JP2012071591A - Fiber reinforcement molding, and manufacturing method of the same - Google Patents

Fiber reinforcement molding, and manufacturing method of the same Download PDF

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JP2012071591A
JP2012071591A JP2011185590A JP2011185590A JP2012071591A JP 2012071591 A JP2012071591 A JP 2012071591A JP 2011185590 A JP2011185590 A JP 2011185590A JP 2011185590 A JP2011185590 A JP 2011185590A JP 2012071591 A JP2012071591 A JP 2012071591A
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thermosetting resin
impregnated
resin foam
carbon fiber
porous sheet
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JP5743271B2 (en
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Yosuke Kasuga
陽介 春日
Masumi Koide
益巳 小出
Yoshinori Sugiura
好典 杉浦
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Inoac Corp
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Inoue MTP KK
Inoac Corp
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Abstract

PROBLEM TO BE SOLVED: To provide a light weight, thin-wall and highly rigid fiber reinforced molding which is also favorable in appearance and has no anxiety of the exfoliation of a coating film when painted.SOLUTION: The molding is composed of a core material 11, fiber reinforcements 21 laminated on both surfaces of the core material 11 and a surface material 25 laminated on at least one side of the fiber reinforcements 21 on the core material 11 which are integrated by curing a thermosetting resin. The core material 11 is formed by curing the thermosetting resin in a state that the thermosetting resin is impregnated in an open cell thermosetting resin foam having continue air bubbles, and a compression ratio of the core material is 200-5,000%. The fiber reinforcement 21 is formed of a reinforcement in which the thermosetting resin is impregnated into a carbon fiber and cured, and a resin ratio of the thermosetting resin after the impregnation is 50-80%. The surface material 25 is formed of a material in which the thermosetting resin is adhered to the surface of a porous sheet and cured. The core material 11, the fiber reinforcements 21 and the surface material 25 are integrated by curing the thermosetting resin.

Description

本発明は、芯材と該芯材の両面に積層された繊維補強材と少なくとも一側の繊維補強材に積層された表面材とからなる繊維強化成形体とその製造方法に関する。   The present invention relates to a fiber reinforced molded article comprising a core material, a fiber reinforcing material laminated on both surfaces of the core material, and a surface material laminated on at least one side of the fiber reinforcing material, and a method for producing the same.

近年、ノートパソコンの筐体として、軽量、薄肉、高剛性の部材が要求されている。軽量、薄肉、高剛性を目的として形成された成形体として、例えば炭素繊維プリプレグを積層して反応硬化させることにより得られる炭素繊維強化体がある。   In recent years, a lightweight, thin, and highly rigid member is required as a casing of a notebook computer. As a molded body formed for the purpose of light weight, thin wall, and high rigidity, for example, there is a carbon fiber reinforced body obtained by laminating carbon fiber prepregs and performing reaction curing.

特許文献１には、炭素繊維の連続繊維を一方向にシート状に配列した繊維強化層の複数層を、特定の配列方向で積層した繊維強化成形品が開示されている。しかし、繊維強化層を構成する炭素繊維が非常に高価なものであるため、繊維強化層の積層数が増えれば増えるほど、繊維強化成形品のコストアップにつながる問題がある。さらに、繊維強化成形品は比重が１．６程度あり、筐体等を構成する部品の軽量化という点では十分ではなかった。   Patent Document 1 discloses a fiber reinforced molded product in which a plurality of fiber reinforced layers in which continuous fibers of carbon fibers are arranged in a sheet shape in one direction are laminated in a specific arrangement direction. However, since the carbon fibers constituting the fiber reinforced layer are very expensive, there is a problem that as the number of laminated fiber reinforced layers increases, the cost of the fiber reinforced molded product increases. Furthermore, the fiber reinforced molded product has a specific gravity of about 1.6, which is not sufficient in terms of reducing the weight of the parts constituting the housing.

特許文献２には、空隙を有する芯材と、該芯材の両面に配置された、連続した炭素繊維とマトリックス樹脂からなる繊維強化材とからなるサンドイッチ構造体が開示されている。しかし、ノートパソコンのような携帯機器の筐体部材として要求される薄肉、高剛性という点では十分ではなかった。   Patent Document 2 discloses a sandwich structure made of a core material having a gap and a fiber reinforcing material made of continuous carbon fibers and a matrix resin disposed on both sides of the core material. However, it was not sufficient in terms of the thin wall and high rigidity required as a casing member for portable devices such as notebook computers.

特許文献３には、少なくとも炭素繊維を含む連続繊維強化織物を軟質部材層の両面に配置したシートを射出成形金型に内にセットし、前記シートの側部に樹脂部品を射出成形した複合成形品が開示されている。しかし、高剛性という点では十分ではなかった。   Patent Document 3 discloses a composite molding in which a continuous fiber reinforced fabric containing at least carbon fibers is placed on both sides of a soft member layer, a sheet is set in an injection mold, and a resin part is injection molded on the side of the sheet. The product is disclosed. However, it was not sufficient in terms of high rigidity.

薄肉で高剛性に優れる繊維強化成形体をより安価に得るためには、高価な炭素繊維の使用量を減らす必要がある。
そのためには、
ａ．圧縮強度と曲げ強度が強く、薄い芯材、
ｂ．その両面に引張強度が強い補強材、
ｃ．芯材と補強材との強固な接着、
を満たすようなサンドイッチ構造が必要となる。特に、繊維強化成形体を曲げたときに最も応力が集中するのは、芯材と補強材の界面であって、この界面の接着強度の強弱が、曲げ弾性率の大小を決定する。 In order to obtain a fiber-reinforced molded article that is thin and excellent in rigidity at a lower cost, it is necessary to reduce the amount of expensive carbon fiber used.
for that purpose,
a. Thin core material with strong compressive strength and bending strength,
b. Reinforcing material with strong tensile strength on both sides,
c. Strong adhesion between the core material and the reinforcing material,
A sandwich structure that satisfies this requirement is required. In particular, when the fiber reinforced molded body is bent, the stress is most concentrated at the interface between the core material and the reinforcing material. The strength of the adhesive strength at this interface determines the magnitude of the bending elastic modulus.

そこで、本出願人は、図９に示すように、芯材１１０と、前記芯材１１０の両面に積層された繊維補強材２１０とからなる繊維強化成形体１００として、前記芯材１１０を、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂を含浸し前記熱硬化性樹脂発泡体を所定の圧縮率で圧縮して前記熱硬化性樹脂を硬化させたもので構成し、一方、前記繊維補強材２１０を、炭素繊維織物に熱硬化性樹脂を含浸して硬化させたもので構成し、前記芯材１１０と前記繊維補強材２１０を、前記熱硬化性樹脂発泡体に含浸した熱硬化性樹脂と前記炭素繊維織物に含浸した熱硬化性樹脂の硬化により一体化させたものを作成した。そして、その繊維強化成形体１００において、前記熱硬化性樹脂発泡体の圧縮率を特定の範囲とし、かつ前記炭素繊維織物に含浸させた熱硬化性樹脂を特定の樹脂比率となるようにすることで、ノートパソコン等の携帯機器の筐体などに好適な軽量、薄肉、高剛性に優れるものになることを出願人は見出し、特願２００９−２４８５０６号として出願した。   Therefore, as shown in FIG. 9, the present applicant continuously uses the core material 110 as a fiber reinforced molded body 100 including a core material 110 and a fiber reinforcing material 210 laminated on both surfaces of the core material 110. A thermosetting resin foam having bubbles is impregnated with a thermosetting resin, and the thermosetting resin foam is compressed at a predetermined compression rate to cure the thermosetting resin. The fiber reinforcing material 210 is composed of a carbon fiber fabric impregnated with a thermosetting resin and cured, and the core material 110 and the fiber reinforcing material 210 are impregnated in the thermosetting resin foam. The resin was integrated with the thermosetting resin impregnated with the carbon fiber fabric. In the fiber reinforced molded body 100, the compression ratio of the thermosetting resin foam is set to a specific range, and the thermosetting resin impregnated in the carbon fiber fabric is set to a specific resin ratio. The applicant found out that it would be excellent in lightweight, thin wall and high rigidity suitable for a casing of a portable device such as a notebook personal computer, and filed as Japanese Patent Application No. 2009-248506.

しかし、前記の軽量、薄肉、高剛性に優れる繊維強化成形体１００は、その表面が炭素繊維織物からなるため、図１０に示すように、炭素繊維織物において繊維が重なり合う部分２１５と、織り目の隙間２１６の部分との間で段差を生じ、外観塗装を施しても前記段差を解消することができず、表面平滑性を得ることが難しいことが判明した。符号２２１は横繊維、２２２は縦繊維である。また、外観塗装を施した場合に前記段差部分にエアが残って塗膜表面にピンホールを生じる場合があることも判明した。特に、ノートパソコンなどの筐体は、美観の向上等の点から外観塗装されることが一般的であるため、外観塗装を施した場合の外観状態は重要であった。さらに、一般的に炭素繊維などの無機物と、ウレタン塗料やＵＶ塗料との相性（密着性）が良くなく、塗膜が剥がれるおそれもある。   However, since the surface of the fiber reinforced molded body 100 that is excellent in light weight, thin wall, and high rigidity is made of a carbon fiber woven fabric, as shown in FIG. It was found that a step was formed between the portion 216 and the step could not be eliminated even if the appearance was applied, and it was difficult to obtain surface smoothness. Reference numeral 221 denotes a transverse fiber, and 222 denotes a longitudinal fiber. Further, it has also been found that when appearance coating is applied, air remains in the stepped portion and pinholes may be formed on the surface of the coating film. In particular, since a case such as a notebook computer is generally externally painted from the standpoint of improving aesthetics, the external appearance when the external appearance is applied has been important. Furthermore, in general, the compatibility (adhesiveness) between an inorganic material such as carbon fiber and a urethane paint or UV paint is not good, and the coating film may be peeled off.

また、前記特許文献３においても、表面が炭素繊維を含む連続繊維強化織物で構成された場合、外観塗装を施しても表面の段差を解消することができず、また塗膜表面にピンホールを生じる問題がある。   Also in Patent Document 3, when the surface is composed of a continuous fiber reinforced fabric containing carbon fibers, the surface level difference cannot be eliminated even if the appearance is applied, and a pinhole is formed on the surface of the coating film. There are problems that arise.

特開２００４−２０９７１７号公報JP 2004-209717 A ＷＯ２００６／０２８１０７号公報WO2006 / 028107 特開２００７−０３８５１９号公報JP 2007-038519 A

本発明は前記の点に鑑みなされたものであって、ノートパソコン等の携帯機器の筐体などに好適な軽量、薄肉、高剛性を有し、かつ塗装した場合の外観が良好で塗膜が剥がれるおそれのない繊維強化成形体及びその製造方法の提供を目的とする。   The present invention has been made in view of the above points, and has a lightweight, thin wall and high rigidity suitable for a casing of a portable device such as a notebook personal computer, and has a good appearance when coated and has a coating film. An object of the present invention is to provide a fiber-reinforced molded article that does not peel off and a method for producing the same.

