WO2017068812A1 - Method for manufacturing fiber-reinforced resin structure, system for manufacturing fiber-reinforced resin structure, and fiber-reinforced resin structure - Google Patents

Abstract

A method for manufacturing a fiber-reinforced resin structure 1 includes: a step in which a heat-curable resin is filled into a groove of a mold formed so as to correspond to the shape of an additional structure, and the heat-curable resin forms a semi-cured additional structure, which is in a semi-cured state; a step in which a heat-curable resin constituting a fiber-reinforced resin forms a semi-cured main body, which is in a semi-cured state; a step in which the semi-cured additional structure in the groove of the mold and the semi-cured main body are pressed against one another and heated, and the heat-curable resins of the semi-cured additional structure and the semi-cured main body are cured such that the main body is adhered to the additional structure; and a step in which the mold is separated from the additional structure.

Description

Manufacturing method of fiber reinforced resin structure, manufacturing system of fiber reinforced resin structure, and fiber reinforced resin structure Cross-reference of related applications

This application is based on Japanese Patent Application No. 2015-208949 filed on October 23, 2015, the contents of which are incorporated herein by reference.

The present invention relates to a method for manufacturing a fiber reinforced resin structure, a system for manufacturing a fiber reinforced resin structure, and a fiber reinforced resin structure.

In recent years, structures using fiber reinforced resins such as light and strong carbon fiber reinforced resin (CFRP) and glass fiber reinforced resin (GFRP) have attracted attention. For example, such a fiber reinforced resin structure is employed in a housing of an electronic device such as a computer or a mobile phone (see Patent Document 1).

By the way, when molding a structure such as a casing of an electronic device as described above, it is necessary to form fine additional structures such as bosses and ribs on the main body of the fiber reinforced resin. The additional structure portion is conventionally formed by insert molding in which a fiber reinforced resin main body portion is fixed in a mold and a thermoplastic resin is injected therein.

JP 2011-165206 A

However, when the above-described insert molding is used, the impregnation resin of the fiber reinforced resin of the main body is generally a thermosetting resin, and the resin of the additional structure is a thermoplastic resin. Adhesion is achieved and the adhesive strength is reduced. Further, at the time of insert molding, since the thermoplastic resin heated and melted to 200 ° C. or higher is injected under high pressure, the product after insert molding is likely to be deformed or distorted by heat shrinkage. As a result, the yield and quality of fiber reinforced resin products are reduced, resulting in high product prices.

The present application has been made in view of such points, and improves the adhesive strength between the main body portion of the fiber reinforced resin and the additional structure portion in the fiber reinforced resin structure. One object of the present invention is to provide a method for manufacturing a fiber reinforced resin structure, a system for manufacturing a fiber reinforced resin structure, and a fiber reinforced resin structure that can reduce the occurrence of distortion.

As a result of intensive studies, the inventors filled a mold groove with a thermosetting resin to be an additional structure portion to form a semi-cured additional structure portion in which the thermosetting resin is in a semi-cured state, and fiber reinforced. A semi-cured main body portion in which the thermosetting resin of the resin is in a semi-cured state is formed, the semi-cured additional structure portion and the semi-cured main body portion are pressed and heated, and the semi-cured additional structure portion and the semi-cured body portion are heated. It has been found that the above-mentioned problems can be solved by curing the thermosetting resin of the main body portion and bonding the additional structure portion and the main body portion, and has completed the present invention.

