29, 30, and 31, the assembly 55 may be an arrangement of a plurality of laminates 50 and one or more foam bodies 30 (foam bodies 30 not previously covered with the fiber body 10). When configured in this way, the thickness of the fiber body 10 contained in the wall of the obtained fiber reinforced resin structure 100-3 may differ depending on the location. Also, when configured in this way, the diameter of the communication hole H of the fiber reinforced resin structure 100-3 may differ greatly depending on the location. Also, when configured in this way, the pitch between the walls (the density/sparseness of the communication hole H) can be adjusted. In this way, such a method can be adopted when it is desired to adjust the required wall thickness (amount of fiber body 10) and the size of the communication hole H, etc., taking into consideration design, strength, cost, weight, etc., and further when it is desired to design a specific area to have high strength.

<<Deformation process>>
In the deformation step, an external force is applied to the plurality of laminates 50 arranged in an assembly 55 .

In addition, since the laminate 50 contains the foam 30, the axis of the laminate 50 (the column axis A of the foam 30) is unlikely to shift when the deformation process is performed. Therefore, the overall arrangement of the multiple laminates 50 (particularly the arrangement of the column axis A of the foam 30) remains almost unchanged before and after the deformation process. As a result, in the obtained fiber-reinforced resin structure 100-3, the hole axes C of each communication hole H can be made parallel to each other.

Since the laminate 50 includes the foam 30, when the sides of the laminate 50 are in contact or close to each other, or when the side of the laminate 50 is in contact with another surface (for example, a fixed surface such as the inner surface of a specified formwork or the outer periphery 70), an external force is applied to the laminate 50, causing a compressive force and a repulsive force to act on the foam 30. As a result, the side of the laminate 50 is deformed so as to be flattened, and a rectangular columnar laminate 50 is formed. When the fibrous body 10 is arranged in a cylindrical shape within the laminate 50, a fiber-reinforced resin structure can be formed in which a flat portion constituting the outer surface of a certain cylindrical fibrous body 10 and a flat portion constituting the outer surface of another cylindrical fibrous body 10 are in contact or close to each other (i.e., such flat portions are parallel to each other).

There are no particular limitations on the method of applying external force during the deformation process.

External force can be applied, for example, by fitting the assembly 55 into a specified formwork.

The application of external force may be performed by sandwiching the assembly 55 with the outer body 70. Also, by performing the curing process while the assembly 55 is sandwiched between the outer body 70, a fiber-reinforced resin structure 100-3 having the outer body 70 as an outer shell can be manufactured. When two outer bodies 70 are used to sandwich the assembly 55 from the front and back, the laminates 50 at the left and right ends have no adjacent members (laminated bodies 50 or outer body 70) and have open sides. When the deformation process is performed in a situation where such open sides exist, there is no force to suppress the deformation of the assembly 55 in the lateral direction, so that the end side of the assembly 55 (the side of the laminate 50 at the end) can form a curved structure in accordance with the expansion of the foam 30.

When applying the outer body 70 to the assembly 55, the outer body 70 may be cured first, and the cured outer body 70 may be brought into contact with the assembly 55 to cure the uncured resin contained in the assembly 55. However, it is preferable to bring the outer body 70 containing the uncured resin into contact with the assembly 55 to cure the uncured resin contained in the assembly 55 and the outer body 70 at the same time.

External force may be applied by tying the entire assembly 55 with a string or the like.

The application of external force is preferably performed by packaging the entire or part of the aggregate 55 in a flexible material such as a bag, sealing it, and then sucking the air from the flexible material to create a reduced pressure atmosphere. In this case, the uncured resin in the fiber body 10 contained in the aggregate 55 is subjected to the suction force of sucking in the air and the compressive force due to the reduced pressure, and is densely packed inside the fiber body 10. Therefore, the fiber reinforced resin structure after curing can form a dense focal structure, and defects are significantly reduced. This improves the physical properties such as the mechanical strength of the fiber reinforced resin structure. In the heat curing process, there is an effect that the fiber body 10 can be uniformly pressed against the outer body 70 due to the pressure difference with the atmospheric pressure, and the foam can further expand to strongly press the fiber body 10 against the outer body 70, and the moldability (the desired shape without wrinkles or twists) can be further improved. There are no particular restrictions on the conditions for the reduced pressure, and it is sufficient to use conditions that are normally used.

When applying an external force, the direction of application of the external force can be adjusted to obtain fiber-reinforced resin structures 100-3 with various structures.

By applying an external force to the assembly 55 in the front-to-rear direction (or in the front-to-rear and left-to-right directions), a fiber-reinforced resin structure 100-3 having an overall rectangular parallelepiped shape, such as that shown in FIG. 20(f), can be obtained.

By applying an external force to the assembly 55 in a generally uniform manner from the periphery of the assembly 55, a cylindrical fiber-reinforced resin structure 100-3 as shown in FIG. 23(f) can be obtained.

By changing the shape of the surface that comes into contact with the aggregate 55 when applying an external force (for example, the inner surface of the formwork used), it is possible to obtain a fiber-reinforced resin structure 100-3, as shown in FIG. 25 (1), in which multiple communicating holes H (or multiple fiber bodies 10) are arranged parallel to each other with the hole axes aligned perpendicular to a certain curve.

In the deformation process, the degree of deformation of the foam 30 and the degree of deformation of the laminate 50 can be adjusted by adjusting the external force. For example, when the external force on the assembly 55 is weakened, the deformation of the laminate 50 is suppressed, and a region (void region) where the external force does not sufficiently contribute to the laminate 50 can be formed. As a result, as shown in FIG. 26, the curved shape can be maintained at the location corresponding to the corner of the laminate 50. Similarly, when a formwork is used when applying the external force, a region (non-following region) where the deformation of the laminate 50 does not follow the corner of the formwork can be formed. When it is not preferable to have such a void region or non-following region, it is preferable to arrange the reinforcing member 15 in advance in the location that may correspond to these regions.

In the method shown in FIG. 20, a laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25 is prepared (FIG. 20(a)), multiple laminates 50 are arranged so that the fibrous bodies 10 are in contact or close to each other (FIG. 20(b)), the multiple laminates 50 arranged are sandwiched between two outer peripheral bodies 70 to form an assembly 55 (FIG. 20(c)), an external force is applied to the assembly 55 to compress the entire assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then the assembly is cured to form a fiber-reinforced resin structure 100-3 (FIG. 20(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 20(f)).

In the method shown in Fig. 21 and Fig. 22, a laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25 is prepared (Fig. 21(a), Fig. 22(a)), a plurality of laminates 50 are arranged in a row with the fibrous bodies 10 in contact or close to each other, and a plurality of rows of the laminates 50 are arranged to form an assembly 55 (Fig. 21(b) to Fig. 21(d), Fig. 22(b) to Fig. 22(d)), an external force is applied to the assembly 55 to compress the whole assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then the assembly is cured to form a fiber-reinforced resin structure 100-3 (Fig. 21(e), Fig. 22(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (Fig. 21(f), Fig. 22(f)).

In the method shown in FIG. 23, a laminate 50 containing a foam 30, a fibrous body 10, and an uncured resin 25 is prepared (FIG. 23(a)), and the laminate 50 is arranged so that the laminate 50 is surrounded by multiple laminates 50 and the fibrous bodies 10 are in contact or close to each other to form an assembly 55 (FIGS. 23(b) to 23(d)). An external force is applied to the assembly 55 to compress the entire assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then the assembly is cured to form a fiber-reinforced resin structure 100-3 (FIG. 23(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 23(f)).

In the method shown in FIG. 24, a laminate 50 including a foam 30, a fiber body 10, and an uncured resin 25 is prepared (FIG. 24(a)), a plurality of laminates 50 are arranged in a row with the fiber bodies 10 in contact or close to each other, and the row of laminates 50 is stacked so that the orientations of the laminates 50 are different to form an assembly 55 (FIGS. 24(b) to 24(d)). An external force is applied to the assembly 55 to compress the entire assembly, thereby deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and then the assembly is cured to form a fiber-reinforced resin structure 100-3 (FIG. 24(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 24(f)).