請求項１の発明は、芯材と、前記芯材の両面に積層された繊維補強材とを有する繊維強化成形体において、前記芯材の少なくとも一側の面の前記繊維補強材の表面には表面材を積層し、前記芯材は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸して前記熱硬化性樹脂発泡体を圧縮した状態で前記熱硬化性樹脂が硬化したものであって、以下の式（Ａ１）で規定される圧縮率Ｃが２００〜５０００％の範囲のものからなり、前記繊維補強材は、炭素繊維織物に熱硬化性樹脂が含浸して硬化したものからなり、前記表面材は、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着して硬化したものからなり、前記芯材と前記繊維補強材と前記表面材が、前記熱硬化性樹脂発泡体に含浸した前記熱硬化性樹脂と前記炭素繊維織物に含浸した前記熱硬化性樹脂と前記多孔性シートに含浸した前記熱硬化性樹脂の硬化により一体化され、前記熱硬化性樹脂発泡体と前記炭素繊維織物と前記多孔性シートに含浸した熱硬化性樹脂は、以下の式（Ｂ１）で規定される樹脂比率Ｒが５０〜８０％の範囲にあり、繊維強化成形体の曲げ弾性率が３０ＧＰａ以上であることを特徴とする繊維強化成形体に係る。   The invention according to claim 1 is a fiber reinforced molded article having a core material and a fiber reinforcing material laminated on both surfaces of the core material, the surface of the fiber reinforcing material on at least one side of the core material. A surface material is laminated, and the core material is cured in a state where the thermosetting resin foam is impregnated with a thermosetting resin foam having open cells and the thermosetting resin foam is compressed. The compression ratio C defined by the following formula (A1) is in the range of 200 to 5000%, and the fiber reinforcement is cured by impregnating a carbon fiber fabric with a thermosetting resin. The surface material comprises a porous sheet impregnated with a thermosetting resin, and the thermosetting resin adheres to the surface of the porous sheet and is cured, and the core material and the fiber reinforcing material And the surface material impregnated in the thermosetting resin foam And the thermosetting resin impregnated in the carbon fiber fabric and the thermosetting resin impregnated in the porous sheet are integrated by curing, the thermosetting resin foam, the carbon fiber fabric, and the The thermosetting resin impregnated in the porous sheet has a resin ratio R defined by the following formula (B1) in the range of 50 to 80%, and the flexural modulus of the fiber-reinforced molded body is 30 GPa or more. According to the featured fiber-reinforced molded article.

Figure 2012071591
Figure 2012071591
Figure 2012071591
Figure 2012071591

請求項２の発明は、請求項１の発明において、前記多孔性シートが、セル膜を除去したウレタン樹脂発泡体からなることを特徴とする。   The invention of claim 2 is characterized in that, in the invention of claim 1, the porous sheet is made of a urethane resin foam from which the cell membrane has been removed.

請求項３の発明は、請求項１又は２の発明において、前記式（Ａ１）で規定される圧縮率Ｃが１０００〜２６００％であることを特徴とする。   The invention of claim 3 is characterized in that, in the invention of claim 1 or 2, the compression ratio C defined by the formula (A1) is 1000 to 2600%.

請求項４の発明は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着した状態で硬化した表面材とよりなって、前記芯材の両面に前記繊維補強材が積層され、前記芯材の少なくとも一側の面の前記繊維補強材の表面に前記表面材が積層されている繊維強化成形体の製造方法であって、炭素繊維織物に熱硬化性樹脂を含浸させて含浸済み炭素繊維織物を得る含浸工程と、連続気泡を有する熱硬化性樹脂発泡体の両面に、前記含浸済み炭素繊維織物を配置し、前記連続気泡を有する熱硬化性樹脂発泡体の少なくとも一側の面の前記含浸済み炭素繊維織物の表面に前記多孔性シートを配置して積層体を得る積層工程と、前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、前記含浸工程における含浸は、以下の式（Ｂ２）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、前記圧縮加熱工程における圧縮は、以下の式（Ａ２）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、前記圧縮加熱工程により、前記炭素繊維織物に含浸している熱硬化性樹脂を押し出して前記熱硬化性樹脂発泡体に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂を硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする。   According to a fourth aspect of the present invention, there is provided a core material obtained by impregnating a thermosetting resin foam having open cells with a thermosetting resin and curing the thermosetting resin in a state where the thermosetting resin foam is compressed. A fiber reinforcing material in which a carbon fiber fabric is impregnated and cured with a thermosetting resin; and a surface material in which the porous sheet is impregnated with the thermosetting resin and the thermosetting resin is adhered to the surface of the porous sheet. The fiber reinforcing material is laminated on both surfaces of the core material, and the surface of the fiber reinforcing material on the surface of at least one side of the core material is laminated. A method of impregnating a carbon fiber fabric with a thermosetting resin to obtain an impregnated carbon fiber fabric, and disposing the impregnated carbon fiber fabric on both surfaces of a thermosetting resin foam having open cells. And thermosetting resin foam having the open cells A step of laminating the porous sheet on the surface of the impregnated carbon fiber fabric on at least one side of the laminate to obtain a laminate, and a compression heating step of compressing and heating the laminate, the impregnation step The impregnation is performed so that the resin ratio R defined by the following formula (B2) is in the range of 50 to 80%, and the compression in the compression heating step is a compression ratio defined by the following formula (A2). C is compressed to 200 to 5000%, and the thermosetting resin impregnated in the carbon fiber fabric is extruded and impregnated in the thermosetting resin foam by the compression heating step, and the porous sheet The core material, the fiber reinforcing material, and the surface material are formed by impregnating the thermosetting resin to cure the thermosetting resin, and the core material, the fiber reinforcing material, and the surface material are integrated. When That.

Figure 2012071591
Figure 2012071591
Figure 2012071591
Figure 2012071591

請求項５の発明は、請求項４の発明において、前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程を、前記含浸工程と平行して、または前記含浸工程後に行い、前記積層工程において、前記含浸済み炭素繊維織物と前記多孔性シートの積層に代えて、前記プリプレグを前記含浸済み炭素繊維織物側が前記連続気泡を有する熱硬化性樹脂発泡体に接するように積層することを特徴とする。   According to a fifth aspect of the present invention, in the fourth aspect of the invention, a prepreg production step for producing a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated is performed in parallel with the impregnation step or the impregnation step. In the laminating step, instead of laminating the impregnated carbon fiber fabric and the porous sheet, the impregnated carbon fiber fabric side is in contact with the thermosetting resin foam having the open cells on the impregnated carbon fiber fabric side. It is characterized by being laminated on.

請求項６の発明は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着した状態で硬化した表面材とよりなって、前記芯材の両面に前記繊維補強材が積層され、前記芯材の少なくとも一側の面の前記繊維補強材の表面に前記表面材が積層されている繊維強化成形体の製造方法であって、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂を含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程と、前記含浸済み熱硬化性樹脂発泡体の両面に炭素繊維織物を配置し、前記含浸済み熱硬化性樹脂発泡体の少なくとも一側の面の前記炭素繊維織物の表面に前記多孔性シートを配置して積層体を得る積層工程と、前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、前記含浸工程における含浸は、以下の式（Ｂ３）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、前記圧縮加熱工程における圧縮は、以下の式（Ａ３）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、前記圧縮加熱工程により、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂を押し出して前記炭素繊維織物に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂を硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする。   According to a sixth aspect of the present invention, there is provided a core material obtained by impregnating a thermosetting resin foam having open cells with a thermosetting resin and curing the thermosetting resin in a state where the thermosetting resin foam is compressed. A fiber reinforcing material in which a carbon fiber fabric is impregnated and cured with a thermosetting resin; and a surface material in which the porous sheet is impregnated with the thermosetting resin and the thermosetting resin is adhered to the surface of the porous sheet. The fiber reinforcing material is laminated on both surfaces of the core material, and the surface of the fiber reinforcing material on the surface of at least one side of the core material is laminated. An impregnation step of impregnating a thermosetting resin foam having open cells with a thermosetting resin to obtain an impregnated thermosetting resin foam, and both sides of the impregnated thermosetting resin foam Place the carbon fiber fabric and make the impregnated thermosetting resin A laminating step of obtaining the laminate by disposing the porous sheet on the surface of the carbon fiber fabric on at least one side of the body, and a compression heating step of compressing and heating the laminate, The impregnation is performed such that the resin ratio R defined by the following formula (B3) is in the range of 50 to 80%, and the compression in the compression heating step is a compression rate C defined by the following formula (A3). Is compressed to 200 to 5000%, and the thermosetting resin impregnated in the thermosetting resin foam is extruded and impregnated in the carbon fiber fabric by the compression heating step, and the porous sheet is impregnated. Impregnation and curing reaction of the thermosetting resin to form the core material, the fiber reinforcing material, and the surface material, and integrating the core material, the fiber reinforcing material, and the surface material. To do.

Figure 2012071591
Figure 2012071591
Figure 2012071591
Figure 2012071591

請求項７の発明は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ前記多孔性シート表面に付着した状態で硬化した表面材とよりなって、前記芯材の両面に前記繊維補強材が積層され、前記芯材の少なくとも一側の面の前記繊維補強材の表面に前記表面材が積層されている繊維強化成形体の製造方法であって、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂Ａを含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程Ａと、炭素繊維織物に熱硬化性樹脂Ｂを含浸させて含浸済み炭素繊維織物を得る含浸工程Ｂと、前記含浸済み熱硬化性樹脂発泡体の両面に前記含浸済み炭素繊維織物を配置し、前記含浸済み熱硬化性樹脂発泡体の少なくとも一側の面の前記含浸済み炭素繊維織物の表面に前記多孔性シートを配置して積層体を得る積層工程と、前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、前記含浸工程Ａ及びＢにおける含浸は、以下の式（Ｂ４）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、前記圧縮加熱工程における圧縮は、以下の式（Ａ４）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、前記圧縮加熱工程により、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂Ａと前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを接触させると共に、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを前記多孔性シートに含浸させた状態で、前記熱硬化性樹脂Ａと前記熱硬化性樹脂Ｂをそれぞれ硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする。   According to a seventh aspect of the present invention, there is provided a core material obtained by impregnating a thermosetting resin foam having open cells with a thermosetting resin and curing the thermosetting resin in a state where the thermosetting resin foam is compressed. A fiber reinforcing material impregnated and cured with a thermosetting resin in a carbon fiber fabric, and a surface material impregnated with a thermosetting resin in a porous sheet and cured in a state of adhering to the surface of the porous sheet, The fiber reinforcing material is laminated on both surfaces of the core material, and the method for producing a fiber reinforced molded body in which the surface material is laminated on the surface of the fiber reinforcing material on at least one surface of the core material, An impregnation step A in which a thermosetting resin foam having an open cell is impregnated with a thermosetting resin A to obtain an impregnated thermosetting resin foam, and a carbon fiber fabric is impregnated with a thermosetting resin B. Impregnation step B for obtaining a carbon fiber fabric, and the impregnated thermosetting The impregnated carbon fiber fabric is disposed on both sides of the porous resin foam, and the porous sheet is disposed on the surface of the impregnated carbon fiber fabric on at least one side of the impregnated thermosetting resin foam. It comprises a laminating step for obtaining a laminate and a compression heating step for compressing and heating the laminate, and the impregnation in the impregnation steps A and B has a resin ratio R defined by the following formula (B4) of 50-80. The compression in the compression heating step is performed such that the compression rate C defined by the following formula (A4) is 200 to 5000%, and the heat is applied by the compression heating step. The thermosetting resin A impregnated in the curable resin foam and the thermosetting resin B impregnated in the carbon fiber fabric are brought into contact with each other, and the thermosetting resin B impregnated in the carbon fiber fabric is used. On the porous sheet In the soaked state, the thermosetting resin A and the thermosetting resin B are cured and reacted to form the core material, the fiber reinforcing material, and the surface material, and the core material and the fiber reinforcing material. And the surface material is integrated.

Figure 2012071591
Figure 2012071591
Figure 2012071591
Figure 2012071591

請求項８の発明は、請求項７の発明において、前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程を、前記含浸工程と平行して、または前記含浸工程後に行い、前記積層工程において、前記含浸済み炭素繊維織物と前記多孔性シートの積層に代えて、前記含浸済み炭素繊維織物側が前記含浸済み熱硬化性樹脂発泡体に接するように積層することを特徴とする。   The invention of claim 8 is the invention of claim 7, wherein a prepreg production step for producing a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated is performed in parallel with the impregnation step or the impregnation step. It is carried out after the process, and in the laminating step, instead of laminating the impregnated carbon fiber woven fabric and the porous sheet, the impregnated carbon fiber woven fabric side is laminated so as to be in contact with the impregnated thermosetting resin foam. Features.