That is, the present invention includes the following aspects.
(1) A method for manufacturing a fiber reinforced resin structure having a main body portion having a fiber reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion. Filling the groove of the mold formed corresponding to the shape with a thermosetting resin to form a semi-cured additional structure in which the thermosetting resin is semi-cured, and thermosetting of the fiber reinforced resin A step of forming a semi-cured body part in which the resin is semi-cured, and heating the semi-cured additional structure part and the semi-cured body part of the groove of the mold by pressing, heating the semi-cured additional structure part and A step of curing a thermosetting resin of the semi-cured main body portion to bond the additional structure portion and the main body portion, and a step of detaching the mold from the additional structure portion. Production method.
(2) The step of filling the groove of the mold with the thermosetting resin is performed by discharging the thermosetting resin from the nozzle to the groove of the mold. The fiber-reinforced resin structure according to (1) Production method.
(3) The step of forming the semi-cured main body part is a combination of a plurality of types of fiber reinforced resin prepreg pieces to form a plate-like body, and both sides thereof are fiber reinforced resin prepreg sheets containing a thermosetting resin. The manufacturing method of the fiber reinforced resin structure as described in (1) or (2) performed by pinching between.
(4) In the step of forming the semi-cured main body, the plate-shaped body is formed by inserting the prepreg piece of the second type of fiber reinforced resin into the opening of the prepreg piece of the first type of fiber reinforced resin. The manufacturing method of the fiber reinforced resin structure as described in (3) to form.
(5) The fiber reinforced resin structure according to (4), wherein the first type of fiber reinforced resin is CFRP, and the second type of fiber reinforced resin is a fiber reinforced resin made of a dielectric. Manufacturing method.
(6) The step of forming the semi-cured main body is performed by forming a plate-like body containing a foamed resin and sandwiching both sides thereof with a prepreg sheet of a fiber reinforced resin containing a thermosetting resin. The manufacturing method of the fiber reinforced resin structure as described in 1) or (2).
(7) The method for producing a fiber-reinforced resin structure according to (6), wherein the foamed resin of the plate-like body is foamed after being sandwiched between the prepreg sheets.
(8) The method for producing a fiber-reinforced resin structure according to (6), wherein the foamed resin of the plate-like body is foamed before being sandwiched between the prepreg sheets.
(9) The method for producing a fiber-reinforced resin structure according to any one of (6) to (8), further comprising a step of forming a step in the semi-cured main body.
(10) The method for producing a fiber-reinforced resin structure according to any one of (6) to (9), further comprising a step of adjusting the thickness of the semi-cured main body.
(11) The method for producing a fiber-reinforced resin structure according to (10), wherein the thickness of the semi-cured main body is adjusted to 1 mm or less.
(12) The method for producing a fiber-reinforced resin structure according to any one of (6) to (11), wherein the plate-like body contains a thermosetting resin.
(13) The fiber-reinforced resin structure according to any one of (1) to (12), wherein in the step of bonding the additional structure portion and the main body portion, the semi-cured main body portion is press-molded into a desired shape. Production method.
(14) The step of bonding the additional structure portion and the main body portion is performed using press molding in which the semi-cured additional structure portion of the mold is pressed against the semi-cured main body portion and pressed. (12) The manufacturing method of the fiber reinforced resin structure in any one of.
(15) The step of bonding the additional structure portion and the main body portion is performed using autoclave molding or vacuum back molding in which the semi-cured additional structure portion and the semi-cured main body portion of the mold are evacuated and pressed. The method for producing a fiber-reinforced resin structure according to any one of (1) to (12).
(16) The step of forming the semi-cured main body portion and the step of bonding the additional structure portion and the main body portion are performed using RTM molding or VaRTM molding, the fiber reinforcement according to (1) or (2) Manufacturing method of resin structure.
(17) A method for producing a fiber reinforced resin structure having a main body portion having a fiber reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion, Filling the mold groove corresponding to the shape with a thermosetting resin and curing the thermosetting resin to form an additional structure, and the fiber reinforced resin thermosetting resin is semi-cured Forming the semi-cured body part in the state of the above, and heating the additional structure part and the semi-cured body part of the groove of the mold by pressing to cure the thermosetting resin of the semi-cured body part And a step of bonding the additional structure portion and the main body portion, and a step of separating the mold from the additional structure portion.
(18) A method for producing a fiber reinforced resin structure, comprising a main body having a fiber reinforced resin containing a thermosetting resin, and an additional structure formed on the surface of the main body. A step of filling a mold groove corresponding to the shape with a thermosetting resin and curing the thermosetting resin to form an additional structure, and a fiber reinforced resin containing the thermosetting resin. Heating the first prepreg sheet in contact with the additional structure, curing the thermosetting resin of the first prepreg sheet, and bonding the first prepreg sheet to the additional structure And a step of stacking and bonding a second prepreg sheet of fiber reinforced resin containing a thermosetting resin and a sheet containing an unfoamed foamed resin, and foaming the foamed resin of the sheet by heating to form a plate While forming the body, The plate-like body is bonded to the first prepreg sheet, and the main body portion composed of the plate-like body and the first prepreg sheet and the second prepreg sheet bonded to both surfaces thereof is bonded to the additional structure portion. A method for producing a fiber reinforced resin structure, comprising the step of bringing the mold into a detached state and the step of separating the mold from the additional structure portion.
(19) A system for manufacturing a fiber reinforced resin structure having a main body portion having a fiber reinforced resin containing a thermosetting resin and an additional structure portion formed on the surface of the main body portion, A mold groove formed in accordance with the shape is filled with a thermosetting resin to form a semi-cured additional structure in which the thermosetting resin is in a semi-cured state. Forming a semi-cured main body portion in a cured state, pressing the semi-cured additional structure portion and the semi-cured main body portion of the groove of the mold, and heating the semi-cured additional structure portion and the semi-cured main body portion; A system for manufacturing a fiber-reinforced resin structure, wherein a thermosetting resin is cured to bond an additional structure portion and a main body portion, and the mold is detached from the additional structure portion.
(20) A fiber reinforced resin structure, comprising a main body portion made of a fiber reinforced resin containing a thermosetting resin, and an additional structure portion made of a thermosetting resin provided on the surface of the main body portion. The main body has a plate-like body in which a plurality of types of fiber-reinforced resin pieces are combined, and a sheet of fiber-reinforced resin containing a thermosetting resin provided on both surfaces of the plate-like body. Fiber reinforced resin structure.
(21) The plate-like body includes a first type of fiber reinforced resin piece having an opening and a second type of fiber reinforced resin piece arranged in the opening. Fiber reinforced resin structure.
(22) The fiber reinforced resin according to (21), wherein the first type of fiber reinforced resin piece is CFRP, and the second type of fiber reinforced resin piece is a fiber reinforced resin made of a dielectric. Structure.
(23) A fiber reinforced resin structure, comprising a main body portion having a fiber reinforced resin containing a thermosetting resin, and an additional structure portion made of a thermosetting resin provided on a surface of the main body portion. The main body has a plate-like body containing a foamed resin, and a fiber-reinforced resin sheet containing a thermosetting resin provided on both surfaces of the plate-like body. .
(24) The fiber-reinforced resin structure according to (23), wherein the plate-like body contains a thermoplastic resin.
(25) The fiber-reinforced resin structure according to (23) or (24), wherein the main body has a step.
(26) The fiber-reinforced resin structure according to any one of (23) to (25), wherein the main body has a thickness of 1 mm or less.

According to the present invention, it is possible to improve the adhesive strength between the main body portion having the fiber reinforced resin and the additional structure portion in the fiber reinforced resin structure, and to reduce the occurrence of deformation and distortion due to thermal shrinkage as in conventional insert molding. The yield and quality of the fiber reinforced resin structure can be improved, and the price of the fiber reinforced resin product can be reduced.