In the method shown in FIG. 26, a laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25 is prepared (FIG. 26(a)), multiple laminates 50 are arranged so that the fibrous bodies 10 are in contact or close to each other (FIGS. 26(b)-(c)), an external force is applied to the assembly 55, and the entire assembly is compressed until the ends of three or more laminates 50 are no longer in contact with each other, deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 26(d)), and then cured to form a fiber-reinforced resin structure 100-3 (FIG. 26(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 26(f)).

In the method shown in FIG. 27, a laminate 50 including a foam 30, a fiber body 10, and an uncured resin 25, and a reinforcing member 15 are prepared (FIG. 27(a)), a plurality of laminates 50 are arranged so that the fiber bodies 10 are in contact or close to each other, and the reinforcing member 15 is arranged between the plurality of laminates 50 (FIG. 27(b)-(c)), an external force is applied to the assembly 55 to compress the entire assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 27(d)), and then the assembly is cured to form a fiber-reinforced resin structure 100-3 (FIG. 27(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 27(f)).

In the method shown in FIG. 28, a relatively large-diameter laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25, and a relatively small-diameter laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25 are prepared (FIG. 28(a)). A plurality of relatively large-diameter laminates 50 are arranged to surround the relatively small-diameter laminate 50 (FIGS. 28(b)-(c)). An external force is applied to the assembly 55 to compress the entire assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 28(d)). The assembly is then cured to form a fiber-reinforced resin structure 100-3 (FIG. 28(e)). The foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 28(f)).

In the method shown in FIG. 29, a laminate 50 including a foam 30, a fiber body 10, and an uncured resin 25, and a foam 30 without a fiber body 10 are prepared, the laminate 50 and the foam 30 are arranged alternately (FIG. 29(a)), the laminate 50 and the foam 30 arranged are sandwiched between two outer peripheral bodies 70 to form an assembly 55 (FIG. 29(b)), an external force is applied to the assembly 55 to compress the whole and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 29(c)), and then cured to form a fiber-reinforced resin structure 100-3 (FIG. 29(d)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 29(e)).

In the method shown in FIG. 30, a laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25, and a foam 30 without a fibrous body 10 are prepared, and the laminate 50 and the foam 30 are arranged so that they are aligned and so that the foam 30 is continuously arranged (FIG. 30(a)). The laminate 50 and the foam 30 arranged are sandwiched between two outer peripheral bodies 70 to form an assembly 55 (FIG. 30(b)). An external force is applied to the assembly 55 to compress the entire assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 30(c)). Then, the assembly is cured to form a fiber-reinforced resin structure 100-3 (FIG. 30(d)). The foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 30(e)).

In the method shown in FIG. 31, a laminate 50 of foam 30, fibrous body 10, and uncured resin 25, and foam 30 without fibrous body 10 are prepared (FIG. 31(a)), multiple laminates 50 are arranged to surround foam 30 (FIG. 31(b)-(c)), an external force is applied to the assembly 55 to compress the entire assembly and deform the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30) (FIG. 31(d)), and then the assembly is cured to form a fiber-reinforced resin structure 100-3 (FIG. 31(e)), and the foam 30 is removed from the fiber-reinforced resin structure 100-3 (FIG. 31(f)).

<<<<IVth embodiment>>>>
<<<<Structure>>>
The fiber reinforced resin structure 100-4 according to the embodiment IV is
The present invention includes at least a fibrous body 10 and a resin 20 impregnated in the fibrous body 10,
The fuel cell includes at least a first communication hole H, a second communication hole H parallel to the first communication hole H, and a wall portion defining the first communication hole H and the second communication hole H;
The first communication hole H and the second communication hole H have a curved hole axis C,
The wall portion includes a fibrous body 10.
It is a fiber-reinforced resin structure.

The first communication hole H and the second communication hole H may also have a polygonal cross-sectional shape in a cross section perpendicular to the hole axis C.

The number of communication holes H contained in the fiber-reinforced resin structure 100-4 may be two or more.

The fiber-reinforced resin structure 100-4 has a plurality of communicating holes H, the communicating holes H having curved hole axes C, and the communicating holes H are arranged so as to be parallel to each other. In this way, it is possible to have a fiber-reinforced resin structure that has the features of the modified example of the fiber-reinforced resin structure 100-1 and the features of the fiber-reinforced resin structure 100-3. Therefore, all matters described for each embodiment can be applied to the fiber-reinforced resin structure 100-4.

In addition, the fiber reinforced resin structure 100-4 according to the IVth embodiment can be expressed as follows:
The present invention includes at least a fibrous body 10 and a resin 20 impregnated in the fibrous body 10,
The fibrous body 10 includes at least a first cylindrical fibrous body 10 and a second cylindrical fibrous body 10,
The first cylindrical fibrous body 10 has a curved polygonal cylindrical structure with a curved cylindrical axis B, and has an outer surface parallel to the cylindrical axis B,
The second tubular fiber body has a curved polygonal tubular structure with a curved tubular axis B and has an outer surface parallel to the tubular axis B,
This is a fiber-reinforced resin structure in which the outer surface of the first tubular fibrous body and the outer surface of the second tubular fibrous body are in contact with or close to each other.

In yet another way, the fiber-reinforced resin structure 100-4 includes a plurality of polygonal cylindrical fiber bodies 10 that are regularly arranged and in contact with or adjacent to each other, and has curved portions 60 that are curved in a predetermined direction and exist across the plurality of fiber bodies 10.

The degree of curvature of the hole axis C of the communicating hole H (or the curvature of the curved portion of the fibrous body 10) can be freely designed as appropriate. In addition, the degree of curvature of multiple communicating holes H may be the same or different.

The direction in which the fiber-reinforced resin structure 100-4 is curved is not particularly limited. For example, as shown in FIG. 32(g), the fiber-reinforced resin structure 100-4 may be curved in the front direction, in other words, in a direction perpendicular to an imaginary plane formed by the arrangement of the multiple communication holes H (or the multiple fiber bodies 10), or as shown in FIG. 33(g), the fiber-reinforced resin structure 100-4 may be curved in the side direction, in other words, in the same direction as the arrangement of the multiple communication holes H (or the multiple fiber bodies 10).

Also, as shown in FIG. 33, the fiber-reinforced resin structure 100-4 may have multiple curved portions 60.

As shown in FIG. 34, the fiber-reinforced resin structure 100-4 may have multiple communication holes H (or multiple fiber bodies 10) arranged in multiple rows.

A configuration in which the entire fiber-reinforced resin structure 100-4 is twisted is also within the scope of the present invention.

The structure according to fiber reinforced resin structure 100-4 can also be expressed as having a structure in which structures according to fiber reinforced resin structure 100-2 and/or modified examples of fiber reinforced resin structure 100-2 are regularly arranged and integrated through resin. Furthermore, the structure according to fiber reinforced resin structure 100-4 can also be expressed as a structure according to fiber reinforced resin structure 100-3 that is curved overall in a predetermined direction while maintaining the cross-sectional shape along the axis.

<<<Production Method>>>
The manufacturing method of the fiber reinforced resin structure 100-4 is, for example,
a preparation step of preparing an assembly 55 having a columnar first foam body 30, a fibrous body 10 covering at least a portion of the side surface of the first foam body 30, and a columnar second foam body 30 adjacent to the first foam body 30 via the fibrous body 10, the assembly 55 being impregnated with an uncured thermosetting resin (uncured resin 25);
a deformation step of applying an external force to the assembly 55 to deform the cross-sectional shapes of the first foam body 30 and the second foam body 30;
a bending process of bending the assembly 55 so that the column axis A of the foam 30 is curved;
and a curing step of thermally curing the thermosetting resin (uncured resin 25) contained in the assembly 55.

The manufacturing method of the fiber-reinforced resin structure 100-4 may be a method in which the deformation step is not performed and a bending step is performed on the assembly 55 as shown in FIG. 20(c), but it is preferable to perform both the deformation step and the bending step. In other words, it is preferable that the manufacturing method of the fiber-reinforced resin structure 100-4 further includes a deformation step in which an external force is applied to the assembly 55 to deform the cross-sectional shapes of the first foam body 30 and the second foam body 30.

The preparation process can be carried out in the same manner as the manufacturing method for the fiber-reinforced resin structure 100-3.