請求項９の発明は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に滲出して付着した状態で硬化した表面材とよりなって、前記芯材の両側の面にそれぞれ前記繊維補強材と前記表面材がこの順に積層されている繊維強化成形体の製造方法であって、炭素繊維織物に熱硬化性樹脂Ｂを含浸させて含浸済み炭素繊維織物を得る含浸工程Ｂと、前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程と、連続気泡を有する熱硬化性樹脂発泡体の両側の面に、それぞれ前記プリプレグを前記含浸済み炭素繊維織物が前記連続気泡を有する熱硬化性樹脂発泡体と接するように配置して積層体を得る積層工程と、前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、前記含浸工程における含浸は、以下の式（Ｂ５）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、前記圧縮加熱工程における圧縮は、以下の式（Ａ５）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、
前記圧縮加熱工程により、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを押し出して前記熱硬化性樹脂発泡体に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂Ｂを硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法に係る。 The invention according to claim 9 is a core material obtained by impregnating a thermosetting resin foam having open cells with a thermosetting resin and curing the thermosetting resin in a state where the thermosetting resin foam is compressed. , A fiber reinforcing material obtained by impregnating and curing a carbon fiber fabric with a thermosetting resin, and a porous sheet impregnated with a thermosetting resin, and the thermosetting resin exudes and adheres to the surface of the porous sheet. The fiber reinforcing material and the surface material are laminated in this order on both sides of the core material, respectively, and the method is a method for producing a fiber reinforced molded body, and is thermosetting to a carbon fiber fabric. An impregnation step B for impregnating the resin B to obtain an impregnated carbon fiber fabric, a prepreg creation step for producing a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated, and thermosetting having open cells On both sides of the resin foam Each of the prepregs is arranged so that the impregnated carbon fiber woven fabric is in contact with the thermosetting resin foam having the open cells to obtain a laminate, and a compression heating step of compressing and heating the laminate. The impregnation in the impregnation step is performed such that the resin ratio R defined by the following formula (B5) is in the range of 50 to 80%, and the compression in the compression heating step is performed by the following formula (A5) Compress so that the specified compression ratio C is 200 to 5000%,
In the compression heating process, the thermosetting resin B impregnated in the carbon fiber fabric is extruded to impregnate the thermosetting resin foam and impregnated in the porous sheet, and the thermosetting resin B is cured. The core material, the fiber reinforcing material, and the surface material are formed by reaction, and the core material, the fiber reinforcing material, and the surface material are integrated. .

Figure 2012071591
Figure 2012071591
Figure 2012071591
Figure 2012071591

請求項１０の発明は、請求項９の発明において、前記含浸工程Ｂに加えて、前記連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂Ａを含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程Ａを有し、前記積層工程において、前記連続気泡を有する熱硬化性樹脂発泡体に代えて、前記含浸済み熱硬化性樹脂発泡体の両側の面に、それぞれ前記プリプレグを配置して積層し、前記圧縮加熱工程において、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂Ａと前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを接触させると共に、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを前記多孔性シートに含浸させた状態で、前記熱硬化性樹脂Ａと前記熱硬化性樹脂Ｂをそれぞれ硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする。   The invention of claim 10 is the invention of claim 9, in addition to the impregnation step B, impregnated thermosetting resin foam by impregnating the thermosetting resin foam having the open cells with the thermosetting resin A. An impregnation step A for obtaining a body, and in the laminating step, instead of the thermosetting resin foam having the open cells, the prepregs are disposed on both sides of the impregnated thermosetting resin foam, respectively. In the compression heating step, the thermosetting resin A impregnated in the thermosetting resin foam and the thermosetting resin B impregnated in the carbon fiber fabric are brought into contact with each other, and the carbon In the state where the porous sheet is impregnated with the thermosetting resin B impregnated in the fiber fabric, the thermosetting resin A and the thermosetting resin B are cured and reacted, respectively, and the core material and the fiber reinforcement Shape the material and the surface material While, characterized by integrating the fibrous reinforcing material and the surface material and the core material.

請求項１１の発明は、連続気泡を有する熱硬化性樹脂発泡体と多孔性シートの積層体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体と前記多孔性シートが圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に滲出して付着した状態で硬化した表面材とよりなって、前記芯材の両側の面に前記繊維補強材が積層され、前記芯材の一側の前記繊維補強材の表面に前記表面材が積層された繊維強化成形体の製造方法であって、炭素繊維織物に熱硬化性樹脂Ｂを含浸させて含浸済み炭素繊維織物を得る含浸工程Ｂと、前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程と、連続気泡を有する熱硬化性樹脂発泡体の一側の面に、前記プリプレグを前記含浸済み炭素繊維織物が前記連続気泡を有する熱硬化性樹脂発泡体と接するように配置すると共に、前記連続気泡を有する熱硬化性樹脂発泡体の他側の面に、別の前記プリプレグを前記多孔性シートが前記連続気泡を有する熱硬化性樹脂発泡体と接するように配置して積層体を得る積層工程と、前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、前記含浸工程における含浸は、以下の式（Ｂ６）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、前記圧縮加熱工程における圧縮は、以下の式（Ａ６）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、前記圧縮加熱工程により、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを押し出して前記熱硬化性樹脂発泡体に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂Ｂを硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法に係る。

Figure 2012071591
Figure 2012071591
 The invention of claim 11 is a state in which a thermosetting resin is impregnated into a laminate of a thermosetting resin foam and a porous sheet having open cells, and the thermosetting resin foam and the porous sheet are compressed. The core material in which the thermosetting resin is cured, the fiber reinforcing material in which the carbon fiber fabric is impregnated and cured with the thermosetting resin, the porous sheet is impregnated with the thermosetting resin, and the thermosetting resin is the porous material. The fiber reinforcing material is laminated on both sides of the core material, and the surface of the fiber reinforcing material on one side of the core material. A method for producing a fiber-reinforced molded article in which the surface material is laminated, the carbon fiber woven fabric being impregnated with a thermosetting resin B to obtain an impregnated carbon fiber woven fabric, and the impregnated carbon fiber woven fabric, Create a prepreg laminated with the porous sheet While arranging the prepreg on the surface of one side of the prepreg forming step and the thermosetting resin foam having open cells, the impregnated carbon fiber fabric is in contact with the thermosetting resin foam having open cells. The other prepreg is disposed on the other surface of the thermosetting resin foam having open cells so that the porous sheet is in contact with the thermosetting resin foam having open cells. And a compression heating step of compressing and heating the laminate, and the impregnation in the impregnation step is such that the resin ratio R defined by the following formula (B6) is in the range of 50 to 80%. The compression in the compression heating step is performed such that the compression ratio C defined by the following formula (A6) is 200 to 5000%, and the carbon fiber fabric is impregnated by the compression heating step. The thermosetting resin B is extruded and impregnated in the thermosetting resin foam and impregnated in the porous sheet, and the thermosetting resin B is cured and reacted to cause the core material, the fiber reinforcing material, and the The present invention relates to a method for producing a fiber-reinforced molded body, wherein a surface material is formed and the core material, the fiber reinforcing material, and the surface material are integrated.
Figure 2012071591
Figure 2012071591

請求項１２の発明は、請求項１１の発明において、前記含浸工程Ｂに加えて、前記連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂Ａを含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程Ａを有し、前記積層工程において、前記連続気泡を有する熱硬化性樹脂発泡体に代えて、前記含浸済み熱硬化性樹脂発泡体の両側の面に、それぞれ前記プリプレグを配置して積層し、前記圧縮加熱工程において、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂Ａと前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを接触させると共に、前記熱硬化性樹脂Ａまたは前記熱硬化性樹脂Ｂを前記多孔性シートに含浸させた状態で、前記熱硬化性樹脂Ａと前記熱硬化性樹脂Ｂをそれぞれ硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする。   According to a twelfth aspect of the present invention, in the invention of the eleventh aspect, in addition to the impregnation step B, the thermosetting resin foam having the open cells is impregnated with the thermosetting resin A to impregnate the thermosetting resin foam. An impregnation step A for obtaining a body, and in the laminating step, instead of the thermosetting resin foam having the open cells, the prepregs are disposed on both sides of the impregnated thermosetting resin foam, respectively. In the compression heating step, the thermosetting resin A impregnated in the thermosetting resin foam and the thermosetting resin B impregnated in the carbon fiber fabric are brought into contact with each other, and the heat In a state where the porous sheet is impregnated with the curable resin A or the thermosetting resin B, the thermosetting resin A and the thermosetting resin B are subjected to a curing reaction, respectively, and the core material and the fiber reinforcing material. And shape the surface material While, characterized by integrating the fibrous reinforcing material and the surface material and the core material.

請求項１３の発明は、請求項４から１２の何れか一項において、前記圧縮率Ｃが１０００〜２６００％であることを特徴とする。   A thirteenth aspect of the invention is characterized in that, in any one of the fourth to twelfth aspects, the compression ratio C is 1000 to 2600%.

請求項１４の発明は、請求項４から１３の何れか一項において、前記多孔性シートが、セル膜を除去したウレタン樹脂発泡体からなることを特徴とする。   A fourteenth aspect of the invention is characterized in that, in any one of the fourth to thirteenth aspects, the porous sheet is made of a urethane resin foam from which the cell membrane has been removed.

繊維強化成形体に関する本発明は、芯材の両面に積層した繊維補強材に、２方向以上の繊維方向を有する炭素繊維織物が用いられているため、炭素繊維織物が２層で済み、低コスト化を実現することができる。さらに、前記樹脂比率が５０〜８０％であり、芯材は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸して前記熱硬化性樹脂発泡体を圧縮した状態で熱硬化性樹脂が硬化したものであって、前記圧縮率が２００〜５０００％の範囲のものからなるため、繊維強化成形体を薄肉にできると共に、軽量性及び高剛性を実現することができる。さらに、芯材に用いられている連続気泡を有する熱硬化性樹脂発泡体は、セル（気泡又は気孔とも称される）が連通しているため、熱硬化性樹脂が含浸して、しかも熱硬化性樹脂発泡体のセル骨格芯材部分に付着することで熱硬化性樹脂を均一に分散保持する。その状態で、上記圧縮率にて圧縮および硬化することで、実質的に空隙が存在していない芯体となって、繊維強化成形体の曲げ強度向上や芯材と繊維強化補強材との接着強度向上効果が得られる。   The present invention relating to a fiber reinforced molded article uses a carbon fiber woven fabric having two or more fiber directions for the fiber reinforcing material laminated on both surfaces of the core material. Can be realized. Furthermore, the resin ratio is 50 to 80%, and the core is thermoset in a state in which the thermosetting resin is impregnated into a thermosetting resin foam having open cells and the thermosetting resin foam is compressed. Since the compression resin is hardened and the compression ratio is in the range of 200 to 5000%, the fiber-reinforced molded body can be made thin, and light weight and high rigidity can be realized. Further, since the thermosetting resin foam having open cells used for the core material has cells (also referred to as bubbles or pores) communicating with each other, it is impregnated with the thermosetting resin and is further thermoset. The thermosetting resin is uniformly dispersed and held by adhering to the cell skeleton core of the curable resin foam. In that state, by compressing and curing at the above-mentioned compression rate, it becomes a core body substantially free of voids, improving the bending strength of the fiber reinforced molded body and bonding between the core material and the fiber reinforced reinforcing material Strength improvement effect is obtained.

本発明は、それらの効果に加えて、芯材の少なくとも一側の面の繊維補強材の表面には多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着した状態で硬化した表面材が積層されているため、前記表面材が積層された表面では、繊維補強材を構成する炭素繊維織物の織り目の隙間部分等で生じる段差が、前記多孔性シートに含浸し、さらには多孔性シートの表面に染み出した熱硬化性樹脂で埋められ、繊維強化成形体の表面が平滑な樹脂層となる。そのため、表面材の表面に塗装を施した場合、前記炭素繊維織物の段差の影響を抑えることができると共に、前記段差部分にエアが残って塗膜表面にピンホールを生じるおそれを無くすことができ、良好な塗装外観が得られる。さらに、表面材によって塗料との密着性が良くなり、塗膜の剥がれを防ぐことができる。   In addition to these effects, the present invention provides that the surface of the fiber reinforcing material on at least one side of the core material is impregnated with the thermosetting resin in the porous sheet, and the thermosetting resin is the surface of the porous sheet. Since the surface material cured in a state of adhering to the surface of the porous sheet is formed, the step generated in the gap portion of the weave of the carbon fiber fabric constituting the fiber reinforcing material is formed on the surface where the surface material is laminated. Further, it is filled with a thermosetting resin that is impregnated into the porous sheet and oozes out on the surface of the porous sheet, and the surface of the fiber-reinforced molded body becomes a smooth resin layer. Therefore, when the surface of the surface material is coated, the influence of the step of the carbon fiber fabric can be suppressed, and the possibility that air remains in the step portion and a pinhole is generated on the surface of the coating film can be eliminated. Good paint appearance can be obtained. In addition, the surface material improves the adhesion to the paint and prevents the coating film from peeling off.