It is a top view which shows an example in case a fiber reinforced resin structure is a housing | casing of an electronic device. It is a schematic diagram which shows the shaping | molding process of a semi-hardened main-body part. It is explanatory drawing which shows the 3 layer structure of a semi-hardened main-body part. It is sectional drawing of a metal mold | die. It is explanatory drawing which shows the example which fills the groove | channel of a metal mold | die with a thermosetting resin. It is explanatory drawing which shows the example which fills the groove | channel of a metal mold | die with a thermosetting resin. It is explanatory drawing of the longitudinal cross-section of a joining apparatus. It is a top view of a joining device. It is explanatory drawing which shows a mode that the semi-hardening addition structure part and semi-hardening main-body part of the metal mold | die were press-contacted in the joining apparatus. It is explanatory drawing which shows a mode that a semi-hardened main-body part is press-molded in a joining apparatus. It is explanatory drawing which shows a mode that the metal mold | die was made to detach | leave from an additional structure part in a joining apparatus. It is explanatory drawing which shows the 3 layer structure of the semi-hardened main-body part of 2nd Embodiment. It is explanatory drawing which shows the formation procedure of a semi-hardened main-body part. It is explanatory drawing which shows the other formation procedure of a semi-hardened main-body part. It is explanatory drawing which shows the example of adjustment of the thickness of a semi-hardened main-body part. It is explanatory drawing which shows the procedure which forms a level | step difference in a semi-hardened main-body part. It is explanatory drawing which shows the other procedure which forms a level | step difference in a semi-hardened main-body part. It is explanatory drawing which shows the other procedure which forms a level | step difference in a semi-hardened main-body part. It is explanatory drawing which shows the other procedure which forms a level | step difference in a semi-hardened main-body part. It is explanatory drawing which shows the adhesion procedure of the main-body part and additional structure part in 3rd Embodiment. It is explanatory drawing which shows the other adhesion procedure of a main-body part and an additional structure part. It is explanatory drawing which shows the adhesion procedure of the main-body part and additional structure part in 4th Embodiment.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings. In addition, the same code | symbol is attached | subjected to the same element and the overlapping description is abbreviate | omitted. Further, the positional relationship such as up, down, left and right is based on the positional relationship shown in the drawings unless otherwise specified. Furthermore, the dimensional ratios in the drawings are not limited to the illustrated ratios. Moreover, the following embodiment is an illustration for explaining the present invention, and the present invention is not limited to this embodiment.

The fiber reinforced resin structure according to the present embodiment has a structure in which an additional structure portion made of a thermosetting resin is added to a main body portion having a fiber reinforced resin containing a thermosetting resin. For example, as shown in FIG. 1, when the fiber reinforced resin structure 1 is a casing of a mobile device, the fiber reinforced resin structure 1 is formed on a tray-like main body 10 and the surface of the main body 10. It has the additional structure part 11 which consists of protrusions, such as a rib and a boss | hub.

In the present specification, the “thermosetting resin” includes not only the resin itself but also those containing inclusions such as fillers. As the filler, for example, an inorganic filler such as chopped glass filler, milled glass filler, carbon black, chopped carbon filler, milled soot carbon filler, silica filler, and hollow glass filler may be used.

Hereinafter, an example of a manufacturing method of the fiber reinforced resin structure 1 will be described.

(First embodiment)
FIG. 2 shows a process of forming the semi-cured body 20 before it is cured to become the body 10. First, two types of fiber reinforced resins, for example, prepregs 30 and 31 of CFRP (carbon fiber reinforced resin) as a first type and GFRP (glass fiber reinforced resin) as a second type are prepared ((( a)). Each of the prepregs 30 and 31 is impregnated with an uncured (uncured (A stage) or semi-cured (B stage)) thermosetting resin such as an epoxy resin.

Next, each of the prepregs 30 and 31 is cut into a predetermined shape by a cutting machine to form each prepreg piece ((b) in FIG. 2). For example, the CFRP prepreg piece 30 is formed in a square shape having an opening 30a at a desired position, and the GFRP prepreg piece 31 is cut to a size matching the opening 30a.

Subsequently, the prepreg pieces 30 and 31 are combined on a plane to form a rectangular plate-like body 40 ((c) in FIG. 2). At this time, the GFRP prepreg piece 31 is fitted into the opening 30 a of the CFRP prepreg piece 30 to form the plate-like body 40.

Next, a fiber-reinforced resin prepreg sheet containing a thermosetting resin, for example, a micro-glass prepreg sheet 41 is attached to both surfaces of the plate-like body 40 ((d) in FIG. 2). As shown in FIG. 3, the prepreg sheet 41 has a rectangular shape that is the same size as the plate-like body 40, and is attached so as to cover both surfaces of the plate-like body 40. The prepreg sheet 41 has a thickness of about 0.005 mm to 0.5 mm, for example. The thermosetting resin of the plate-like body 40 and the prepreg sheet 41 is maintained and controlled in a semi-cured (B stage) state. In this way, the semi-cured main body 20 composed of three layers (the plate-like body 40 and the prepreg sheet 41) in which the thermosetting resin is semi-cured is formed. For example, the semi-cured main body 20 is manufactured by supplying the prepregs 30 and 31, cutting the supplied prepregs 30 and 31, and combining the cut prepreg pieces 30 and 31 to form the plate-like body 40. Further, the main body forming apparatus A is used in which the prepreg sheet 41 is bonded to the plate-like body 40.