For the bending process, the above content can be referred to, except that the object to be bent has changed from the laminate 50 to the assembly 55. That is, in the bending process, an external force is applied to the multiple laminates 50 arranged as an assembly 55 so that the column axes A of the multiple foams 30 contained in the assembly 55 are curved. The external force can be applied by fitting the assembly 55 into a formwork, as described above.

For the deformation process, the above contents can be referred to. That is, in the deformation process, an external force is applied to the multiple laminates 50 arranged as an assembly 55, and the cross-sectional shape of the multiple foam bodies 30 is deformed. The external force can be applied by fitting the assembly 55 into a formwork, as described above.

As mentioned above, the deformation process and the bending process may be performed simultaneously or separately.

The curing process is as described above. As shown in FIG. 32(f), the curing process causes the multiple fibrous bodies 10 and the like contained in the aggregate 55 to be integrated via the thermosetting resin.

As described above, the cooling process, cutting process and removal process may also be performed.

In the method shown in Figures 32 and 33, a laminate 50 including a foam 30, a fibrous body 10, and an uncured resin 25 is prepared (Figures 32(a) and 33(a)), multiple laminates 50 are arranged so that the fibrous bodies 10 are in contact or in close proximity to each other, and the multiple laminates 50 arranged are sandwiched between two outer peripheral bodies 70 to form an assembly 55 (Figures 32(b) to 32(d), and 33(b) to 33(d)), and an external force is applied to the assembly 55 to compress the entire assembly to form the laminate 50 (foam 30). The cross-sectional shape perpendicular to the axis is deformed, and an external force is applied from the side of the assembly 55 to curve the axis of the laminate 50 (foam 30) (Fig. 32(e), Fig. 33(e)), and then cured to form a fiber-reinforced resin structure 100-4 having a curved portion 60 (the hole axis C of the communicating hole H is curved) (Fig. 32(f), Fig. 33(f)), and the foam 30 is removed from the fiber-reinforced resin structure 100-4 (Fig. 32(g), Fig. 33(g)).

In the method shown in FIG. 34, although not shown in detail, a laminate 50 containing a foam 30, a fibrous body 10, and an uncured resin 25 is prepared, a plurality of laminates 50 are arranged in a row with the fibrous bodies 10 in contact or close to each other, and a plurality of rows of the laminates 50 are arranged to form an assembly 55, and an external force is applied to the assembly 55 to compress the entire assembly, thereby deforming the cross-sectional shape perpendicular to the axis of the laminate 50 (foam 30), and an external force is applied from the side of the assembly 55 to curve the axis of the laminate 50 (foam 30), and then the assembly is cured to form a fiber-reinforced resin structure 100-4 having a curved portion 60 (the hole axis C of the communicating hole H is curved), and the foam 30 is removed from the fiber-reinforced resin structure 100-4.

In addition, in each embodiment, the column axis A, the cylinder axis B, and the hole axis C can be considered to be located in approximately the same place, so the column axis A, the cylinder axis B, and the hole axis C can be interpreted as being interchangeable.

Next, we will explain modified examples of each of the above-mentioned embodiments using Figures 35 to 45.

When describing the modified examples of the fiber-reinforced resin structure shown in Figures 35 to 45, the same components as those described above will be given the same reference numerals, and their description will be omitted or simplified. Furthermore, the fiber-reinforced resin structures described in the various modified examples below include those manufactured in the same manner as any of the manufacturing methods described in the above-mentioned embodiment examples. Therefore, the manufacturing methods of the above-mentioned embodiment examples will be cited as appropriate.

First, we will explain the modified fiber-reinforced resin structure shown in Figures 35 to 40.

In the following description, the fiber-reinforced resin structure shown in Figures 35(a), 36(a), 37(a), 38(a), and 39(a) will be referred to as fiber-reinforced resin structure A, and the fiber-reinforced resin structure shown in Figures 35(b), 36(b), 37(b), 38(b), 39(b), and 40(c) will be referred to as fiber-reinforced resin structure B.

The method for producing the fiber reinforced resin structure A includes the steps of:
The method includes the steps of preparing a laminate 50 having a columnar foam 30 and a fibrous body 10 wound around a side portion of the foam 30 one or more times, the laminate 50 being impregnated with an uncured thermosetting resin (uncured resin) in the fibrous body 10, bending the laminate 50 so that the column axis A of the foam 30 is curved, and applying an external force to the laminate 50 to thermally cure the thermosetting resin contained in the laminate 50,
A method for producing a fiber-reinforced resin structure, characterized in that the 25% compressive load of the foam measured in accordance with JIS K6400-2:2012 is 1 to 2000 kPa (excluding a method using a foam capable of secondary foaming as the foam 30; and a covering body having an uncured thermosetting resin (uncured resin) and bleed holes through which gas can seep out, and covering the laminate 30).

The method for producing the fiber reinforced resin structure B includes the steps of:
The method includes the steps of preparing a laminate 50 having a columnar foam 30 and a fibrous body 10 wound around a side portion of the foam 30 one or more times, the laminate 50 being impregnated with an uncured thermosetting resin (uncured resin) in the fibrous body 10, bending the laminate 50 so that the column axis A of the foam 30 is curved, applying an external force to the laminate 50 to thermally cure the thermosetting resin contained in the laminate 50, cooling the laminate 50 after thermal curing to shrink the foam 30, and removing the foam 30 contained in the laminate 50 after shrinking the foam 30,
A method for producing a fiber-reinforced resin structure, characterized in that the 25% compressive load of the foam measured in accordance with JIS K6400-2:2012 is 1 to 2000 kPa (excluding a method using a foam capable of secondary foaming as the foam 30; and a covering body having an uncured thermosetting resin (uncured resin) and bleed holes through which gas can seep out, and covering the laminate 30).

The fiber reinforced resin structure A is
The foamed article includes at least a columnar foam body, a fibrous body surrounding the foam body, and a resin impregnated in the fibrous body.
The foam body 30 is preferably a solid body extending at least from one end to the other end of the fibrous body 10,
The fibrous body 10 is a fiber-reinforced resin structure in which a part or the entirety of the fibrous body 10 is curved.

The fiber reinforced resin structure B is
The present invention includes at least a fibrous body 10 and a resin 20 impregnated in the fibrous body 10,
The fibrous body 10 is a fiber-reinforced resin structure in which a part or the entirety of the fibrous body 10 is curved.

Comparing fiber-reinforced resin structure A and fiber-reinforced resin structure B, the main difference is that fiber-reinforced resin structure A includes foam 30, while fiber-reinforced resin structure B does not include foam 30.

In the following description, the process of preparing the laminate 50 is referred to as the "preparation process", the process of curving the laminate 50 as the "curving process", the process of curing the uncured resin impregnated in the fibrous body 10 as the "curving process", the process of cooling the laminate 50 after the curing process to shrink the foam 30 as the "cooling process", and the process of removing the foam 30 contained in the laminate 50 after the cooling process as the "removal process". Although not described here, each manufacturing method can further carry out the above-mentioned deformation process (see, for example, FIG. 38(b)).

In the fiber-reinforced resin structure A, the foam 30 extends from one end of the fibrous body 10 to the other end, but this is not limited to the configuration. For example, the foam 30 may extend from one end of the fibrous body 10 to just before the other end. That is, the foam 30 may extend from one end of the fibrous body 10 but not to the other end of the fibrous body 10. Similarly, the foam 30 may extend only between a first position that is a predetermined distance away from one end of the fibrous body 10 toward the center, and a second position that is a predetermined distance away from the other end of the fibrous body 10 toward the center.

<Modification 1>
Fig. 35 is a perspective view showing a fiber-reinforced resin structure according to Modification 1. As shown in Fig. 35(a), a fiber-reinforced resin structure 100-5 according to Modification 1 is manufactured by the method described in Fig. 17. Here, Fig. 17 illustrates a fiber-reinforced resin structure having one curved portion, whereas Modification 1 shown in Fig. 35 illustrates a fiber-reinforced resin structure having a plurality of curved portions.

In the manufacturing method of the fiber-reinforced resin structure 100-5 according to the first modification, the bending process includes a plurality of steps. Specifically, the bending process includes a step of bending the laminate 50 at a first position that is a predetermined distance away from one end of the laminate 50 toward the center, a step of bending the laminate 50 at a second position that is a predetermined distance away from the other end of the laminate 50 toward the center, and a step of bending the laminate 50 so that the column axis A of the foam 30 present between the first and second positions has a predetermined shape (for example, a V-shape or a rectangular shape). In the first modification, the laminate 50 is bent so that the column axis A of the foam 30 present between the first and second positions has a U-shape or an inverted U-shape.