また、繊維強化成形体の製造方法に関する本発明は、低コスト化、薄肉、軽量性、高剛性及び外観の良好を実現できる繊維強化成形体を容易に得ることができる。
特に本発明では、炭素繊維織物の繊維内に熱硬化性樹脂を入り込ませて、かつ熱硬化性樹脂発泡体のセル内にも熱硬化性樹脂を入り込ませて積層することで、熱硬化性樹脂発泡体と炭素繊維織物とを各々に含浸した熱硬化性樹脂を介して物理的に強固に接着させるため、芯材と炭素繊維補強材との強固な接着強度を確保することができる。 Moreover, the present invention relating to a method for producing a fiber-reinforced molded body can easily provide a fiber-reinforced molded body that can realize cost reduction, thinness, lightness, high rigidity, and good appearance.
In particular, in the present invention, the thermosetting resin is put into the fibers of the carbon fiber fabric, and the thermosetting resin is also put into the cells of the thermosetting resin foam to laminate the thermosetting resin. Since the foam and the carbon fiber fabric are physically and strongly bonded to each other through the thermosetting resin impregnated with the foam and the carbon fiber fabric, it is possible to secure a strong adhesive strength between the core material and the carbon fiber reinforcing material.

さらに、薄肉の繊維強化成形体を得るには、炭素繊維織物間の芯材の位置に配置する熱硬化性樹脂の保持材及び芯材の厚み調整用スペーサーとしての連続気泡の熱硬化性樹脂発泡体を、厚みの薄いものとする必要がある。しかし、連続気泡の熱硬化性樹脂発泡体を、圧縮することなくそのまま芯材の位置に使用した場合、次の２つの問題がある。
ａ．薄い芯材層なので、その厚みに合わせて連続気泡の熱硬化性樹脂発泡体を薄く均一にスライスすることが困難である。薄くスライスすると、厚みがばらつきやすい。
ｂ．スライスした連続気泡の熱硬化性樹脂発泡体は、非圧縮状態にした断面について見ると、縦方向に発泡体のセル骨格を有する断面と、セル骨格のない断面が存在する。そのため、圧縮せずに繊維強化成形体を成形した場合、断面ごとで熱硬化性樹脂の樹脂比率が異なり、弱い断面の影響によって全体の曲げ弾性率が低下する。
それに対して、本発明のように連続気泡の熱硬化性樹脂発泡体を、厚い状態で加工して圧縮することにより、次の効果が得られる。
イ．熱硬化性樹脂発泡体の厚みのばらつきは、その圧縮率に反して減少する。
ロ．熱硬化性樹脂発泡体内においてランダムに積層された状態のセル骨格が圧縮によって折り重なるので、各断面における樹脂比率のばらつきが小さくなる。
ハ．厚みの厚い状態のほうが、熱硬化性樹脂の含浸が容易である。
そのため、本発明では、連続気泡の熱硬化性樹脂発泡体を、厚みの厚い状態で使用し、熱硬化性樹脂を含浸させた状態で圧縮することとし、圧縮率及び含浸量を特定の範囲に設定した。
なお、請求項１〜１４における式（Ａ１）〜式（Ａ６）の圧縮率に関する計算式は何れも同一であり、以下一つの式、例えば式（Ａ１）で圧縮率の式を代表させる。また、請求項１〜１０における式（Ｂ１）〜式（Ｂ６）の樹脂比率に関する計算式は何れも同一であり、以下一つの式、例えば式（Ｂ１）で樹脂比率の式を代表させる。 Furthermore, in order to obtain a thin-walled fiber-reinforced molded body, the open cell thermosetting resin foam is used as a thermosetting resin holding material and a spacer for adjusting the thickness of the core material arranged at the position of the core material between the carbon fiber fabrics. The body needs to be thin. However, when the open cell thermosetting resin foam is used as it is at the position of the core material without being compressed, there are the following two problems.
a. Since it is a thin core layer, it is difficult to slice the open-cell thermosetting resin foam thinly and uniformly according to its thickness. When sliced thinly, the thickness tends to vary.
b. The sliced open-cell thermosetting resin foam has a cross section having a cell skeleton of the foam in the vertical direction and a cross section having no cell skeleton when viewed in a non-compressed cross section. Therefore, when a fiber-reinforced molded body is molded without being compressed, the resin ratio of the thermosetting resin is different for each cross section, and the entire bending elastic modulus is lowered due to the influence of the weak cross section.
On the other hand, the following effect is acquired by processing and compressing the open cell thermosetting resin foam in a thick state as in the present invention.
A. The variation in the thickness of the thermosetting resin foam decreases against the compression ratio.
B. Since the cell skeleton in a state of being randomly laminated in the thermosetting resin foam is folded by compression, variation in the resin ratio in each cross section is reduced.
C. In the thicker state, the impregnation with the thermosetting resin is easier.
Therefore, in the present invention, the open cell thermosetting resin foam is used in a thick state and compressed in a state impregnated with the thermosetting resin, and the compression rate and the amount of impregnation are within a specific range. Set.
In addition, the calculation formula regarding the compression rate of the formulas (A1) to (A6) in claims 1 to 14 is the same, and the formula of the compression rate is represented by one formula, for example, the formula (A1). In addition, the calculation formulas relating to the resin ratio in the formulas (B1) to (B6) in claims 1 to 10 are the same, and the formula for the resin ratio is represented by one formula, for example, the formula (B1) below.

本発明における繊維強化成形体の第１実施形態の断面図である。It is sectional drawing of 1st Embodiment of the fiber reinforced molded object in this invention. 本発明における繊維強化成形体の第２実施形態の断面図である。It is sectional drawing of 2nd Embodiment of the fiber reinforced molded object in this invention. 本発明における繊維強化成形体の第３実施形態の断面図である。It is sectional drawing of 3rd Embodiment of the fiber reinforced molded object in this invention. 本発明における製造方法の第１実施形態の工程を示す図である。It is a figure which shows the process of 1st Embodiment of the manufacturing method in this invention. 本発明における製造方法の第２実施形態の工程を示す図である。It is a figure which shows the process of 2nd Embodiment of the manufacturing method in this invention. 本発明における製造方法の第３実施形態の工程を示す図である。It is a figure which shows the process of 3rd Embodiment of the manufacturing method in this invention. 本発明における製造方法の第４実施形態の工程を示す図である。It is a figure which shows the process of 4th Embodiment of the manufacturing method in this invention. 本発明における製造方法の第５実施形態の一部の工程を示す図である。It is a figure which shows the one part process of 5th Embodiment of the manufacturing method in this invention. 従来の繊維強化成形体の断面図である。It is sectional drawing of the conventional fiber reinforced molded object. 炭素繊維織物の平面図及び断面図である。It is the top view and sectional drawing of a carbon fiber fabric.

以下、本発明の繊維強化成形体及びその製造方法について図面を用いて説明する。
図１に示す本発明の第１実施形態に係る繊維強化成形体１０は、芯材１１と、前記芯材１１の両面に積層一体化された繊維補強材２１と、前記芯材１１の少なくとも一側の面の繊維補強材２１の表面に積層一体化された表面材２５とからなり、ノートパソコン等の携帯機器の筐体などに用いられる。前記繊維強化成形体１０は、所定サイズの板状からなり、厚みが０．３〜２．０ｍｍ、曲げ弾性率（ＪＩＳ Ｋ ７０７４−１９８８ Ａ法）が３０ＧＰａ以上６０ＧＰａ以下、好ましくは３５ＧＰａ以上５５ＧＰａ以下、比重１．２以上１．５以下、好ましくは１．２５以上１．４０以下、特に好ましくは１．２８以上１．３５以下のものである。厚みが０．３ｍｍ未満では剛性が得られず、２．０ｍｍより厚いと携帯機器全体が厚くなり適さない。なお、前記繊維強化成形体１０は、携帯機器の筐体として用いられる場合、筐体の側壁等が、射出成形等のいわゆるアウトサート成形で、所定の表面位置に適宜立設される。 Hereinafter, the fiber reinforced molded product and the manufacturing method thereof of the present invention will be described with reference to the drawings.
A fiber reinforced molded body 10 according to the first embodiment of the present invention shown in FIG. 1 includes a core material 11, a fiber reinforcing material 21 laminated and integrated on both surfaces of the core material 11, and at least one of the core material 11. It is composed of a surface material 25 laminated and integrated on the surface of the fiber reinforcing material 21 on the side surface, and is used for a housing of a portable device such as a notebook personal computer. The fiber-reinforced molded body 10 has a plate shape of a predetermined size, has a thickness of 0.3 to 2.0 mm, and a flexural modulus (JIS K 7074-1988 A method) of 30 GPa to 60 GPa, preferably 35 GPa to 55 GPa. The specific gravity is 1.2 or more and 1.5 or less, preferably 1.25 or more and 1.40 or less, particularly preferably 1.28 or more and 1.35 or less. If the thickness is less than 0.3 mm, rigidity cannot be obtained, and if it is more than 2.0 mm, the entire portable device becomes thick, which is not suitable. When the fiber-reinforced molded body 10 is used as a casing of a portable device, the side walls of the casing are appropriately erected at a predetermined surface position by so-called outsert molding such as injection molding.

前記芯材１１は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸して前記熱硬化性樹脂発泡体を圧縮した状態で前記熱硬化性樹脂が硬化したものであって、前記式（Ａ１）で規定される圧縮率が２００〜５０００％の範囲、特に好ましくは１０００〜２６００％のものからなる。前記圧縮率の範囲とすることにより、前記繊維強化成形体１０の薄肉化と剛性の向上が図れる。   The core material 11 is obtained by curing the thermosetting resin in a state where the thermosetting resin foam is impregnated into a thermosetting resin foam having open cells and the thermosetting resin foam is compressed. The compression rate defined by the formula (A1) is in the range of 200 to 5000%, particularly preferably 1000 to 2600%. By setting the compression rate within the range, the fiber-reinforced molded body 10 can be thinned and the rigidity can be improved.

前記連続気泡を有する熱硬化性樹脂発泡体は、特に限定されるものではなく、例えば、ウレタン樹脂発泡体又はメラミン樹脂発泡体から選択することができる。また、前記繊維強化成形体１０に難燃性が求められる場合には、前記熱硬化性樹脂発泡体としては難燃性のものが好ましく、メラミン樹脂発泡体は樹脂単体が良好な難燃性を有するため、前記熱硬化性樹脂発泡体として好適なものである。前記熱硬化性樹脂発泡体の圧縮前の元厚みは、前記圧縮率により異なるが、例えば１〜２５ｍｍを挙げる。この範囲に元厚みがあると、適度な量の熱硬化性樹脂を含浸でき、加熱圧縮後の歩留まりも良い。元厚みが１ｍｍより薄いと、含浸した熱硬化性樹脂が保持できず、樹脂比率がばらつく為、曲げ弾性率（剛性）が低下する。元厚みが２５ｍｍより厚いと、厚さ２ｍｍ以下の繊維強化成形体を得ようとした場合、圧縮が困難で、均一な厚みの繊維強化成形体が得られない。また、前記熱硬化性樹脂発泡体は、圧縮容易性、含浸性、軽量性、剛性の点から、圧縮前の密度が５〜８０ｋｇ／ｍ３のものが好ましい。 The thermosetting resin foam having the open cells is not particularly limited, and can be selected from, for example, a urethane resin foam or a melamine resin foam. When the fiber reinforced molded body 10 is required to have flame retardancy, the thermosetting resin foam is preferably flame retardant, and the melamine resin foam has good flame retardancy when the resin alone is used. Therefore, it is suitable as the thermosetting resin foam. Although the original thickness before compression of the said thermosetting resin foam changes with the said compression rates, 1-25 mm is mentioned, for example. When the original thickness is within this range, an appropriate amount of thermosetting resin can be impregnated, and the yield after heat compression is good. When the original thickness is less than 1 mm, the impregnated thermosetting resin cannot be retained, and the resin ratio varies, so that the flexural modulus (rigidity) decreases. When the original thickness is greater than 25 mm, when trying to obtain a fiber reinforced molded product having a thickness of 2 mm or less, compression is difficult and a fiber reinforced molded product having a uniform thickness cannot be obtained. The thermosetting resin foam preferably has a density before compression of 5 to 80 kg / m 3 from the viewpoints of easy compression, impregnation, light weight and rigidity.