Next, a process for forming the semi-cured additional structure portion 50 before being cured to become the additional structure portion 11 will be described. As shown in FIG. 4, the metal mold | die 60 which has the groove | channel 61 corresponding to the shape of the additional structure part 11 is formed. And the groove | channel 61 of the metal mold | die 60 is filled with the thermosetting resin which is the same as the semi-hardened main-body part 20, and is not hardened, for example, an epoxy resin. Such filling is performed, for example, by a resin filling device 72 having a resin tank 70 and a nozzle 71 as shown in FIG. When the groove 61 of the mold 60 is wide laterally, the nozzle 71 is moved laterally while discharging the liquid thermosetting resin B from the nozzle 71, and the groove 61 is filled with the thermosetting resin. When the groove 61 of the mold 60 is deep as shown in FIG. 6, the nozzle 71 is inserted into the groove 61, and the nozzle 71 is raised while discharging the liquid thermosetting resin B to form the groove 61. Fill with thermosetting resin B. Depending on the shape of the groove 61, the lateral movement and vertical movement of the nozzle 71 may be combined to fill the resin. The filled thermosetting resin is maintained and controlled in a semi-cured (B stage) state. Thus, the semi-cured addition structure 50 in which the thermosetting resin is semi-cured is formed on the mold 60.

Next, as shown in FIG. 7, the semi-cured main body portion 20 and the semi-cured additional structure portion 50 of the mold 60 are installed in the joining device 80. For example, as shown in FIGS. 7 and 8, the bonding apparatus 80 includes a mounting table 90, a heater 91 built in the mounting table 90, and a side press machine 92 disposed around the mounting table 90. The semi-cured main body 20 is installed and held on a mounting table 90 as shown in FIG. The semi-cured additional structure portion 50 is installed above the mounting table 90 with the groove 61 of the mold 60 facing downward. Next, as shown in FIG. 9, the mold 60 is lowered, and the semi-cured additional structure portion 50 of the mold 60 is pressed against the semi-cured main body portion 20 on the mounting table 90 and pressed by press molding. In this state, for example, the semi-cured main body portion 20 and the semi-cured structure portion 50 are heated to, for example, about 150 ° C. by the heater 91 built in the mounting table 90, and the respective thermosetting resins in the semi-cured state are cured (C stage state). To). Thus, the semi-cured main body portion 20 is cured to become the main body portion 10, and the semi-cured additional structure portion 50 is cured to become the additional structure portion 11. At this time, the main body portion 10 and the additional structure portion 11 are bonded and integrated.

Then, when the semi-cured main body 20 and the semi-cured additional structure 50 are heat-bonded, the side press machine 92 moves inward as shown in FIG. 10, and the periphery of the semi-cured main body 20 is press-molded.

Thereafter, as shown in FIG. 11, the mold 60 is raised and detached from the integrated additional structure 11 and the main body 10. Thus, the fiber reinforced resin structure 1 integrally including the main body portion 10 and the additional structure portion 11 is molded. That is, it has a main body portion 10 made of a fiber reinforced resin containing a thermosetting resin, and an additional structure portion 11 made of a thermosetting resin provided on the surface of the main body portion 10, A fiber reinforced resin having a plate-like body 40 in which two kinds of fiber-reinforced resin pieces 30 and 31 are combined, and a prepreg sheet 41 of a fiber reinforced resin containing a thermosetting resin provided on both surfaces of the plate-like body 40. The structure 1 is manufactured. Thereafter, the fiber reinforced resin structure 1 is completed by performing a process of removing burrs, a coating process, and the like. In the present embodiment, the main body forming device A, the resin filling device 72, and the joining device 80 constitute a fiber reinforced resin structure manufacturing system.

According to the present embodiment, the semi-cured additional structure portion 50 made of a semi-cured thermosetting resin and the semi-cured main body portion 20 in which the thermosetting resin is in a semi-cured state are pressed and cured, so that the additional structure portion 50 and the main body portion 10 can be bonded, so that the same kind of material can be bonded, and the bonding strength between the main body portion 10 and the additional structure portion 11 can be improved. Moreover, since the main body part 10 and the additional structure part 11 have a similar composition, the main body part 10 and the additional structure part 11 can be bonded under low temperature and low pressure without using insert molding. Generation of deformation and distortion due to contraction can be reduced. As a result, the yield and quality of the product of the fiber reinforced resin structure 1 can be improved, and the product price of the fiber reinforced resin structure 1 can be reduced.

In the step of filling the groove 61 of the mold 60 with the liquid thermosetting resin, since the thermosetting resin is discharged from the nozzle 71 to the groove 61 of the mold 60, the filling of the thermosetting resin can be performed easily and easily. It can be done properly.

In the step of forming the semi-cured main body 20, a plate-like body 40 is formed by combining prepreg pieces 30 and 31 of two types of fiber reinforced resin, and both sides of the prepreg are made of fiber reinforced resin containing a thermosetting resin. The sheet 41 was sandwiched. Thereby, in the fiber reinforced resin structure 1, different types of fiber reinforced resins can be used, and the application of the fiber reinforced resin structure 1 can be expanded. For example, as shown in FIG. 1, the main body 10 is mainly composed of a high strength CFRP piece 30, and a GFRP piece 31 made of a dielectric material that easily transmits radio waves is used in a part of the main body 10. It can be used as a case for attached mobile devices. In this case, a lightweight and thin mobile device housing can be realized at a low price. The fiber reinforced resin made of a dielectric is not limited to GFRP, and other organic fibers such as polyester, inorganic fibers, and the like may be used.

Further, in the step of forming the semi-cured main body 20, the prepreg piece 31 of the second type fiber reinforced resin (GFRP) is provided in the opening 31 a of the prepreg piece 30 of the first type fiber reinforced resin (CFRP). The plate-like body 40 was formed by inserting. Thereby, the main-body part 10 which consists of multiple types of fiber reinforced resin can be manufactured easily.

In the step of bonding the additional structure portion 11 and the main body portion 10, the semi-cured main body portion 20 is press-molded into a desired shape, so there is no need to separately perform the step of forming the entire shape of the semi-cured main body portion 20, The manufacturing time of the fiber reinforced resin structure 1 can be shortened.