In the fiber-reinforced resin structure 100-5 according to the first modified example, the cylindrical fiber body 10 has an opening 10a, an opening 10b, a plurality of curved portions 60a to 60c, and a plurality of non-curved portions 60d to 60g.

Opening 10a opens in the X1 direction, and opening 10b opens in the X2 direction. The opening directions of openings 10a and 10b can be set arbitrarily. For example, the opening directions of openings 10a and 10b can both be set to the X1 direction.

When viewed from the front (in the Y direction), the curved portion 60a is bent in an inverted U-shape. Similarly, when viewed from the front (in the Y direction), the curved portion 60b is bent in an L-shape, and the curved portion 60c is bent in a mirror image of the L-shape. Note that the fibrous body 10 may be configured to have at least one of the curved portions 60a to 60c.

The non-curved portion 60d extends linearly in the X2 direction from the opening 10a to the curved portion 60c. The non-curved portion 60e extends linearly in the X1 direction from the opening 10b to the curved portion 60b. The non-curved portion 60f extends linearly in the Z direction to connect the curved portion 60c and the curved portion 60a. The non-curved portion 60g extends linearly in the Z direction to connect the curved portion 60b and the curved portion 60a.

<Modification 2>
Fig. 36 is a perspective view showing a fiber-reinforced resin structure according to Modification 2. As shown in Fig. 36(a), the fiber-reinforced resin structure according to Modification 2 has a plurality of laminates 50. Here, Fig. 17 illustrates a fiber-reinforced resin structure in which one laminate 50 is curved, whereas Modification 2 illustrates a fiber-reinforced resin structure in which a plurality (e.g., four) of laminates 50 are assembled and curved.

The manufacturing method of the fiber-reinforced resin structure 100-5 according to the second modification includes an arrangement process in which a plurality of laminates (laminates 50a to 50d) are assembled into an assembly (also called a laminate group), and a bending process is a process in which a part of the assembly is curved. The bending process is also called a twisting process.

The arrangement process is a process of arranging multiple laminates 50 to form an assembly 55 so that the column axis A of the foam 30 extends in the X direction. At this time, the multiple laminates 50 are aligned in the Y direction. Specifically, the laminates 50a are aligned adjacent to laminate 50b, laminate 50b is aligned adjacent to laminate 50c, and laminate 50d is aligned adjacent to laminate 50c.

The bending process is a process of bending a predetermined position located between one end and the other end of the assembly 55. In the example shown in FIG. 36(a), the predetermined position is bent by changing the arrangement of the stacks at one end (the right side in the figure) of the assembly 55. More specifically, the predetermined position is bent by lifting one end of the stack 50c and the stack 50d upward and stacking them on one end of the stack 50a and the stack 50b. The bending process may be a process of bending at least one of the one end and the other end of the assembly 55. In other words, one end and/or the other end of the assembly 55 may be curved.

As shown in FIG. 36(b), the fiber-reinforced resin structure 100-5 according to the second modification includes a plurality of fiber bodies 10 (fiber bodies 10a to 10d), each of which has a curved portion 60 (twisted portion 60) and a non-curved portion (non-twisted portion). The non-curved portions of the fiber bodies 10a to 10d all extend linearly in the X direction.

The fiber-reinforced resin structure 100-5 of the second modification has an end 70, an end 80, and communication holes H1 to H4.

The end 70 has four openings 10a1, 10b1, 10c1, and 10d1. These openings 10a1 to 10d1 are arranged in a row in the Y direction along a plane perpendicular to the X direction.

The end portion 80 has four openings 10a2, 10b2, 10c2, and 10d2. These four openings 10a2 to 10d2 are arranged in two rows in the Y direction along a plane perpendicular to the X direction. Specifically, of the two rows, the openings 10a2 and 10b2 are lined up in the first row on the lower layer, and the openings 10c2 and 10d2 are lined up in the second row on the upper layer. In other words, the end portion 80 has a lower layer 80a composed of the openings 10a2 and 10b2, and an upper layer 80b composed of the openings 50c2 and 50d2.

The communication hole H1 connects the opening 10a1 and the opening 10a2 of the fibrous body 10a. The communication hole H2 connects the opening 10b1 and the opening 10b2 of the fibrous body 10b. The communication hole H3 connects the opening 10c1 and the opening 10c2 of the fibrous body 10c. The communication hole H4 connects the opening 10d1 and the opening 10d2 of the fibrous body 10d.

The communication holes H1 to H4 extend linearly in the X direction from the end 70 to just before the curved portion 60, and then curve at the curved portion 60. After bending at the curved portion 60, the communication holes H1 and H2 extend linearly in the X direction to the lower layer 80a of the end 80. On the other hand, the communication holes H3 and H4 extend linearly in the X direction to the upper layer 80b of the end 80 after bending at the curved portion 60.

The bending process (twisting process) in variant 2 differs from the bending process described above in that the column axis of the foam contained in the laminate or assembly is bent in multiple directions (two directions, the Y direction and the Z direction, in Figure 36 (a)).

<Modification 3>
Fig. 37 is a perspective view showing a fiber-reinforced resin structure according to Modification 3. As shown in Fig. 37(a) , in the fiber-reinforced resin structure according to Modification 3, similarly to Modification 2, a plurality of laminates 50 are assembled into an assembly 55, and the assembly 55 is curved.

When comparing the fiber-reinforced resin structure according to Modification 3 with the fiber-reinforced resin structure according to Modification 2, the main difference is the shape of one end and the shape of the curved portion. Therefore, in describing the fiber-reinforced resin structure according to Modification 3, the differences from the fiber-reinforced resin structure according to Modification 2 described above will be described, and descriptions of the commonalities will be omitted as appropriate.

In the manufacturing method of the fiber-reinforced resin structure according to the third modification, the arrangement step includes three steps. Specifically, it includes a step of placing the laminates 50a and 50b adjacent to each other to form a first assembly of one layer so that the column axis A of the foam 30 extends in the X direction, a step of placing the laminates 50c and 50d adjacent to each other to form a second assembly of one layer so that the column axis A of the foam 30 extends in the X direction, and a step of placing the second assembly on the first assembly to form a two-layer assembly 55.

In the manufacturing method of the fiber-reinforced resin structure according to the third modification, the bending process includes two steps. Specifically, it includes a step of twisting the aggregate 55 by rotating the other end 180 degrees relative to one end with the column axis direction (X direction) of the foam 30 as the rotation axis so that a specific portion located between one end and the other end of the aggregate 55 becomes the curved portion 60, and a step of interposing a cylindrical guide material C in the curved portion 60.

During the bending process, when the guide material C is interposed, the guide material C is interposed between the first assembly made up of the laminates 50a and 50b and the second assembly made up of the laminates 50c and 50d so that they are separated from each other at the bending portion 60.

After the bending process, the uncured resin impregnated in the fiber body 10 is cured with the guide material C interposed between the first and second aggregates. The aggregate 55 is then cooled and the guide material C is removed to obtain the fiber-reinforced resin structure 100-5 shown in FIG. 37(a). The foam 30 is removed from the fiber-reinforced resin structure 100-5 shown in FIG. 37(a) to obtain the fiber-reinforced resin structure 100-5 shown in FIG. 37(b).

In the bending process of the third modified example, the other end is rotated 180 degrees to twist the assembly 55, but this rotation angle can be set arbitrarily. For example, the other end may be rotated 45 degrees or 360 degrees relative to the one end.

In addition, in the manufacturing method of the modified example 3, the curved portion 60 has an opening that opens in the Z direction by interposing a cylindrical guide material C between the first and second assemblies, but this is not limited to the configuration, and the curved portion 60 may have no opening. In other words, in the manufacturing method of the modified example 3, the cylindrical guide material C is not interposed between the first and second assemblies. After this, the other end is rotated a predetermined angle (for example, 1 degree to 360 degrees, or 360 degrees or more) relative to one end to twist the assembly 55.

The fiber-reinforced resin structure of variant example 3 has an end 70, an end 80, and communication holes H1 to H4.