前記熱硬化性樹脂発泡体に含浸する熱硬化性樹脂は、特に限定されないが、前記繊維強化成形体１０の剛性を高めるためには、熱硬化性樹脂自体がある程度の剛性を有する必要があり、エポキシ樹脂、フェノール樹脂、エポキシ樹脂とフェノール樹脂の混合物からなる群より選択することができる。また、前記繊維強化成形体１０に難燃性が求められる場合、前記熱硬化性樹脂は難燃性のものが好ましい。フェノール樹脂は良好な難燃性を有するため、前記熱硬化性樹脂発泡体に含浸させる熱硬化性樹脂として好適なものである。   The thermosetting resin impregnated in the thermosetting resin foam is not particularly limited, but in order to increase the rigidity of the fiber-reinforced molded body 10, the thermosetting resin itself needs to have a certain degree of rigidity. It can be selected from the group consisting of epoxy resins, phenol resins, and mixtures of epoxy resins and phenol resins. When the fiber reinforced molded body 10 is required to have flame retardancy, the thermosetting resin is preferably flame retardant. Since the phenol resin has good flame retardancy, it is suitable as a thermosetting resin impregnated in the thermosetting resin foam.

前記繊維補強材２１は、炭素繊維織物に熱硬化性樹脂が含浸し、硬化したものからなる。前記炭素繊維織物は、軽量及び高剛性に優れるものであり、特に、繊維が一方向のみではない織り方のものが好ましく、例えば、縦糸と横糸で構成される平織、綾織、朱子織及び３方向の糸で構成される三軸織などが好適である。また、前記炭素繊維織物は、熱硬化性樹脂の含浸及び剛性の点から、繊維重さが９０〜４００ｇ／ｍ２のものが好ましい。 The fiber reinforcing material 21 is made of a carbon fiber fabric impregnated with a thermosetting resin and cured. The carbon fiber woven fabric is excellent in light weight and high rigidity, and is particularly preferably a fabric in which the fibers are not only in one direction, for example, plain weave, twill weave, satin weave and three directions composed of warp and weft. A triaxial weaving made of yarn is suitable. The carbon fiber woven fabric preferably has a fiber weight of 90 to 400 g / m 2 from the viewpoint of impregnation with a thermosetting resin and rigidity.

前記炭素繊維織物に含浸する熱硬化性樹脂は、特に限定されないが、前記繊維強化成形体１０の剛性を高めるためには、熱硬化性樹脂自体がある程度の剛性を有する必要があり、エポキシ樹脂、フェノール樹脂、エポキシ樹脂とフェノール樹脂の混合物からなる群より選択することができる。また、前記繊維強化成形体１０に難燃性が求められる場合、前記熱硬化性樹脂は難燃性のものが好ましい。フェノール樹脂は良好な難燃性を有するため、前記炭素繊維織物に含浸させる熱硬化性樹脂として好適なものである。   The thermosetting resin impregnated in the carbon fiber fabric is not particularly limited, but in order to increase the rigidity of the fiber-reinforced molded body 10, the thermosetting resin itself needs to have a certain degree of rigidity, and an epoxy resin, It can be selected from the group consisting of phenolic resins, mixtures of epoxy resins and phenolic resins. When the fiber reinforced molded body 10 is required to have flame retardancy, the thermosetting resin is preferably flame retardant. Since the phenol resin has good flame retardancy, it is suitable as a thermosetting resin impregnated in the carbon fiber fabric.

また、前記熱硬化性樹脂発泡体にメラミン樹脂を用い、前記熱硬化性樹脂発泡体（メラミン樹脂発泡体）に含浸させる前記熱硬化性樹脂及び前記炭素繊維織物に含浸させる前記熱硬化性樹脂をフェノール樹脂とした場合には、難燃剤を使用しなくても、ノートパソコン等の携帯機器の筐体用として充分な難燃性を有する繊維強化成形体を得ることができる。   In addition, a melamine resin is used for the thermosetting resin foam, and the thermosetting resin impregnated in the thermosetting resin foam (melamine resin foam) and the thermosetting resin impregnated in the carbon fiber fabric are used. When a phenol resin is used, a fiber-reinforced molded article having sufficient flame retardancy for a casing of a portable device such as a notebook personal computer can be obtained without using a flame retardant.

また、前記熱硬化性樹脂は、前記式（Ｂ１）で規定される樹脂比率が５０〜８０％、特には５５〜７０％となるように前記熱硬化性樹脂発泡体と前記炭素繊維織物と前記多孔性シートに含浸させることが好ましい。前記樹脂比率とすることにより、前記繊維強化成形体１０を薄肉化しても軽量性及び剛性をより良好にすることができる。
なお、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量であり、溶剤を除去した後であれば、前記芯材と繊維補強材及び多孔性シートの一体化前あるいは一体化後の何れでもよい。 The thermosetting resin has a resin ratio defined by the formula (B1) of 50 to 80%, particularly 55 to 70%, and the thermosetting resin foam, the carbon fiber fabric, and the It is preferable to impregnate the porous sheet. By setting it as the said resin ratio, even if it thins the said fiber reinforced molded object 10, lightness and rigidity can be made more favorable.
In addition, the weight after impregnation in the formula of the resin ratio is the weight after drying after impregnation and removing the solvent when the thermosetting resin is dissolved in the solvent, and after removing the solvent. If it exists, it may be either before or after the integration of the core material, the fiber reinforcing material and the porous sheet.

前記表面材２５は、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が滲出して前記多孔性シート表面に付着し、露出して硬化したものからなる。前記表面材２５は、後述する繊維強化成形体１０の製造時の圧縮加熱工程において炭素繊維織物に含浸している熱硬化性樹脂が多孔性シート２５Ａ（図４〜図６に示す）に含浸して付着し、さらには多孔性シート２５Ａの表面から熱硬化性樹脂が染み出し（滲出し）て硬化することにより形成され、その際に表面材２５の表面に平滑な樹脂層を形成して繊維強化成形体１０の表面を平滑にする。   The surface material 25 is made of a porous sheet impregnated with a thermosetting resin, and the thermosetting resin oozes out and adheres to the surface of the porous sheet, and is exposed and cured. The surface material 25 is impregnated in a porous sheet 25A (shown in FIGS. 4 to 6) with a thermosetting resin impregnated in a carbon fiber fabric in a compression heating process at the time of manufacturing the fiber-reinforced molded body 10 described later. Furthermore, the thermosetting resin oozes out from the surface of the porous sheet 25A (exudation) and hardens. At that time, a smooth resin layer is formed on the surface of the surface material 25 to form fibers. The surface of the reinforced molded body 10 is smoothed.

前記多孔性シート２５Ａは、熱硬化性樹脂の含浸を良好にし、均一樹脂層を形成するために、多孔性のもの（多数の孔を有するもの）とされる。前記多孔性シート２５Ａの材質は特に限定されるものではないが、多孔性のもの（多数の孔を有するもの）であって、圧縮加熱工程における熱で溶けず、孔が埋まらない程度の耐熱性を有するものが好ましい。また、前記多孔性シート２５Ａの形態も特に限定されず、織物、不織布、紙、発泡体などから、適宜選択することができる。それらの中でも、ウレタン樹脂発泡体製の多孔性シートは、扱い易く、軽量性に優れ、しかも圧縮により前記繊維補強材２１の炭素繊維織物における織り目の隙間部分等の段差を効果的に緩和することができ、好ましいものである。   The porous sheet 25A is made porous (having a large number of holes) in order to improve the impregnation of the thermosetting resin and form a uniform resin layer. The material of the porous sheet 25A is not particularly limited. However, the porous sheet 25A is porous (having a large number of pores), and does not melt by heat in the compression heating process, and does not fill the pores. Those having the following are preferred. Further, the form of the porous sheet 25A is not particularly limited, and can be appropriately selected from woven fabric, non-woven fabric, paper, foam and the like. Among them, the porous sheet made of urethane resin foam is easy to handle, excellent in lightness, and effectively relieves steps such as gaps in the weave of the carbon fiber fabric of the fiber reinforcement 21 by compression. This is preferable.

前記多孔性シート２５Ａをウレタン樹脂発泡体とする場合には、溶解処理や爆発処理などの公知の除膜処理でセル膜を除去したウレタン樹脂発泡体が特に好ましい。セル膜を除去したウレタン樹脂発泡体は、連通気孔構造となっているため、繊維強化成形体１０の製造時の圧縮加熱工程において、前記炭素繊維織物に含浸している熱硬化性樹脂が多孔性シートに含浸し、さらに表面に染み出し易くなり、熱硬化性樹脂の硬化により前記芯材１１と前記繊維補強材２１及び表面材２５の一体化がより確実なものとなると共に、前記多孔性シート２５Ａの表面から染み出した熱硬化性樹脂が硬化することによって、表面がより平滑な樹脂層となる。なお、セル膜が除去されていないウレタン樹脂発泡体は、セル膜が残っているため、多孔性シート２５Ａに用いた場合、熱硬化性樹脂の含浸及び染み出しが良好ではなく、結果として表面の平滑性及び塗装密着性（塗膜の剥がれ難さ）が低下するようになる。   When the porous sheet 25A is a urethane resin foam, a urethane resin foam from which the cell membrane has been removed by a known film removal treatment such as a dissolution treatment or an explosion treatment is particularly preferable. Since the urethane resin foam from which the cell membrane has been removed has a continuous vent structure, the thermosetting resin impregnated in the carbon fiber woven fabric is porous in the compression heating process during the production of the fiber reinforced molded body 10. The sheet is impregnated and easily oozes out to the surface, and the core material 11, the fiber reinforcing material 21 and the surface material 25 are more reliably integrated by curing the thermosetting resin, and the porous sheet The thermosetting resin that oozes from the surface of 25A is cured, so that the surface of the resin layer becomes smoother. Note that the urethane resin foam from which the cell membrane has not been removed has the cell membrane remaining, so when used for the porous sheet 25A, impregnation and exudation of the thermosetting resin is not good, and as a result Smoothness and paint adhesion (hardness of peeling of the coating film) are lowered.

前記多孔性シート２５Ａとして用いられるウレタン樹脂発泡体のセル数は８〜８０個／２５ｍｍ（ＪＩＳ Ｋ６４００−１）が好ましく、１０〜８０個／２５ｍｍ（ＪＩＳ Ｋ６４００−１）がより好ましい。セル数が８個／２５ｍｍより少ない場合には、薄いシート状に加工した場合に空隙（気孔）が大きくなり過ぎ、炭素繊維織物の凹凸を埋めるのに必要な量の熱硬化性樹脂を保持することが難しくなる傾向がある。一方、セル数が８０個／２５ｍｍより多い場合には、逆に空隙が少なくなって熱硬化性樹脂の含浸性が低下し、多孔性シートの表面から熱硬化性樹脂を充分に染み出させることが難しくなる。   The number of cells of the urethane resin foam used as the porous sheet 25A is preferably 8 to 80 cells / 25 mm (JIS K6400-1), and more preferably 10 to 80 cells / 25 mm (JIS K6400-1). When the number of cells is less than 8 pieces / 25 mm, the gap (pores) becomes too large when processed into a thin sheet shape, and the amount of thermosetting resin necessary to fill the unevenness of the carbon fiber fabric is retained. Tend to be difficult. On the other hand, when the number of cells is more than 80/25 mm, the voids are reduced and the impregnation property of the thermosetting resin is lowered, and the thermosetting resin is sufficiently oozed out from the surface of the porous sheet. Becomes difficult.