(Second Embodiment)
In the step of forming the semi-cured main body portion 20 described in the first embodiment, the plate-like body 40 is formed by combining the prepreg pieces 30 and 31 of two kinds of fiber reinforced resins, and both surfaces thereof are thermosetting. The fiber reinforced resin containing the resin was sandwiched between the prepreg sheets 41. As shown in FIG. 12, the plate-like body 100 containing the foamed resin was formed, and both surfaces of the fiber reinforced resin containing the thermosetting resin were formed. The prepreg sheet 41 may be sandwiched. That is, the main body portion 10 formed by curing the semi-cured main body portion 20 includes a plate-like body 100 containing a foamed resin, and a fiber reinforced resin containing a thermosetting resin provided on both surfaces of the plate-like body 100. It may have a sheet 41. Here, the foamed resin means a resin in which a large number of foams are mixed. For example, a spherical body such as acrylic foamed by heating is used for the foam, and a thermosetting resin such as an epoxy resin is used for the resin containing the foam.

In the process of forming the semi-cured main body 20, for example, as shown in FIG. 13, the foamed resin is foamed by heating to form the plate-like body 100, and then the prepreg sheet 41 is bonded to both surfaces of the plate-like body 100.

In the process of forming another semi-cured main body 20, as shown in FIG. 14, an unfoamed foamed resin sheet 101 is sandwiched between two prepreg sheets 41, and then the foamed resin is foamed by heating and the resin is cured. A plate-like body 100 is formed. In this case, the prepreg sheet 41 and the plate-like body 100 are bonded when the foamed resin is foamed.

The plate-like body 100 containing a foamed resin is excellent in workability because the foam is compressed and deformed. Therefore, for example, the thickness of the semi-cured main body 20 (main body 10) having a three-layer structure including the plate body 100 and the prepreg sheet 41 may be adjusted. At this time, the thickness of the semi-cured main body 20 may be adjusted to 1 mm or less. Such thickness adjustment is performed, for example, when the semi-cured main body 20 and the semi-cured additional structure 50 shown in FIG. 9 described above are joined, and the semi-cured additional structure 50 of the mold 60 and the semi-cured of the mounting table 90. This can be done by adjusting the compression force between the main body portion 20 and the main body portion 20. Further, the adjustment of the thickness is performed by sandwiching an unfoamed foamed resin sheet 101 between prepreg sheets 41 as shown in FIG. 15, and placing the foamed resin sheet 101 and the prepreg sheet 41 at a desired interval (final semi-cured main body 20 It is also possible to carry out by foaming the foamed resin by heating in this state. At this time, foaming (expansion) of the foamed resin is regulated by the holding body 110, and the thickness of the semi-cured main body 20 becomes equal to the interval between the two holding bodies 110. Furthermore, the plate-like body 100 after foaming can be pressed to a predetermined thickness and then sandwiched between prepreg sheets 41. According to such an example, an extremely thin and light semi-cured main body portion 20 (main body portion 10) of 1 mm or less can be formed, so that a light and strong fiber-reinforced resin structure 1 can be realized.

Further, a step may be formed in the semi-cured main body 20 (main body 10) by utilizing the fact that the plate-like body 100 is excellent in workability. For example, as shown in FIG. 16, the step 130 is formed by forming a step 120 having a desired shape, for example, a concave shape, on the plate-like body 100 during foaming, and pressing the plate-like body 100 and the prepreg sheet 41 together. Can be performed. The step 130 can also be formed by pressing the foamed flat plate-like body 100 and the prepreg sheet 41 together with a press machine having a convex portion as shown in FIG. Further, as shown in FIG. 18, the unfoamed foamed resin sheet 101 is sandwiched between the prepreg sheets 41, and the foamed resin sheet 101 and the prepreg sheet 41 are separated by a desired interval (an interval that matches the thickness of the final semi-cured main body 20. It can also be carried out by foaming the foamed resin by heating in this state. Further, as shown in FIG. 19, a concave step 140 is formed in advance on one prepreg sheet 41, and the prepreg sheet 41 having the step 140, another prepreg sheet 41 having a plate shape, and the plate-like body 100 are desired. It is also possible to dispose the foamed resin by foaming the foamed resin by heating in this state. According to this example, even if it is a thin semi-cured main body part 20 having a thickness of 1 mm or less, it is possible to form the semi-cured main body part 20 having a desired step that can be used for, for example, a battery housing part. Moreover, even if it is the thin semi-hardened main-body part 20 of 1 mm or less, the level | step difference whose thickness change rate is 50% or more can be formed. Therefore, it is possible to realize the fiber reinforced resin structure 1 having various shapes with lightness and strength.

It should be noted that the thickness of the semi-cured main body 20 and the shape of the steps of the semi-cured main body 20 adjusted in the above example are not limited to the above examples. Moreover, the structure and manufacturing process of the fiber reinforced resin structure 1 not specifically mentioned in the second embodiment are the same as those in the first embodiment, for example.

(Third embodiment)
In the second embodiment, the semi-cured additional structure and the semi-cured main body are bonded by heating and curing. However, the semi-cured additional structural part is cured in advance, and the cured additional structural part is cured. The semi-cured main body portion may be heated to cure the semi-cured main body portion. In such a case, for example, as shown in FIG. 20, the groove 61 of the mold 60 formed corresponding to the shape of the additional structure portion 11 is filled with the thermosetting resin, and the thermosetting resin is cured by heating to add the additional structure. Part 11 is formed. Moreover, the semi-hardened main-body part 20 in which the thermosetting resin of the fiber reinforced resin is semi-cured is formed. This semi-cured main body 20 forms a plate-like body 100 containing a foamed resin as in the second embodiment, for example, and both surfaces thereof are prepreg sheets 41 of a fiber reinforced resin containing a thermosetting resin. It is formed by pinching. The semi-cured main body 20 forms a plate-like body 40 by combining prepreg pieces of a plurality of types of fiber reinforced resin as in the first embodiment, and both surfaces of the semi-cured main body 20 are fibers containing a thermosetting resin. It can also be formed by being sandwiched between prepreg sheets 41 of reinforced resin. Thereafter, the semi-cured main body portion 20 is placed on the placing table 90 of the joining device 80, for example.