The end 70 has four openings 10a1, 10b1, 10c1, and 10d1. These openings 10a1 to 10d1 are arranged in two rows in the Y direction along a plane perpendicular to the X direction. Specifically, of the two rows, the openings 10c1 and 10d1 are lined up in the first row on the lower layer, and the openings 10a1 and 10b1 are lined up in the second row on the upper layer. In other words, the end 70 has a lower layer 70a composed of the openings 10c1 and 10d1, and an upper layer 70b composed of the openings 10a1 and 10b1.

The end portion 80 has four openings 10a2, 10b2, 10c2, and 10d2. These four openings 10a2 to 10d2 are arranged in two rows in the Y direction along a plane perpendicular to the X direction. Specifically, of the two rows, the openings 10b2 and 10a2 are lined up in the first row on the lower layer, and the openings 10c2 and 10d2 are lined up in the second row on the upper layer. In other words, the end portion 80 has a lower layer 80a composed of the openings 10b2 and 10a2, and an upper layer 80b composed of the openings 10c2 and 10d2.

The communication hole H1 connects the opening 10a1 and the opening 10a2 of the fibrous body 10a. The communication hole H2 connects the opening 10b1 and the opening 10b2 of the fibrous body 10b. The communication hole H3 connects the opening 10c1 and the opening 10c2 of the fibrous body 10c. The communication hole H4 connects the opening 10d1 and the opening 10d2 of the fibrous body 10d.

The communication holes H1 and H2 extend linearly in the X direction from the upper layer 70b of the end 70 to just before the curved portion 60, then bend at the curved portion 60, and then extend linearly in the X direction to the lower layer 80a of the end 80. On the other hand, the communication holes H3 and H4 extend linearly in the X direction from the lower layer 70a of the end 70 to just before the curved portion 60, then bend at the curved portion 60, and then extend linearly in the X direction to the upper layer 80b of the end 80.

<Modification 4>
Fig. 38-1 is a perspective view showing a fiber-reinforced resin structure according to Modification 4. A fiber-reinforced resin structure 100-5 according to Modification 4 shown in Fig. 38(c) is manufactured by the method described in Fig. 19, but here, differences from the method described in Fig. 19 will be mainly described.

First, as shown in FIG. 38-1(a), a plurality of laminates 50 having a curved structure (formed into an L-shape) obtained by carrying out a bending process and a plurality of cylindrical laminates 50 are prepared. In the L-shaped laminates 50, one side of the L-shape is laid down, while the other side of the L-shape is raised, and the raised sides of the L-shaped laminates 50 are arranged so that they are in contact with each other. In addition, one end face of the cylindrical laminate 50 is arranged so as to be joined to the side of the L-shaped laminate 50. Note that in FIG. 38-1(a) and (b), the laminates 50 are shown slightly separated from each other so that the shapes of the laminates 50 can be easily seen, but in reality, they are in contact with each other as described above.

As shown in FIG. 38-1(b), the L-shaped laminate 50 and the cylindrical laminate 50 are in contact with each other, and then a deformation process is carried out. Finally, the laminate is hardened, so that the L-shaped laminate 50 becomes a plurality of non-parallel communicating holes (a plurality of communicating holes with an L-shaped cross section), and the cylindrical laminate 50 becomes a plurality of blind holes extending in a straight line, producing a fiber-reinforced resin structure 100-5 (see FIG. 38-1(c)). Note that the foam 30 is omitted in FIGS. 38-1(a) and (b) for simplicity.

<Modification 4-1>
In addition, the fiber-reinforced resin structure 100-5 may be not only the one shown in FIG. 38-1(c) but also, for example, the fiber-reinforced resin structure 100-5 shown in FIG. 38-2(e) (this is referred to as modified example 4-1). Specifically, as described in FIG. 38-1(a), the upright side portions of the L-shaped laminates 50 are arranged so as to contact each other, and one end face of the cylindrical laminate 50 is arranged so as to be joined to the side face of the L-shaped laminate 50 to form an upper part (see reference numeral 50U in FIG. 38-2(d)). In addition, a plurality of cylindrical laminates (see reference numeral 50D1 in FIG. 38-2(d)) are prepared below the upper part 50U, and a lower part (see reference numeral 50D in FIG. 38-2(d)) is prepared in which one end face of each of the other cylindrical laminates (see reference numeral 50D2 in FIG. 38-2(d)) is joined to the side face of the one cylindrical laminate 50. With the lower surface of the upper part in contact with the upper surface of the lower part, the deformation process is carried out as described above, and finally curing is performed, so that the upper part 50U and the lower part 50D are integrated as shown in Fig. 38-2, and the fiber-reinforced resin structure 100-5 shown in Fig. 38-2(e) is obtained. Note that, for simplicity, Fig. 38-2 does not show the cylindrical laminate 50 shown in Fig. 38-1(a), and only shows the fiber-reinforced resin structure 100-5 shown in Fig. 38-2(e) and Fig. 38-2(d), which shows the fiber-reinforced resin structure 100-5 disassembled therefrom.

In this modification 4-1, the upper surface of 50D1 of the lower portion 50D, which was a cylindrical laminate before curing, and the lower surface of 50U1 of the upper portion 50U, which was a cylindrical laminate before curing, come into contact with each other and harden, so that the strength of 50D1 and 50U1 can be improved. Also, the upper surface of 50D2 of the lower portion 50D, which was another cylindrical laminate before curing, and the lower surface of 50U2 of the upper portion 50U, which was an L-shaped laminate before curing, come into contact with each other and harden, so that the strength of 50D2 and 50U2 can be improved. As a result, the strength of the entire fiber-reinforced resin structure 100-5 can be improved.

<Modifications 5 and 6>
39 and 40 are perspective views showing fiber-reinforced resin structures according to Modifications 5 and 6. A fiber-reinforced resin structure 100-6 according to Modifications 5 and 6 is manufactured by the method described in FIG.

Comparing the fiber-reinforced resin structures according to Modifications 1 to 4 with the fiber-reinforced resin structures according to Modifications 5 and 6, there is a difference in that in the fiber-reinforced resin structures according to Modifications 1 to 4, a portion of the fiber body 10 is curved, whereas in the fiber-reinforced resin structures according to Modifications 5 and 6, the entire fiber body 10 is curved. In other words, the fiber-reinforced resin structures according to Modifications 1 to 4 have non-curved portions, whereas the fiber-reinforced resin structures according to Modifications 5 and 6 do not have non-curved portions.

As shown in FIG. 39, in the manufacturing method of the fiber-reinforced resin structure 100-6 according to the fifth modification, in the bending process, the laminate 50 is bent so that the column axis A of the foam 30 is wound in a spiral shape in a plane.

After the bending process, the uncured resin impregnated in the fiber body 10 is cured, and then the laminate 50 is cooled to obtain the fiber-reinforced resin structure 100-6 shown in FIG. 39(a). Then, the foam 30 is removed from the fiber-reinforced resin structure 100-6 shown in FIG. 39(a), to obtain the fiber-reinforced resin structure 100-6 shown in FIG. 39(b).

As shown in FIG. 39(b), the fiber-reinforced resin structure 100-6 according to the fifth modification includes at least a fiber body 10 and a resin 20 impregnated in the fiber body 10, and the fiber body 10 has a cylindrical shape with a cylindrical axis B that is spiral in plan view. In other words, the fiber-reinforced resin structure 100-6 is formed into a spiral shape by being folded multiple times in plan view so that the diameter from the virtual center M shown in FIG. 39(b) gradually increases.

As shown in FIG. 40, in the manufacturing method of the fiber-reinforced resin structure 100-6 according to the sixth modification, in the bending process, the laminate 50 is bent so that the column axis A of the foam 30 is wound in a spiral spring shape.

In the bending process, a cylindrical guide material C is prepared, and the laminate 50 is wound around the outer circumferential surface of the guide material C.

After the bending process, the uncured resin impregnated in the fiber body 10 is cured while the laminate 50 is wound around the outer peripheral surface of the guide material C. The laminate 50 is then cooled and the guide material C is removed to obtain the fiber-reinforced resin structure 100-6 shown in FIG. 40(a). The foam 30 is removed from the fiber-reinforced resin structure 100-6 shown in FIG. 40(a) to obtain the fiber-reinforced resin structure 100-6 shown in FIG. 40(b).