前記多孔性シート２５Ａの厚みは、材質によって異なるが、非圧縮状態（繊維強化成形体の製造前）で０．４ｍｍ〜３ｍｍ、より好ましくは０．６ｍｍ〜２ｍｍである。非圧縮状態の厚みが０．４ｍｍより小さい場合には、繊維強化成形体１０の製造時の圧縮加熱工程において、均一な樹脂層を形成し難くなり、繊維強化成形体１０の表面の平滑性が低下するようになる。一方、前記非圧縮状態の厚みが３ｍｍより大きくなると、繊維強化成形体１０の曲げ弾性率の低下を引き起こすと共に、熱硬化性樹脂の染み出しムラが発生し易くなり、表面の平滑性が低下するようになる。   The thickness of the porous sheet 25A varies depending on the material, but is 0.4 mm to 3 mm, more preferably 0.6 mm to 2 mm in an uncompressed state (before the production of the fiber-reinforced molded body). When the thickness in the uncompressed state is smaller than 0.4 mm, it becomes difficult to form a uniform resin layer in the compression heating process at the time of manufacturing the fiber reinforced molded body 10, and the surface smoothness of the fiber reinforced molded body 10 is improved. It begins to decline. On the other hand, when the thickness in the uncompressed state is larger than 3 mm, the bending elastic modulus of the fiber reinforced molded body 10 is lowered, and the unevenness of the thermosetting resin is likely to occur and the surface smoothness is lowered. It becomes like this.

前記芯材１１と前記繊維補強材２１及び前記表面材２５の一体化は、前記熱硬化性樹脂が含浸した熱硬化性樹脂発泡体と炭素繊維織物と多孔性シート２５Ａの積層体を圧縮した状態で前記熱硬化性樹脂を硬化させることによって行うことができる。前記熱硬化性樹脂発泡体に含浸した熱硬化性樹脂と前記炭素繊維織物に含浸した熱硬化性樹脂とは、同一種類でも異種類でもよいが、前記芯材１１と繊維補強材２１との接着性を良好にするには同一種類とするのが好ましい。   Integration of the core material 11, the fiber reinforcing material 21, and the surface material 25 is a compressed state of a laminate of a thermosetting resin foam impregnated with the thermosetting resin, a carbon fiber fabric, and a porous sheet 25A. This can be done by curing the thermosetting resin. The thermosetting resin impregnated in the thermosetting resin foam and the thermosetting resin impregnated in the carbon fiber fabric may be of the same type or different types, but the core 11 and the fiber reinforcement 21 are bonded. In order to improve the properties, the same kind is preferable.

前記繊維強化成形体１０における前記表面材２５の表面には、用途に応じて所定の方法で塗装が施され、塗膜が形成される。塗料としては、ウレタン系・アクリル系・ポリエステル系・酢酸ビニル系等が挙げられ、また塗装方法としては、スプレー塗装、コーター塗装、ディッピング塗装等が挙げられる。塗装量は適宜決定されるが、例として、膜厚５〜４０μｍを挙げる。   The surface of the surface material 25 in the fiber reinforced molded body 10 is coated by a predetermined method according to the use, and a coating film is formed. Examples of the paint include urethane, acrylic, polyester, and vinyl acetate, and examples of the coating method include spray coating, coater coating, and dipping coating. Although the coating amount is determined as appropriate, a film thickness of 5 to 40 μm is given as an example.

図２に示す第２実施形態の繊維強化成形体１０Ｗは、前記第１実施形態の繊維強化成形体１０における芯材１１の両側の繊維補強材２１に、それぞれ前記表面材２５を積層一体化したものであり、各部材の構成は、第１実施形態の繊維強化成形体１０において説明したとおりである。   In the fiber reinforced molded body 10W of the second embodiment shown in FIG. 2, the surface material 25 is laminated and integrated on the fiber reinforcing materials 21 on both sides of the core material 11 in the fiber reinforced molded body 10 of the first embodiment. The configuration of each member is as described in the fiber reinforced molded body 10 of the first embodiment.

図３に示す第３実施形態の繊維強化成形体１０Ｚは、前記第１実施形態の繊維強化成形体１０における芯材１１の一側の面に、前記繊維補強材２１と前記表面材２５をこの順に積層一体化し、前記芯材１１の反対側の面には、前記多孔性シートに熱硬化性樹脂が含浸し硬化した硬化層２６と前記繊維補強材２１がこの順に積層一体化したものである。前記硬化層２６の多孔性シートと熱硬化性樹脂は、前記表面材２５の多孔性シート及び熱硬化性樹脂と同様である。なお、前記芯材１１と前記硬化層２６とは積層一体化しており、前記芯材１１と前記硬化層２６とで二層構造の芯材を構成している。   In the fiber reinforced molded body 10Z of the third embodiment shown in FIG. 3, the fiber reinforcing material 21 and the surface material 25 are arranged on one surface of the core material 11 in the fiber reinforced molded body 10 of the first embodiment. The laminated layer is integrated in order, and on the opposite surface of the core material 11, the cured layer 26 in which the porous sheet is impregnated with a thermosetting resin and cured is laminated and integrated in this order. . The porous sheet and the thermosetting resin of the cured layer 26 are the same as the porous sheet and the thermosetting resin of the surface material 25. The core material 11 and the cured layer 26 are laminated and integrated, and the core material 11 and the cured layer 26 constitute a core material having a two-layer structure.

次に、本発明の繊維強化成形体の製造方法について説明する。繊維強化成形体の製造方法は、含浸工程、積層工程、圧縮加熱工程とからなる。
まず、製造方法の第１実施形態について説明する。製造方法の第１実施形態では、図４に示す（４−１）の含浸工程において、炭素繊維織物２１Ａに熱硬化性樹脂２１Ｂを含浸させ、含浸済み炭素繊維織物２１Ｃを形成する。前記炭素繊維織物２１Ａ及び前記熱硬化性樹脂２１Ｂは、前記繊維強化成形体１０において説明したとおりである。含浸時に用いる熱硬化性樹脂２１Ｂは、未硬化の液状からなる。また、含浸を容易にするため、前記熱硬化性樹脂２１Ｂは溶剤に溶かしたものが好ましく、含浸後に、含浸済み炭素繊維織物２１Ｃを前記熱硬化性樹脂の硬化反応を生じない温度で乾燥させることにより、前記含浸済み炭素繊維織物２１Ｃから溶剤を除去する。含浸手段は、液状の熱硬化性樹脂２１Ｂを収容した槽に前記炭素繊維織物２１Ａを浸ける方法、スプレーにより行う方法、ロールコータにより行う方法等、適宜の方法により行うことができる。 Next, the manufacturing method of the fiber reinforced molded object of this invention is demonstrated. The manufacturing method of a fiber reinforced molded object consists of an impregnation process, a lamination process, and a compression heating process.
First, a first embodiment of the manufacturing method will be described. In the first embodiment of the manufacturing method, in the impregnation step (4-1) shown in FIG. 4, the carbon fiber fabric 21A is impregnated with the thermosetting resin 21B to form the impregnated carbon fiber fabric 21C. The carbon fiber fabric 21A and the thermosetting resin 21B are as described in the fiber reinforced molded body 10. The thermosetting resin 21B used at the time of impregnation is made of an uncured liquid. In order to facilitate impregnation, the thermosetting resin 21B is preferably dissolved in a solvent. After impregnation, the impregnated carbon fiber fabric 21C is dried at a temperature at which the curing reaction of the thermosetting resin does not occur. To remove the solvent from the impregnated carbon fiber fabric 21C. The impregnation means can be performed by an appropriate method such as a method of immersing the carbon fiber fabric 21A in a tank containing the liquid thermosetting resin 21B, a method of spraying, a method of using a roll coater, or the like.

前記炭素繊維織物２１Ａに、前記式（Ｂ１）で規定する樹脂比率が、５０〜８０％、特には５５〜７０％となるように熱硬化性樹脂２１Ｂを含浸させることが好ましい。
なお、製造方法の第１実施形態では、前記含浸工程において炭素繊維織物２１Ａのみに熱硬化性樹脂２１Ｂを含浸させる。前記炭素繊維織物２１Ａに含浸した熱硬化性樹脂２１Ｂは、後述のように圧縮加熱工程で前記熱硬化性樹脂発泡体１１Ａ及び多孔性シート２５Ａに含浸するため、前記樹脂比率の式（Ｂ１）におけるＷｂ（＝熱硬化性樹脂含浸後の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）−Ｗａ（＝熱硬化性樹脂含浸前の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）は、含浸工程において炭素繊維織物２１Ａに含浸した熱硬化性樹脂２１Ｂの重量と等しい値である。また、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量である。 The carbon fiber fabric 21A is preferably impregnated with the thermosetting resin 21B so that the resin ratio defined by the formula (B1) is 50 to 80%, particularly 55 to 70%.
In the first embodiment of the manufacturing method, only the carbon fiber fabric 21A is impregnated with the thermosetting resin 21B in the impregnation step. Since the thermosetting resin 21B impregnated in the carbon fiber fabric 21A is impregnated in the thermosetting resin foam 11A and the porous sheet 25A in the compression heating process as described later, in the resin ratio formula (B1) Wb (= total weight of thermosetting resin foam, carbon fiber fabric and porous sheet after impregnation with thermosetting resin) −Wa (= thermosetting resin foam and carbon fiber fabric before impregnation of thermosetting resin) The total weight of the porous sheet) is equal to the weight of the thermosetting resin 21B impregnated in the carbon fiber fabric 21A in the impregnation step. Further, the weight after impregnation in the formula of the resin ratio is the weight after removing the solvent by drying after impregnation when the thermosetting resin is used in a solvent.

図４に示す（４−２）の積層工程では、連続気泡を有する熱硬化性樹脂発泡体１１Ａの両面に、前記（４−１）の含浸工程で得られた含浸済み炭素繊維織物２１Ｃを配置し、さらに前記熱硬化性樹脂発泡体１１Ａの一方の側の面における含浸済み炭素繊維織物２１Ｃの表面に多孔性シート２５Ａを配置して積層体１０Ａとする。連続気泡を有する熱硬化性樹脂発泡体１１Ａ及び多孔性シート２５Ａは、前記繊維強化成形体１０において説明したとおりである。なお、前記積層作業は、次に行う（４−３）の圧縮加熱工程で用いるプレス成形用下型３１の上面に、前記含浸済み炭素繊維織物２１Ｃ、前記熱硬化性樹脂発泡体１１Ａ、前記含浸済み炭素繊維織物２１Ｃ、前記多孔性シート２５Ａの順に重ねて行ってもよい。また、前記含浸済み炭素繊維織物２１Ｃと連続気泡を有する熱硬化性樹脂発泡体１１Ａ及び多孔性シート２５Ａは、平面サイズが同サイズのものが好ましいが、異なっている場合には、後述の圧縮加熱工程後にトリミングすればよい。   In the laminating step (4-2) shown in FIG. 4, the impregnated carbon fiber fabric 21C obtained in the impregnation step (4-1) is disposed on both surfaces of the thermosetting resin foam 11A having open cells. Further, a porous sheet 25A is arranged on the surface of the impregnated carbon fiber fabric 21C on one surface of the thermosetting resin foam 11A to obtain a laminate 10A. The thermosetting resin foam 11 </ b> A and the porous sheet 25 </ b> A having open cells are as described in the fiber reinforced molded body 10. The lamination operation is performed on the upper surface of the press molding lower mold 31 used in the compression heating step (4-3) to be performed next, the impregnated carbon fiber fabric 21C, the thermosetting resin foam 11A, and the impregnation. The carbon fiber fabric 21C and the porous sheet 25A may be stacked in this order. Further, the impregnated carbon fiber fabric 21C and the thermosetting resin foam 11A having the open cells and the porous sheet 25A preferably have the same plane size, but if they are different, the compression heating described later is used. Trimming may be performed after the process.