Next, the additional structure portion 11 of the groove 61 of the mold 60 and the semi-cured main body portion 20 are pressed and heated, the thermosetting resin of the prepreg sheet 41 of the semi-cured main body portion 20 is cured, and the additional structure portion 11. And the main body 10 are bonded together. At this time, the thickness of the main body 10 may be adjusted by adjusting the distance between the mold 60 and the mounting table 90. Thereafter, the mold 60 is removed from the additional structure portion 11, and the fiber reinforced resin structure 1 is obtained.

In the above example, as shown in FIG. 21, a three-layer structure comprising an unfoamed foamed resin sheet 101 and two prepreg sheets 41 on both sides thereof is placed on a mounting table 90, and the three-layer structure is You may make it adhere | attach the main-body part 10 and the additional structure part 11 which consist of a three-layer structure by making foaming resin foam by heating. In this case, for example, the interval between the mold 60 and the mounting table 90 is adjusted to a desired interval (an interval according to the final thickness of the main body 10), and in this state, the foamed resin is foamed by heating. By doing so, the foamed resin sheet 101 expands and expands, the upper prepreg sheet 41 comes into contact with the additional structure portion 11, and the thermosetting resin of the prepreg sheet 41 is cured, so that the main body portion 10 and the additional structure are formed. The part 11 adheres.

(Fourth embodiment)
In the third embodiment, the three-layer structure main body 10 is integrally formed. However, the three-layer structure of the main body 10 is separated, and the additional structure 11 and the first prepreg sheet 41a are bonded in advance. May be. In such a case, for example, as shown in FIG. 22, the groove 61 of the mold 60 formed corresponding to the shape of the additional structure portion 11 is filled with the thermosetting resin, and the thermosetting resin is cured by heating to add the additional structure. Part 11 is formed. Next, the 1st prepreg sheet 41a of the fiber reinforced resin containing a thermosetting resin is made to contact the additional structure part 11, it heats in that state, and the thermosetting resin of the 1st prepreg sheet 41a is hardened. The first prepreg sheet 41 a adheres to the additional structure portion 11. On the other hand, the mounting table in a state where the second prepreg sheet 41b of fiber reinforced resin containing a thermosetting resin and the foamed resin sheet 101 containing an unfoamed foamed resin are overlapped and bonded (two-layer structure) 90. Next, the foamed resin of the foamed resin sheet 101 is foamed by heating to form the plate-like body 100. At this time, for example, the interval between the mold 60 and the mounting table 90 is adjusted to a desired interval (an interval according to the final thickness of the main body portion 10), and the plate-like body 100 expands and the upper first prepreg Bonded to the sheet 41a. In this way, the main body portion 10 and the additional structure portion 11 composed of the plate-like body 100 and the first prepreg sheet 41a and the second prepreg sheet 41b adhered to both surfaces thereof are bonded. Finally, the mold 60 is removed from the additional structure portion 11, and the fiber reinforced resin structure 1 is obtained.

The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the idea described in the claims, and these naturally belong to the technical scope of the present invention. It is understood.

For example, in the above embodiment, the main body portion 10 is composed of two types of fiber reinforced resins. However, the present invention is not limited to two types, and the present invention is also applicable to a case where the main body portion 10 is composed of one type or three or more types of fiber reinforced resins. Is applicable. Also, the type of fiber reinforced resin is not limited to CFRP and GFRP, and other fiber reinforced resins using organic and inorganic fibers such as quartz, polyester, boron, aramid, kevlar, polyethylene, xylon, and polyimide may be used. Good.

In the above-described embodiment, the semi-cured main body 20 is press-molded into a desired shape in the step of bonding the additional structure 11 and the main body 10. It may be performed before or after the step of adhering.

In the process of forming the semi-cured main body 20 described above, the plate-like body 40 is formed by combining the prepreg pieces 30 and 31 of two types of fiber reinforced resin, and both sides thereof are sandwiched between the prepreg sheets 41. You may make it form the semi-hardened main-body part 20 of the state in which the thermosetting resin of fiber reinforced resin is semi-hardened by the method. If semi-curing is not necessary, semi-curing may not be performed.

Moreover, although the same resin was used for the thermosetting resin contained in the fiber reinforced resin of the main body portion 10 and the thermosetting resin of the additional structure portion 11, different resins are used as long as they are thermosetting resins. May be. Moreover, the kind of thermosetting resin of the main-body part 10 and the additional structure part 11 is not specifically limited, A phenol resin, a urea resin, a melamine resin, an unsaturated polyester resin, a silicon resin, a polyurethane resin, You may use resin, such as a hysumerimito resin.

In the above embodiment, the step of filling the groove 61 of the mold 60 with the liquid thermosetting resin is performed by discharging the thermosetting resin from the nozzle 71 to the groove 61 of the mold 60. This method may be used. For example, methods such as vacuum casting, resin injection, RTM, and VaRTM may be used.

In the above embodiment, the step of adhering the additional structure portion 11 and the main body portion 10 is performed using press molding in which the semi-cured additional structure portion 50 of the mold 60 is pressed against the semi-cured main body portion 20 and pressed. However, the case where adhesion is performed by a method other than press molding is also included in the present invention. For example, the present invention includes a case of using a general autoclave molding or vacuum bag molding in which the semi-cured additional structure portion 50 and the semi-cured main body portion 20 of the mold 60 are evacuated and pressed in a vacuum bag.