As described above, by curving one laminate 50 or curving an assembly 55 composed of a plurality of laminates 50, fiber-reinforced resin structures of various shapes can be formed. In addition, by combining a laminate 50 of a predetermined shape with a laminate 50 of a different shape from the predetermined shape, such as a laminate 50 of a curved structure or a cylindrical laminate 50, it is possible to manufacture fiber-reinforced resin structures of various shapes. Although not shown and described, a fiber-reinforced resin structure may be manufactured by combining laminates 50 of different sizes, or a desired fiber-reinforced resin structure can be manufactured by determining the number, shape, and size of the laminates 50 and combining them appropriately. In addition, various lightweight and high-strength parts can be obtained by fitting the pre-cured laminate 50 or assembly 55 into a predetermined mold and applying an external force, and curing the uncured resin impregnated in the fiber body 10. For example, an oar for use in a boat or canoe can be obtained from the assembly 55 shown in FIG. 36(a) (not shown). For example, a propeller for propelling an aircraft or a ship can be obtained from the assembly 55 shown in FIG. 37(a) (not shown). For example, a manhole cover, a receiving part of a parabolic antenna, or a lid for a container for containing a specific liquid or solid can be obtained from the laminate 50 shown in FIG. 39(a) (not shown). For example, a container for containing a specific liquid or solid can be obtained from the laminate 50 shown in FIG. 40(a) (not shown). The fiber-reinforced resin structure 100-5 shown in FIG. 38-1(c) and FIG. 38-2(f) can be used as a protective member for protecting a harness by passing the harness through the through hole, or as a container for supporting and storing a rod-shaped object in an upright state by inserting the rod-shaped object into the through hole (for example, if the rod-shaped object is an umbrella, the container can be an umbrella stand, etc.).

<Modification 7>
41 and 42 are perspective views showing a fiber-reinforced resin structure according to Modification 7. As shown in FIG. 42(a), a fiber-reinforced resin structure 100-7 according to Modification 7 is manufactured by the method described in FIG. 32 and FIG. 33. That is, in Modification 7, an assembly 55 shown in FIG. 32(e) or FIG. 33(e) is provided by the method described in FIG. 32(a) to FIG. 32(d) or FIG. 33(a) to FIG. 33(d). Here, FIG. 32 and FIG. 33 show an example in which four laminates 50 are sandwiched between two outer peripheral bodies 70, but in Modification 7, for example, nine laminates 50 are sandwiched between two outer peripheral bodies 70 to form a rectangular plate-shaped assembly 55.

An external force is applied to this assembly 55 to compress the entire assembly, and an external force is applied so that both ends of the assembly approach each other around the central laminate 50 (the fifth laminate 50 from the left in FIG. 41) of the nine laminates 50 (in other words, an external force is applied so as to bend the central laminate 50), thereby deforming the assembly 55 so that its cross section has an L-shape, and then allowing it to harden. This forms a fiber-reinforced resin structure 100-7 having a bent portion 60W and an L-shaped cross section, and the foam 30 is removed from this fiber-reinforced resin structure 100-7.

Then, by cutting the fiber-reinforced resin structure 100-7 vertically (up and down as viewed in FIG. 41) along "A1, A1" shown in FIG. 41(a), a fiber-reinforced resin structure 100-7A having an L-shaped cross section as shown in FIG. 41(b) can be obtained. Also, by cutting the fiber-reinforced resin structure 100-7 vertically along "A2, A2" or "A3, A3" shown in FIG. 41(a), a fiber-reinforced resin structure 100-7B having an H-shaped cross section as shown in FIG. A(b) can be obtained.

The fiber-reinforced resin structure 100-7A has a corner 90 in which a communication hole H is formed, a pair of wall portions 92 that extend outward from the corner 90 and face each other, and a pair of wall portions 93 that extend outward from the corner 90 in a different direction from the pair of wall portions 92 and face each other. In this modified example, the pair of wall portions 92 and 93 extend perpendicular to each other. It goes without saying that the angle formed by the pair of wall portions B and C is not limited to being perpendicular, and any appropriate angle can be set.

As shown in FIG. 42, for example, the fiber-reinforced resin structure 100-7A can function as a glass frame (sometimes called a "glass plate corner," "edge seal," "glass edge projector," "corner block," "corner piece," etc.) for protecting the edge (side) of the glass plate 95 by inserting the end of the glass plate 95 between the pair of wall portions 92 and 93. In this case, after inserting the end of the glass plate 95 between the pair of wall portions 92 and 93, the glass plate 95 can be fixed to the glass frame by a fixing device 97 such as a pin or a screw. The glass plate 95 may be fixed to the fiber-reinforced resin structure 100-7A by adhesion or the like instead of the fixing device 97 described above, and the fixing method is not particularly limited.

In this way, by inserting the glass plate 95 into the pair of walls 92, 93, the edge of the glass plate 95 is covered by the pair of walls 92, 93, and the edge of the glass plate 95 can be protected by the pair of walls 92, 93. Furthermore, since there is a corner 90 with a communication hole H formed therein between the pair of walls 92, 93 as described above, even if an external force is applied to the corner 90 (even if another structure collides with the corner 90), the communication hole H can mitigate the impact.

Here, the fiber-reinforced resin structure 100-7A is used as a glass frame to protect the edge of the glass plate 95, but instead, for example, a plate-shaped member such as a panel (not shown) may be inserted between each of the pair of wall portions 92, 93 and used as a frame member to protect a plate member other than the glass plate 95. In short, it is sufficient that the object can be inserted into the pair of wall portions 92, 93 of the fiber-reinforced resin structure 100-7A, and there is no particular limitation on the object to be inserted into the pair of wall portions 92, 93.

In the case of glass plate 95, fiber-reinforced resin structure 100-7A functions as a glass frame to protect the edge of glass plate 95, but in the case of an object such as a metal panel that does not need to be protected, it also functions as a connecting member that connects one object to another object at right angles to each other. From this perspective, in the case of glass plate 95, as shown in FIG. 42, one glass plate 95 (the glass plate 95 on the far left in FIG. 42) and another glass plate 95 (the glass plate 95 in the center in FIG. 42) can also be said to be connected to each other at a perpendicular angle.

Here, it is preferable that the distance between the pair of walls 92, 93 is slightly larger than the thickness of the object to be inserted between the pair of walls 92, 93. In this case, the object can be easily inserted between the pair of walls 92, 93, and damage to the object caused by friction between the object and the inner surfaces of the walls 92, 93 when the object is inserted between the pair of walls 92, 93 can be prevented.

On the other hand, the fiber-reinforced resin structure 100-7B has a pair of walls 92 that face each other and extend in a straight line, a pair of walls 93 that face each other and extend in a straight line in the opposite direction to the pair of walls 92, and a connecting plate 94 that connects the pair of walls 92, 93. As with the above-mentioned fiber-reinforced resin structure 100-7B, this fiber-reinforced resin structure 100-7B also has an object such as a glass plate 95 inserted into the pair of walls 92, 93, which functions as a protective member that protects the object and a connecting member that connects the object. Needless to say, the object can be fixed to the fiber-reinforced resin structure 100-7B by the above-mentioned fixing device 97 (see FIG. 42(b)) or by adhesive or the like.

<Modification 8>
Fig. 43 is a perspective view showing a fiber-reinforced resin structure according to Modification 8. As shown in Fig. 43, a fiber-reinforced resin structure 100-8 according to Modification B is manufactured by the method described in Fig. 32 and Fig. 33. That is, in this Modification A, an assembly 55 shown in Fig. 32(e) or Fig. 33(e) is provided by the method described in Fig. 32(a) to Fig. 32(d) or Fig. 33(a) to Fig. 33(d). Here, while Figs. 32 and 33 show examples using peripheral bodies 70 of the same size, in this modified example 8, for one peripheral body 70 (the left peripheral body 70 in Figs. 32(e) and 33(e)), a peripheral body of a length sufficient to be flush with the side surface of the endmost stack 50 in the assembly 55 (the side surface of the rightmost stack 50 in Figs. 32(e) and 33(e)) is used, and for the other peripheral body 70 (the right peripheral body 70 in Figs. 32(e) and 33(e)), a peripheral body of a length sufficient to protrude further outward from the side surface of the endmost stack 50 in the stack 50 is used. Specifically, in Figs. 32(e) and 33(e), the end of the peripheral body 70 protrudes slightly outward from the side surface of the endmost stack 50 in the assembly 55, but instead, for the other peripheral body 70 in this modified example 8, a peripheral body protruding a predetermined length outward from the side surface of the endmost stack 50 in the assembly 55 is used. The length of the other outer peripheral body 70 is not limited to this, and can be set to any appropriate length; in short, an appropriate length can be applied depending on the number of folds, which will be described later, etc.