図４に示す（４−３）の圧縮加熱工程では、前記積層体１０Ａをプレス成形用下型３１と上型３３により圧縮すると共に加熱する。圧縮は、前記繊維強化成形体１０で説明した式（Ａ１）により得られる圧縮率が２００〜５０００％、特に好ましくは１０００〜２６００％となるように調整する。前記圧縮加熱工程時、前記プレス成形用下型３１と上型３３間には適宜の位置にスペーサを設置して、前記プレス成形用下型３１と上型３３間が所定間隔（積層体の所定圧縮厚み）となるようにされる。また、積層体の加熱方法は特に限定されないが、前記プレス成形用下型３１と上型３３にヒータ等の加熱手段を設けて、前記プレス成形用下型３１と上型３３を介して加熱するのが簡単である。加熱温度は、前記含浸している熱硬化性樹脂の硬化反応温度以上とされる。   In the compression heating step (4-3) shown in FIG. 4, the laminated body 10A is compressed and heated by the press molding lower mold 31 and the upper mold 33. The compression is adjusted so that the compression ratio obtained by the formula (A1) described in the fiber reinforced molded body 10 is 200 to 5000%, particularly preferably 1000 to 2600%. During the compression heating step, a spacer is installed at an appropriate position between the press molding lower mold 31 and the upper mold 33, and a predetermined interval (predetermined of the laminate) is provided between the press molding lower mold 31 and the upper mold 33. Compression thickness). The heating method of the laminated body is not particularly limited, but heating means such as a heater is provided in the lower mold 31 for press molding and the upper mold 33, and heating is performed via the lower mold 31 for press molding and the upper mold 33. It's easy. The heating temperature is set to be equal to or higher than the curing reaction temperature of the impregnated thermosetting resin.

前記圧縮加熱工程時に前記積層体１０Ａが圧縮されると、前記積層体１０Ａの含浸済み炭素繊維織物２１Ｃから熱硬化性樹脂が押し出され、前記含浸済み炭素繊維織物２１Ｃと接している前記熱硬化性樹脂発泡体１１Ａに含浸すると共に前記多孔性シート２５Ａに含浸し、前記積層体１０Ａの全体に含浸する。さらに前記多孔性シート２５Ａに含浸した前記熱硬化性樹脂は、前記多孔性シート２５Ａの表面に染み出し（滲出し）、露出して均一な樹脂層を形成する。その際、圧縮後の熱硬化性樹脂発泡体、炭素繊維織物、多孔性シートの空間容積を上回る過剰な熱硬化性樹脂は、型外部へ押し出されて、熱硬化性樹脂中に存在する微小なボイドや意図せずにできた微小な空隙は除いて、実質的に空隙が存在していない積層体となる。前記積層体１０Ａの全体に含浸した熱硬化性樹脂は、加熱により硬化反応を開始し、前記積層体１０Ａが圧縮された状態で硬化する。なお、前記多孔性シート２５Ａがウレタン樹脂発泡体からなる場合には前記多孔性シート２５Ａも圧縮された状態で前記熱硬化性樹脂が硬化する。前記熱硬化性樹脂発泡体１１Ａから前記芯材１１が形成され、また、前記含浸済み炭素繊維織物２１Ｃから前記繊維補強材２１が形成され、前記多孔性シート２５Ａから表面材２５が形成され、前記芯材１１と前記繊維補強材２１及び前記表面材２５が一体化して前記第１実施形態の繊維強化成形体１０が形成される。その後、加熱圧縮を解除して前記繊維強化成形体１０を得る。このようにして得られた繊維強化成形体１０は、前記表面材２５の表面が、前記多孔性シート２５Ａの表面に染み出した熱硬化性樹脂の硬化によって平滑な樹脂層となっている。   When the laminate 10A is compressed during the compression heating step, the thermosetting resin is extruded from the impregnated carbon fiber fabric 21C of the laminate 10A and is in contact with the impregnated carbon fiber fabric 21C. The resin foam 11A is impregnated and the porous sheet 25A is impregnated to impregnate the entire laminate 10A. Further, the thermosetting resin impregnated in the porous sheet 25A oozes out (exudes) on the surface of the porous sheet 25A and is exposed to form a uniform resin layer. At that time, excessive thermosetting resin exceeding the space volume of the thermosetting resin foam, the carbon fiber woven fabric, and the porous sheet after being compressed is pushed out of the mold, and the minute amount existing in the thermosetting resin. Except for voids and unintentional fine voids, the laminate is substantially free of voids. The thermosetting resin impregnated in the entire laminate 10A starts a curing reaction by heating, and is cured in a state where the laminate 10A is compressed. When the porous sheet 25A is made of a urethane resin foam, the thermosetting resin is cured while the porous sheet 25A is also compressed. The core material 11 is formed from the thermosetting resin foam 11A, the fiber reinforcing material 21 is formed from the impregnated carbon fiber fabric 21C, and the surface material 25 is formed from the porous sheet 25A. The core material 11, the fiber reinforcing material 21, and the surface material 25 are integrated to form the fiber reinforced molded body 10 of the first embodiment. Thereafter, the heat compression is released to obtain the fiber reinforced molded body 10. In the fiber reinforced molded body 10 thus obtained, the surface of the surface material 25 is a smooth resin layer by curing of the thermosetting resin that has oozed out on the surface of the porous sheet 25A.

なお、前記製造方法の第１実施形態における積層工程で、前記連続気泡を有する熱硬化性樹脂発泡体１１Ａの両面に、前記含浸工程で得られた含浸済み炭素繊維織物２１Ｃを配置し、前記熱硬化性樹脂発泡体１１Ａの両側の炭素繊維織物２１Ｃの表面に多孔性シート２５Ａをそれぞれ配置して積層体を作成し、その後に前記圧縮加熱工程を行えば、表面材を両面に有する前記第２実施形態の繊維強化成形体１０Ｗを製造することができる。   In the laminating step in the first embodiment of the manufacturing method, the impregnated carbon fiber fabric 21C obtained in the impregnation step is disposed on both surfaces of the thermosetting resin foam 11A having the open cells, and the heat If the porous sheet 25A is respectively arranged on the surface of the carbon fiber fabric 21C on both sides of the curable resin foam 11A to form a laminate, and then the compression heating step is performed, the second material having a surface material on both sides is obtained. The fiber-reinforced molded body 10W of the embodiment can be manufactured.

製造方法の第２実施形態では、図５に示す（５−１）の含浸工程において、連続気泡を有する熱硬化性樹脂発泡体１１Ａに熱硬化性樹脂１１Ｂを含浸させ、含浸済み熱硬化性樹脂発泡体１１Ｃを形成する。前記連続気泡を有する熱硬化性樹脂発泡体１１Ａ及び前記熱硬化性樹脂１１Ｂは、前記繊維強化成形体１０において説明したとおりである。含浸時に用いる熱硬化性樹脂１１Ｂは、未硬化の液状からなる。また、含浸を容易にするため、前記熱硬化性樹脂１１Ｂは溶剤に溶かしたものが好ましく、含浸後に、含浸済み熱硬化性樹脂発泡体１１Ｃを前記熱硬化性樹脂の硬化反応を生じない温度で乾燥させて含浸済み熱硬化性樹脂発泡体１１Ｃから溶剤を除去する。含浸手段は、液状の熱硬化性樹脂１１Ｂを収容した槽に前記熱硬化性樹脂発泡体１１Ａを浸ける方法、スプレーにより行う方法、ロールコータにより行う方法等、適宜の方法により行う。   In the second embodiment of the manufacturing method, in the impregnation step (5-1) shown in FIG. 5, the thermosetting resin foam 11A having open cells is impregnated with the thermosetting resin 11B, and the impregnated thermosetting resin is obtained. A foam 11C is formed. The thermosetting resin foam 11 </ b> A having the open cells and the thermosetting resin 11 </ b> B are as described in the fiber reinforced molded body 10. The thermosetting resin 11B used at the time of impregnation is made of an uncured liquid. Further, in order to facilitate the impregnation, the thermosetting resin 11B is preferably dissolved in a solvent. After the impregnation, the impregnated thermosetting resin foam 11C is heated at a temperature that does not cause a curing reaction of the thermosetting resin. The solvent is removed from the impregnated thermosetting resin foam 11C by drying. The impregnation means is performed by an appropriate method such as a method of immersing the thermosetting resin foam 11A in a tank containing the liquid thermosetting resin 11B, a method of spraying, or a method of using a roll coater.

前記熱硬化性樹脂発泡体１１Ａに、前記式（Ｂ１）で規定する樹脂比率が、５０〜８０％、特には５５〜７０％となるように前記熱硬化性樹脂１１Ｂを含浸させることが好ましい。
なお、第２実施形態では、前記含浸工程において熱硬化性樹脂発泡体１１Ａのみに熱硬化性樹脂１１Ｂを含浸させる。前記熱硬化性樹脂発泡体１１Ａに含浸した熱硬化性樹脂１１Ｂが、後述するように圧縮加熱工程で前記炭素繊維織物２１Ａ及び多孔性シート２５Ａに含浸するため、前記樹脂比率の式（Ｂ１）におけるＷｂ（＝熱硬化性樹脂含浸後の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）−Ｗａ（＝熱硬化性樹脂含浸前の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）は、含浸工程において熱硬化性樹脂発泡体１１Ａに含浸した熱硬化性樹脂１１Ｂの重量と等しい値である。また、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量である。 The thermosetting resin foam 11A is preferably impregnated with the thermosetting resin 11B so that the resin ratio defined by the formula (B1) is 50 to 80%, particularly 55 to 70%.
In the second embodiment, only the thermosetting resin foam 11A is impregnated with the thermosetting resin 11B in the impregnation step. Since the thermosetting resin 11B impregnated in the thermosetting resin foam 11A impregnates the carbon fiber fabric 21A and the porous sheet 25A in the compression heating process as will be described later, in the resin ratio formula (B1) Wb (= total weight of thermosetting resin foam, carbon fiber fabric and porous sheet after impregnation with thermosetting resin) −Wa (= thermosetting resin foam and carbon fiber fabric before impregnation of thermosetting resin) The total weight of the porous sheet) is equal to the weight of the thermosetting resin 11B impregnated in the thermosetting resin foam 11A in the impregnation step. Further, the weight after impregnation in the formula of the resin ratio is the weight after removing the solvent by drying after impregnation when the thermosetting resin is used in a solvent.

図５に示す（５−２）の積層工程では、前記含浸済み熱硬化性樹脂発泡体１１Ｃの両面に、炭素繊維織物２１Ａを配置し、さらに前記含浸済み熱硬化性樹脂発泡体１１Ｃの一方の側の面における炭素繊維織物２１Ａの表面に多孔性シート２５Ａを配置して積層体１０Ｂを得る。前記炭素繊維織物２１Ａ及び前記多孔性シート２５Ａは、前記繊維強化成形体１０において説明したとおりである。なお、前記積層作業は、次に行う（５−３）の圧縮加熱工程で用いるプレス成形用下型３１の上面に、前記炭素繊維織物２１Ａ、前記含浸済み熱硬化性樹脂発泡体１１Ｃ、前記炭素繊維織物２１Ａ、前記多孔性シート２５Ａの順に重ねて行ってもよい。また、前記含浸済み熱硬化性樹脂発泡体１１Ｃと炭素繊維織物２１Ａ及び多孔性シート２５Ａは、平面サイズが同サイズのものが好ましいが、異なっている場合には、後述の圧縮加熱工程、最終的にトリミングすればよい。   In the laminating step (5-2) shown in FIG. 5, the carbon fiber fabric 21A is disposed on both surfaces of the impregnated thermosetting resin foam 11C, and one of the impregnated thermosetting resin foams 11C is further disposed. A porous sheet 25A is arranged on the surface of the carbon fiber fabric 21A on the side surface to obtain a laminate 10B. The carbon fiber fabric 21A and the porous sheet 25A are as described in the fiber reinforced molded body 10. The laminating operation is performed on the upper surface of the press molding lower mold 31 used in the compression heating step (5-3) to be performed next, the carbon fiber fabric 21A, the impregnated thermosetting resin foam 11C, and the carbon. The fiber fabric 21A and the porous sheet 25A may be stacked in this order. Further, the impregnated thermosetting resin foam 11C, the carbon fiber fabric 21A, and the porous sheet 25A preferably have the same plane size, but if they are different, the compression heating step described below, You can trim it.