Furthermore, in the present invention, the step of forming the semi-cured main body 20 in which the thermosetting resin of the fiber reinforced resin is semi-cured, the semi-cured additional structure 50 and the semi-cured main body 20 of the groove 61 of the mold 60. Are heated in contact with each other and the thermosetting resin of the semi-cured additional structure portion 50 and the semi-cured main body portion 20 is cured to bond the additional structure portion 11 and the main body portion 10 together. The case of using RTM molding, VaRTM molding, or the like is also included. That is, in the RTM molding, a semi-cured additional structure portion 50 of the mold 60 is overlapped with a reinforcing fiber (no resin) and a thermosetting resin is poured into the reinforcing fiber under pressure, so that the semi-cured semi-cured state is obtained. At the same time as forming the cured main body portion 20, the semi-cured additional structure portion 50 and the semi-cured main body portion 20 of the mold 60 are pressed against each other to bond the additional structure portion 11 and the main body portion 10. Also, in VaRTM molding, a semi-cured semi-cured state is obtained by stacking reinforcing fibers (no resin) on the semi-cured additional structure portion 50 of the mold 60 and vacuum-flowing thermosetting resin into the reinforcing fibers. At the same time as forming the main body 20, the semi-cured additional structure 50 and the semi-cured main body 20 of the mold 60 are pressed against each other to bond the additional structure 11 and the main body 10 together.

Moreover, in the example using the above RTM molding and VaRTM molding, when forming the semi-cured main body portion 20 made of two types of fiber reinforced resins, for example, two types of fiber reinforced resins of CFRP and GFRP, for example, CFRP and GFRP Each of the dry cloths (reinforced fibers not impregnated with resin) is cut into arbitrary shapes, the dry cloth pieces are combined with each other on the same plane to form a flat surface, and both surfaces thereof are sandwiched between different flat dry cloths. Then, the semi-cured additional structure 50 of the mold 60 is placed on the dry cloth having three layers, and the thermosetting resin is poured into the dry cloth while applying pressure or vacuum suction.

In the said embodiment, although the example used for the housing | casing of electronic devices, such as a computer and a mobile phone, was shown as the fiber reinforced resin structure 1, this invention is all kinds of fibers, such as a car, daily necessities, household appliances, and industrial equipment. Applicable to reinforced resin structures. The main body portion 10 is not limited to a tray shape, and the additional structure portion 11 is not limited to a rib or boss projection.

The manufacturing system of the fiber reinforced resin structure is not limited to the configuration of the above embodiment.

For reference, a three-layer structure having a plate-like body having a thermosetting resin containing a foamed resin and a sheet of fiber reinforced resin containing a thermosetting resin provided on both surfaces of the plate-like body. The fiber reinforced resin structure can be proposed. According to such a technique, a fiber-reinforced resin structure having a very thin and light strength can be realized. The fiber reinforced resin structure may have a step. The fiber reinforced resin structure may have a thickness of 1 mm or less.

The present invention improves the adhesive strength between the main body portion having the fiber reinforced resin in the fiber reinforced resin structure and the additional structure portion added to the main body portion, and is also deformed or distorted by heat shrinkage as in conventional insert molding. It is useful in reducing the occurrence of

DESCRIPTION OF SYMBOLS 1 Fiber reinforced resin structure 10 Main body part 11 Additional structure part 20 Semi-hardened main body part 30, 31 Prepreg piece 40 Plate body 41 Prepreg sheet 50 Semi-hardened additional structure part 60 Mold 61 Groove 71 Nozzle B Thermosetting resin

Claims (26)