As shown in FIG. 40, an external force is applied to the end of the other outer peripheral body 70 so as to fold a predetermined length from the end of the other outer peripheral body 70, and this folded portion is further folded by repeatedly applying an external force (by going through a folding process in which the end of the other outer peripheral body 70 is folded multiple times), so that the end of the other outer peripheral body 70 is folded into multiple layers. By hardening the assembly 55 in this state, a plate-shaped fiber-reinforced resin structure 100-8 is formed, and the end of this fiber-reinforced resin structure 100-8 becomes a protruding portion 70G formed by hardening the end of the other outer peripheral body 70 in a state where it is folded into multiple layers. Thereafter, the foam 30 is removed from the fiber-reinforced resin structure 100-8 (see FIG. 43(a)).

In this modification 8, as shown in FIG. 43(a), the thickness of the protruding portion 70G of the plate-shaped fiber-reinforced resin structure 100-8 is half the thickness W1 of the central portion of the plate-shaped fiber-reinforced resin structure 100-8. In addition, the protruding portion 70G is formed with a bolt hole BL1 for inserting a bolt BL. The fiber-reinforced resin structure 100-8 formed in this manner can be used, for example, as a panel material (for example, a floor panel, a wall panel, a roof panel, a frame material, a partition, a door panel, a building material such as a wall material for a container house, an arcade, etc.).

That is, in the plate-shaped fiber reinforced resin structure 100-8 as a panel material, as shown in FIG. 43(a), the respective protrusions 70G of the fiber reinforced resin structure 100-8 are joined together, and then the bolts BL are inserted into the bolt holes BL1 formed in the respective protrusions 70G and fastened with nuts NT, so that the respective fiber reinforced resin structures 100-8 are connected together, as shown in FIG. 43(b). In other words, the protrusions 70G can be said to be a connecting portion for joining the fiber reinforced resin structures 100-8 together. In this modification 8, the thickness of the protrusions 70G is halved, so that when the protrusions 70G of the respective fiber reinforced resin structures 100-8 are joined together, the thickness of the protrusions 70G matches the thickness of the fiber reinforced resin structures 100-8, and the surfaces of the fiber reinforced resin structures 100-8 as panel materials joined together become flush, resulting in a good appearance.

The thickness of the protrusion 70G is not limited to the above thickness, and may be, for example, 1/3 of the thickness W1, and it goes without saying that this thickness can be set appropriately by adjusting the number of times the end of the other outer peripheral body 70 is folded. Also, in this modification 8, the bolt hole BL1 is formed after the assembly 55 is hardened, but instead, the bolt hole BL1 may be formed before hardening.

<Modification 9>
FIG. 44 is a perspective view showing a fiber-reinforced resin structure according to Modification 9. As shown in FIG. 44(a), the fiber-reinforced resin structure 100-9 according to Modification C is formed in an airfoil shape. The cross-sectional shape of this fiber-reinforced resin structure 100-9 is as shown in FIG. 44(b). That is, the fiber-reinforced resin structure 100-9 has a through hole H1 located on one side (the end on the left side as viewed in FIG. 44) and having an airfoil cross-sectional shape with one end side formed at an acute angle and the other end formed in an arc shape, a plurality of through holes H2 having a circular cross-sectional shape, and a through hole H3 having a substantially semicircular cross-sectional shape located on the very other side of the fiber-reinforced resin structure 100-9. In addition, the multiple through holes H2 have gradually larger diameters as they move from one end to the other end, and gradually smaller diameters as they move from halfway toward the other end, and these through holes H1, H2, and H3 give the fiber-reinforced resin structure 10-9 an wing shape.

This fiber-reinforced resin structure 100-9 is generally formed by arranging the laminates 50 each having the shape of the through holes H1, H2, and H3 as shown in FIG. 44(b), and then winding the outer periphery 70 around them to form an assembly 55 (not shown). The assembly 55 is compressed and hardened, and then the foam 30 is removed. In this modification 9, in order to maintain the shape of the through hole H2, which has a circular cross-sectional shape, a foam having a hardness that does not deform when hardened is used. In this way, a through hole of a desired shape can be formed. It is to be noted that the point of "using a foam having a hardness that does not deform when hardened" described in this modification 9 is not only applicable to this modification 9, but can be applied to any of the above-mentioned embodiments.

The fiber-reinforced resin structure 100-9 of this modification 9 can be used, for example, in the rear wing of a car. The shape of the fiber-reinforced resin structure 100-9 is not limited to that shown in FIG. 44, and it can be formed into various shapes. That is, by appropriately combining laminates 50 of various shapes, it is possible to form a fiber-reinforced resin structure 100-9 of a desired shape. Specifically, it is possible to form through holes of various shapes as shown in FIG. E, which will be described next as modifications 10-1 to 10-3.

<Modification 10-1>
As shown in Fig. 45(a), cylindrical laminates 50 are arranged so as to spiral around a cylindrical core material made of resin or metal, and an outer periphery 70 is wound around the outer periphery of these laminates 50 to form an assembly 55. When the entire assembly 55 is compressed, as shown in Fig. 45(b), the cross-sectional shape of the laminates 50 is deformed so as to fill the gaps between the adjacent laminates 50 and the gaps between the outer periphery 70, and the adjacent laminates 50 and the outer periphery 70 are bonded together. When the assembly 55 in this state is cured, a fiber-reinforced resin structure 100-10 having a core material SZ is formed as shown in Fig. 45(c).

<Modification 10-2>
As shown in FIG. 45(d), a plurality of (three in the figure) laminates 50 are bundled together so that they are in contact with each other, and then the outer circumferential body 70 is wound around the bundle of laminates 50 so that the inner circumferential surface of the outer circumferential body 70 and the outer circumferential surface of the bundle of laminates 50 are in contact with each other to form an assembly 55. When the entire assembly 55 is compressed to be squeezed, the cross-sectional shape of each laminate 50 is deformed to fill the gaps between the adjacent laminates 50 and the gaps between the outer circumferential body 70, as shown in FIG. 45(e), and the adjacent laminates 50 and the outer circumferential body 70 are bonded together. When the assembly 55 in this state is cured and the foam 30 is removed, a cylindrical fiber-reinforced resin structure 100-11 having a plurality of through holes H formed therein is formed as shown in FIG. 45(f). In other words, the fiber-reinforced resin structure 100-11 is formed as a cylindrical member having partition walls (ribs) KH on the inside that divide the inside of the cylinder into three. In this way, by having the partition walls KH, the strength of the fiber reinforced resin structure 100-11 can be improved.

<Modification 10-3>
As shown in Fig. 45(g), a central laminate 50A and laminates 50B having a smaller diameter than the laminate 50A are arranged above and below the laminate 50A so as to be in contact with each other, and laminates 50C having an even smaller diameter than the laminates 50A and B are arranged on both sides of the joint between the top laminate 50B and the central laminate 50A and on both sides of the joint between the bottom laminate 50B and the central laminate 50A so as to be in contact with the laminates 50A and B. Thereafter, the outer circumferential body 70 is wound around them to form an assembly 55, and when the entire assembly 55 is compressed, the cross-sectional shapes of the respective laminates 50A to C are deformed so as to fill the gaps between the adjacent laminates 50A to C and the outer circumferential body 70, as shown in Fig. 45(h), and the adjacent laminates 50A to C and the outer circumferential body 70 are joined together. After the assembly 55 in this state is cured, the foam 30 is removed, and a cylindrical fiber-reinforced resin structure 100-12 having an elliptical cross-sectional shape and a plurality of through holes H of different sizes formed therein is formed as shown in FIG. 45(i). In other words, the fiber-reinforced resin structure 100-12 is formed as a cylindrical member having partition walls KH that divide the inside into a plurality of sections, and the presence of these partition walls KH makes it possible to improve the strength as described above. In this way, by using the laminates 50 having different diameters, a plurality of through holes KH having different cross-sectional areas can be formed, and the size and shape of the cross-sectional area of the through holes KH can be appropriately set by adjusting the size and shape of the laminates 50. In the fiber-reinforced resin structure 100-11 shown in Fig. 45, in order to enhance the shape retention of the laminate 50 (foam 30), it is needless to say that the curing step may be carried out in a state in which the laminate 50 (which may be a single body or a plurality of bodies) is fitted into a formwork, or a shrink tape is arranged around the laminate 50. This also applies to the fiber-reinforced resin structure 100-5 shown in Figs. 36 to 38, the fiber-reinforced resin structure 100-9 shown in Fig. 44, and the like, and it is needless to say that this can be applied to any of the above-mentioned embodiments as necessary.

By appropriately combining and carrying out each of the steps described above, it is possible to manufacture a variety of fiber-reinforced resin structures with complex shapes.

<Uses of fiber-reinforced resin structures>
Various fiber-reinforced resin structures have been described above, and the fiber-reinforced resin structures described above can be applied to various things. Next, uses of the fiber-reinforced resin structures described in this specification will be listed in order. Note that the uses of the fiber-reinforced resin structures listed below are merely examples, and it goes without saying that the fiber-reinforced resin structures can be used appropriately for purposes other than those listed below.

<Pipe material>
For example, the fiber reinforced resin structure 100-1 having a cylindrical, rectangular or hexagonal columnar shape shown in Figs. 14 to 16 can be used as a pipe material. The fiber reinforced resin structure as a pipe material is not limited to the fiber reinforced resin structure 100-1 having the above-mentioned cross-sectional shape, and may have a triangular or trapezoidal cross-sectional shape, or may have a plurality of through holes having different cross-sectional shapes and sizes as shown in Figs. 23, 26 to 28, and 45, and may have partition walls that divide these through holes. In addition, the fiber reinforced resin structure may be a curved fiber reinforced resin structure shown in Figs. 17, 18, and 34, or a bent fiber reinforced resin structure shown in Figs. 19, 39, and 40. Depending on the use and specifications, the above-mentioned embodiment or other appropriate shapes of fiber reinforced resin structures can be used. In addition, the fiber reinforced resin structure as a pipe material of this type may be provided with a flange or a handle.

<Panel material>
For example, the fiber-reinforced resin structures in Figures 20 to 22, 29, 30, 32, 33, 43, etc. can be used as panel materials, and any of the fiber-reinforced resin structures can be connected to form a straight line, a bent shape, a circle, etc. In this case, for example, the fiber-reinforced resin structure shown in Figure 42 may be used to connect fiber-reinforced resin structures formed in a plate shape, or as shown in Figure 43, a protrusion (connecting portion) 70G shown in Figure 43 may be provided on any of the fiber-reinforced resin structures to connect the fiber-reinforced resin structures.

<Bicycle-related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in handlebars, frames, and the like of bicycles.

<Motorcycle related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in motorcycle handlebars, frames, swing arms, cowlings, wings, manifolds, wheels, various pipes through which gas or liquid passes, and the like.

<Automobile-related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in automobile reinforcements (pillars, side sills, seat structures, etc.), wings, bonnets, floor panels (bulkheads, etc.), roof panels (outer panels, door beams, etc.), bucket seats, tower bars, intake manifolds, under-panels, wheels, various pipes through which gas or liquid passes, and the like.

<Bus related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in bus reinforcements (pillars, side sills, seat structures, etc.), wings, bonnets, floor panels (bulkheads, etc.), roof panels (outer panels, door beams, etc.), bucket seats, tower bars, intake manifolds, under-panels, wheels, various pipes through which gas or liquid passes, luggage racks, handrails (various pipes used as handrails), etc.

<Truck related>
The fiber-reinforced resin structure of the above-mentioned embodiment can be used, for example, in truck reinforcements (pillars, side sills, seat structures, etc.), wings, bonnets, floor panels (bulkheads, etc.), roof panels (outer panels, door beams, etc.), bucket seats, tower bars, intake manifolds, under-panels, wheels, various pipes through which gases or liquids pass, aerodynamic panels, cargo bed panels, maintenance panels (seat structures, pillars, ladder frames, etc.), luggage containers, refrigerated vehicle containers, camper shells, intake manifolds for towing trailers, baskets for high-altitude work, side guards (wheels), etc.

<Container related>
The fiber-reinforced resin structure of the above-described embodiment can be used for, for example, outer panels, floor panels, frames, etc. in cargo containers, container houses, dome houses, etc.

<Train related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, for door panels of train bodies, interior partings (seat structures), luggage racks, handrails (various pipes used as handrails), platform doors, etc.

<Aviation related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in aircraft seat structures, intake manifolds, propellers, blades, wings, helicopter rotors, turbine parts, partings, door panels, bulkheads, various pipes through which gas or liquid passes, and the like.

<Space-related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in seat structures of spacecraft (rockets, etc.), intake manifolds, wings, blades, turbine parts, bulkheads, various pipes through which gas or liquid passes, and the like.

<Shipping related>
The fiber-reinforced resin structure of the above-mentioned embodiment can be used, for example, in ship seat structures, hulls, decks (floor panels), ladders, keels, masts, booms, propellers, blades, bulkheads, oars, paddles, intake manifolds, various pipes through which gas or liquid passes, and the like.

<Construction-related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, for floor panels, wall panels, roof panels, frame materials, partitions, container houses, door panels, arcades, and the like of buildings.

<Civil engineering, infrastructure, and other related>
The fiber-reinforced resin structure of the above-mentioned embodiment can be used for, for example, piping such as water pipes, gate bars, fences, safety fences, aquariums, lids, parabolic antennas, blades, supports, elevator cages, cases, platform doors, insulated workbenches, insulated ladders, tanks, shelters, gratings (suitable shapes such as honeycomb shapes can be applied), playground equipment, artificial fishing reefs, underwater fences for accreting reefs, gates, benches, various parts of musical instruments, and the like.

<Industrial equipment related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in various parts of industrial robots, rollers, work tables, turbine parts, and the like.

<Medical equipment related>
The fiber-reinforced resin structure of the above-described embodiment can be used, for example, in medical device heads, X-ray fluoroscopy stretchers, X-ray fluoroscopy operating tables, wheelchair parts, crutches, medical robot parts, infectious disease isolation shelters, and various pipes through which gases or liquids pass.

＜Sports related＞
It can be used in baseball bats, tennis rackets (frames, etc.), table tennis rackets, ice hockey sticks, pucks, golf drivers, shafts of irons, fishing rods, etc.

100-1 to 100-12 Fiber-reinforced resin structure 10 Fiber body 15 Reinforcing member 20 Resin (cured resin)
25 Resin (uncured resin)
30 Foam body 50 Laminated body 55 Assembly body 60 Curved portion 70 Outer periphery body A Column axis B Cylinder axis C Hole axis H Communication hole

Claims (5)

The present invention includes a method for preparing a laminate having a columnar foam and a fibrous body covering at least a part of a side surface of the foam, the method including the steps of preparing a laminate in which the fibrous body is impregnated with an uncured thermosetting resin, curving the laminate so that the column axis of the foam is curved, and thermally curing the thermosetting resin contained in the laminate,
A method for producing a fiber-reinforced resin structure, wherein the foam has a 25% compressive load of 1 to 2000 kPa as measured in accordance with JIS K6400-2:2012 (excluding a method using a foam capable of secondary foaming as the foam; and a covering having bleed holes through which the uncured thermosetting resin and gas can seep out and covering the laminate). The manufacturing method according to claim 1, wherein the fibrous body is wound around the side surface of the foam body one or more times in the laminate. The manufacturing method according to claim 1 or 2, wherein the foam is an olefin-based resin foam. The method according to any one of claims 1 to 3, wherein the foam has a density of 1 to 800 kg/ ^m3 . cooling the laminate after the heat curing step to shrink the foam;
The method according to any one of claims 1 to 4, further comprising the step of removing the foam contained in the laminate after the step of shrinking the foam.

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