1. A method for producing a fiber reinforced resin structure having a main body part having a fiber reinforced resin containing a thermosetting resin and an additional structure part formed on the surface of the main body part,
   Filling the groove of the mold formed corresponding to the shape of the additional structure portion with a thermosetting resin, and forming the semi-cured additional structure portion in which the thermosetting resin is in a semi-cured state;
   A step of forming a semi-cured main body portion in which the thermosetting resin of the fiber reinforced resin is in a semi-cured state;
   The semi-cured additional structure portion of the mold groove and the semi-cured main body portion are pressed and heated, and the thermosetting resin of the semi-cured additional structure portion and the semi-cured main body portion is cured to provide an additional structure. Bonding the part and the body part;
   And a step of detaching the mold from the additional structure portion.
2. The method for producing a fiber-reinforced resin structure according to claim 1, wherein the step of filling the mold groove with the thermosetting resin is performed by discharging the thermosetting resin from a nozzle into the mold groove.
3. In the step of forming the semi-cured main body, a plate-like body is formed by combining prepreg pieces of a plurality of types of fiber reinforced resin, and both surfaces thereof are sandwiched between prepreg sheets of a fiber reinforced resin containing a thermosetting resin. The manufacturing method of the fiber reinforced resin structure of Claim 1 or 2 performed by.
4. The step of forming the semi-cured main body portion forms a plate-like body by inserting the prepreg piece of the second type of fiber reinforced resin into the opening of the prepreg piece of the first type of fiber reinforced resin. The manufacturing method of the fiber reinforced resin structure of Claim 3.
5. The first type of fiber reinforced resin is CFRP;
   The method for producing a fiber-reinforced resin structure according to claim 4, wherein the second type of fiber-reinforced resin is a fiber-reinforced resin made of a dielectric.
6. The step of forming the semi-cured main body is performed by forming a plate-like body containing a foamed resin and sandwiching both sides thereof with a prepreg sheet of a fiber reinforced resin containing a thermosetting resin. 2. A method for producing a fiber-reinforced resin structure according to 2.
7. The method for producing a fiber-reinforced resin structure according to claim 6, wherein the foamed resin of the plate-like body is foamed after being sandwiched between the prepreg sheets.
8. The method for producing a fiber-reinforced resin structure according to claim 6, wherein the foamed resin of the plate-like body is foamed before being sandwiched between the prepreg sheets.
9. The method for producing a fiber-reinforced resin structure according to any one of claims 6 to 8, further comprising a step of forming a step in the semi-cured main body.
10. The method for producing a fiber-reinforced resin structure according to any one of claims 6 to 9, further comprising a step of adjusting a thickness of the semi-cured main body.
11. The method for producing a fiber-reinforced resin structure according to claim 10, wherein the thickness of the semi-cured main body is adjusted to 1 mm or less.
12. The method for producing a fiber-reinforced resin structure according to any one of claims 6 to 11, wherein the plate-like body contains a thermosetting resin.
13. The method for producing a fiber-reinforced resin structure according to any one of claims 1 to 12, wherein in the step of bonding the additional structure portion and the main body portion, the semi-cured main body portion is press-molded into a desired shape.
14. The step of adhering the additional structure portion and the main body portion is performed using press molding in which the semi-cured additional structure portion of the mold is pressed against the semi-cured main body portion and pressed. A method for producing a fiber-reinforced resin structure according to claim 1.
15. The step of adhering the additional structure portion and the main body portion is performed using autoclave molding or vacuum back molding in which the semi-cured additional structure portion and the semi-cured main body portion of the mold are evacuated and pressed. Item 13. A method for producing a fiber-reinforced resin structure according to any one of Items 1 to 12.
16. The process of forming the said semi-hardened main-body part, the process of adhere | attaching the said additional structure part and the said main-body part are performed using RTM shaping | molding or VaRTM shaping | molding, The manufacture of the fiber reinforced resin structure of Claim 1 or 2 Method.
17. A method for producing a fiber reinforced resin structure having a main body part having a fiber reinforced resin containing a thermosetting resin and an additional structure part formed on the surface of the main body part,
    Filling the mold groove formed corresponding to the shape of the additional structure portion with a thermosetting resin, and curing the thermosetting resin to form the additional structure portion;
    A step of forming a semi-cured main body portion in which the thermosetting resin of the fiber reinforced resin is in a semi-cured state;
    The additional structure portion of the groove of the mold and the semi-cured main body portion are pressed and heated, the thermosetting resin of the semi-cured main body portion is cured, and the additional structure portion and the main body portion are bonded together; ,
    And a step of detaching the mold from the additional structure portion.
18. A method for producing a fiber reinforced resin structure having a main body part having a fiber reinforced resin containing a thermosetting resin and an additional structure part formed on the surface of the main body part,
    Filling the mold groove formed corresponding to the shape of the additional structure portion with a thermosetting resin, and curing the thermosetting resin to form the additional structure portion;
    The first prepreg sheet of fiber reinforced resin containing a thermosetting resin is heated in contact with the additional structure portion, the thermosetting resin of the first prepreg sheet is cured, and the first prepreg sheet is cured. Adhering a prepreg sheet to the additional structure,
    A step of stacking and adhering a second prepreg sheet of fiber reinforced resin containing a thermosetting resin and a sheet containing an unfoamed foam resin;
    While the foamed resin of the sheet is foamed by heating to form a plate-like body, the plate-like body is adhered to the first prepreg sheet, and the first prepreg adhered to the plate-like body and both surfaces thereof. A step of bonding the main body portion made of a sheet and a second prepreg sheet and the additional structure portion; and
    And a step of detaching the mold from the additional structure portion.
19. A system for manufacturing a fiber reinforced resin structure having a main body part having a fiber reinforced resin containing a thermosetting resin and an additional structure part formed on the surface of the main body part,
    Filling the mold groove corresponding to the shape of the additional structure part with a thermosetting resin to form a semi-cured additional structure part in which the thermosetting resin is semi-cured, and thermosetting the fiber reinforced resin Forming a semi-cured main body portion in a semi-cured state, and pressing the semi-cured additional structure portion and the semi-cured main body portion of the groove of the mold to heat the semi-cured additional structure portion and the semi-cured additional structure portion; A system for manufacturing a fiber reinforced resin structure, wherein a thermosetting resin of a cured main body portion is cured to bond the additional structure portion and the main body portion, and the mold is detached from the additional structure portion.
20. A fiber reinforced resin structure,
    A main body made of a fiber reinforced resin containing a thermosetting resin;
    An additional structure made of a thermosetting resin provided on the surface of the main body,
    The main body includes a plate-like body in which a plurality of types of fiber-reinforced resin pieces are combined, and a fiber-reinforced resin sheet containing a thermosetting resin provided on both surfaces of the plate-like body. Structure.
21. 21. The fiber reinforced fiber according to claim 20, wherein the plate-like body includes a first type of fiber reinforced resin piece having an opening and a second type of fiber reinforced resin piece arranged in the opening. Resin structure.
22. The first type of fiber reinforced resin piece is CFRP;
    The fiber-reinforced resin structure according to claim 21, wherein the second type of fiber-reinforced resin piece is a fiber-reinforced resin made of a dielectric.
23. A fiber reinforced resin structure,
    A main body having a fiber reinforced resin containing a thermosetting resin;
    An additional structure made of a thermosetting resin provided on the surface of the main body,
    The said main-body part is a fiber reinforced resin structure which has the plate-shaped body containing a foamed resin, and the sheet | seat of the fiber reinforced resin containing the thermosetting resin provided in both surfaces of the said plate-shaped body.
24. The fiber-reinforced resin structure according to claim 23, wherein the plate-like body contains a thermoplastic resin.
25. The fiber-reinforced resin structure according to claim 23 or 24, wherein the main body has a step.
26. The fiber-reinforced resin structure according to any one of claims 23 to 25, wherein the main body has a thickness of 1 mm or less.

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