図５に示す（５−３）の圧縮加熱工程では、前記積層体１０Ｂをプレス成形用下型３１と上型３３により、圧縮すると共に加熱する。圧縮は、前記繊維強化成形体１０で説明した式（Ａ１）により得られる圧縮率が２００〜５０００％、特に好ましくは１０００〜２６００％となるようにされる。前記圧縮加熱工程時、前記プレス成形用下型３１と上型３３間には適宜の位置にスペーサを設置して、前記プレス成形用下型３１と上型３３間が所定間隔（積層体の所定圧縮厚み）となるようにされる。また、積層体の加熱方法は特に限定されないが、前記プレス成形用下型３１と上型３３にヒータ等の加熱手段を設けて、前記プレス成形用下型３１と上型３３を介して行うのが簡単である。加熱温度は、前記含浸している熱硬化性樹脂の硬化反応温度以上とされる。   In the compression heating step (5-3) shown in FIG. 5, the laminate 10B is compressed and heated by the press molding lower mold 31 and the upper mold 33. The compression is performed so that the compression ratio obtained by the formula (A1) described in the fiber reinforced molded body 10 is 200 to 5000%, particularly preferably 1000 to 2600%. During the compression heating step, a spacer is installed at an appropriate position between the press molding lower mold 31 and the upper mold 33, and a predetermined interval (predetermined of the laminate) is provided between the press molding lower mold 31 and the upper mold 33. Compression thickness). Further, the heating method of the laminate is not particularly limited, and heating means such as a heater is provided in the press molding lower mold 31 and the upper mold 33, and the heating is performed via the press molding lower mold 31 and the upper mold 33. Is simple. The heating temperature is set to be equal to or higher than the curing reaction temperature of the impregnated thermosetting resin.

前記圧縮加熱工程時に前記積層体１０Ｂが圧縮されると、前記積層体１０Ｂの含浸済み熱硬化性樹脂発泡体１１Ｃから熱硬化性樹脂が押し出され、前記含浸済み熱硬化性樹脂発泡体１１Ｃと接している炭素繊維織物２１Ａに含浸し、さらには前記多孔性シート２５Ａに含浸し、前記積層体１０Ｂの全体に含浸する。また、前記多孔性シート２５Ａに含浸した前記熱硬化性樹脂は、前記多孔性シート２５Ａの表面に染み出し（滲出し）、露出して均一な樹脂層を形成する。その際、圧縮後の熱硬化性樹脂発泡体、炭素繊維織物、多孔性シートの空間容積を上回る過剰な熱硬化性樹脂は、型外部へ押し出されて、熱硬化性樹脂中に存在する微小なボイドや意図せずにできた微小な空隙は除いて、実質的に空隙が存在していない積層体となる。前記積層体１０Ｂの全体に含浸した熱硬化性樹脂は、加熱により硬化反応を開始し、前記積層体１０Ｂの圧縮状態、すなわち前記含浸済み熱硬化性樹脂発泡体１１Ｃが圧縮された状態で硬化する。なお、前記多孔性シート２５Ａがウレタン樹脂発泡体からなる場合には前記多孔性シートも圧縮された状態で前記熱硬化性樹脂が硬化する。それにより、前記含浸済み熱構成樹脂発泡体１１Ｃから前記芯材１１が形成され、また、前記炭素繊維織物２１Ａから前記繊維補強材２１が形成され、前記多孔性シート２５Ａから前記表面材２５が形成され、前記芯材１１と前記繊維補強材２１及び前記表面材２５が一体化して前記第１実施形態の繊維強化成形体１０が形成される。その後、加熱圧縮を解除して前記繊維強化成形体１０を得る。このようにして得られた繊維強化成形体１０は、前記表面材２５の表面が、前記多孔性シート２５Ａの表面に染み出した熱硬化性樹脂の硬化によって平滑な樹脂層となっている。   When the laminate 10B is compressed during the compression heating step, a thermosetting resin is extruded from the impregnated thermosetting resin foam 11C of the laminate 10B and comes into contact with the impregnated thermosetting resin foam 11C. The carbon fiber woven fabric 21A is impregnated, and further, the porous sheet 25A is impregnated to impregnate the entire laminate 10B. Further, the thermosetting resin impregnated in the porous sheet 25A oozes out (exudes) on the surface of the porous sheet 25A and is exposed to form a uniform resin layer. At that time, excessive thermosetting resin exceeding the space volume of the thermosetting resin foam, the carbon fiber woven fabric, and the porous sheet after being compressed is pushed out of the mold, and the minute amount existing in the thermosetting resin. Except for voids and unintentional fine voids, the laminate is substantially free of voids. The thermosetting resin impregnated in the entire laminate 10B starts a curing reaction by heating, and is cured in a compressed state of the laminate 10B, that is, in a state where the impregnated thermosetting resin foam 11C is compressed. . When the porous sheet 25A is made of a urethane resin foam, the thermosetting resin is cured while the porous sheet is also compressed. Thereby, the core material 11 is formed from the impregnated thermal constituent resin foam 11C, the fiber reinforcing material 21 is formed from the carbon fiber fabric 21A, and the surface material 25 is formed from the porous sheet 25A. Then, the core material 11, the fiber reinforcing material 21, and the surface material 25 are integrated to form the fiber reinforced molded body 10 of the first embodiment. Thereafter, the heat compression is released to obtain the fiber reinforced molded body 10. In the fiber reinforced molded body 10 thus obtained, the surface of the surface material 25 is a smooth resin layer by curing of the thermosetting resin that has oozed out on the surface of the porous sheet 25A.

なお、前記製造方法の第２実施形態における積層工程で、前記含浸済み熱硬化性樹脂発泡体１１Ｃの両面に炭素繊維織物２１Ａを配置し、さらに前記含浸済み熱硬化性樹脂発泡体１１Ｃの両側の炭素繊維織物２１Ａの表面にそれぞれ多孔性シート２５Ａを配置して積層体を作成し、その後に前記圧縮加熱工程を行えば、表面材を両面に有する前記第２実施形態の繊維強化成形体１０Ｗを製造することができる。   In addition, in the laminating step in the second embodiment of the manufacturing method, the carbon fiber fabric 21A is disposed on both surfaces of the impregnated thermosetting resin foam 11C, and further, on both sides of the impregnated thermosetting resin foam 11C. If the porous sheet 25A is respectively arranged on the surface of the carbon fiber fabric 21A to create a laminate, and then the compression heating step is performed, the fiber-reinforced molded body 10W of the second embodiment having the surface material on both sides is obtained. Can be manufactured.

製造方法の第３実施形態では、含浸工程が含浸工程Ａと含浸工程Ｂの２種類の含浸工程からなる。
図６に示す（６−１）のように、含浸工程Ａでは、連続気泡を有する熱硬化性樹脂発泡体１１Ａに熱硬化性樹脂１１Ｂ（請求項６の熱硬化性樹脂Ａに相当）を含浸させ、含浸済み熱硬化性樹脂発泡体１１Ｃを得る。一方、含浸工程Ｂでは、炭素繊維織物２１Ａに熱硬化性樹脂２１Ｂ（請求項６の熱硬化性樹脂Ｂに相当）を含浸させ、含浸済み炭素繊維織物２１Ｃを形成する。前記連続気泡を有する熱硬化性樹脂発泡体１１Ａ、前記熱硬化性樹脂１１Ｂ、前記炭素繊維織物２１Ａ、前記熱硬化性樹脂２１Ｂは、前記繊維強化成形体１０において説明したとおりである。含浸時に用いる熱硬化性樹脂１１Ｂ，２１Ｂは、未硬化の液状からなる。また、含浸を容易にするため、前記熱硬化性樹脂１１Ｂ，２１Ｂは溶剤に溶かしたものが好ましく、含浸後に、含浸済み熱硬化性樹脂発泡体１１Ｃ及び含浸済み炭素繊維織物２１Ｃを、前記熱硬化性樹脂の硬化反応を生じない温度で乾燥させて含浸済み熱硬化性樹脂発泡体１１Ｃ及び含浸済み炭素繊維織物２１Ｃから溶剤を除去する。含浸手段は、液状の熱硬化性樹脂を収容した槽に前記熱硬化性樹脂発泡体あるいは炭素繊維織物を浸ける方法、スプレーにより行う方法、ロールコータにより行う方法等、適宜の方法により行う。 In the third embodiment of the manufacturing method, the impregnation step includes two types of impregnation steps, impregnation step A and impregnation step B.
As shown in (6-1) in FIG. 6, in the impregnation step A, the thermosetting resin foam 11A having open cells is impregnated with the thermosetting resin 11B (corresponding to the thermosetting resin A of claim 6). The impregnated thermosetting resin foam 11C is obtained. On the other hand, in the impregnation step B, the carbon fiber fabric 21A is impregnated with a thermosetting resin 21B (corresponding to the thermosetting resin B of claim 6) to form an impregnated carbon fiber fabric 21C. The thermosetting resin foam 11 </ b> A having the open cells, the thermosetting resin 11 </ b> B, the carbon fiber fabric 21 </ b> A, and the thermosetting resin 21 </ b> B are as described in the fiber reinforced molded body 10. The thermosetting resins 11B and 21B used at the time of impregnation are made of an uncured liquid. In order to facilitate impregnation, the thermosetting resins 11B and 21B are preferably dissolved in a solvent. After the impregnation, the impregnated thermosetting resin foam 11C and the impregnated carbon fiber fabric 21C are subjected to the thermosetting. The solvent is removed from the impregnated thermosetting resin foam 11C and the impregnated carbon fiber fabric 21C by drying at a temperature that does not cause a curing reaction of the curable resin. The impregnation means is performed by an appropriate method such as a method of immersing the thermosetting resin foam or carbon fiber fabric in a tank containing a liquid thermosetting resin, a method of spraying, a method of using a roll coater, or the like.

前記熱硬化性樹脂発泡体１１Ａへの前記熱硬化性樹脂１１Ｂの含浸と、前記炭素繊維織物２１Ａへの熱硬化性樹脂２１Ｂの含浸は、前記式（Ｂ１）で規定される樹脂比率が、５０〜８０％、特には５５〜７０％となるように含浸させることが好ましい。
製造方法の第３実施形態では、前記熱硬化性樹脂発泡体１１Ａに含浸した熱硬化性樹脂１１Ｂの重量と前記炭素繊維織物２１Ａに含浸した熱硬化性樹脂２１Ｂの重量の合計は、前記樹脂比率の式（Ｂ１）におけるＷｂ（＝熱硬化性樹脂含浸後の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）−Ｗａ（＝熱硬化性樹脂含浸前の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）と等しい値である。なお、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量である。 The impregnation of the thermosetting resin 11B into the thermosetting resin foam 11A and the impregnation of the thermosetting resin 21B into the carbon fiber fabric 21A have a resin ratio defined by the formula (B1) of 50. It is preferable to impregnate so that it may become -80%, especially 55-70%.
In the third embodiment of the manufacturing method, the sum of the weight of the thermosetting resin 11B impregnated in the thermosetting resin foam 11A and the weight of the thermosetting resin 21B impregnated in the carbon fiber fabric 21A is the resin ratio. Wb (= total weight of thermosetting resin foam, carbon fiber fabric and porous sheet after impregnation of thermosetting resin) -Wa (= thermosetting resin foam before impregnation of thermosetting resin) The total weight of the body, the carbon fiber fabric and the porous sheet). In addition, the weight after impregnation in the formula of the resin ratio is the weight after drying after impregnation and removing the solvent when the thermosetting resin is dissolved in a solvent.

図６に示す（６−２）の積層工程では、前記含浸済み熱硬化性樹脂発泡体１１Ｃの両面に、前記含浸済み炭素繊維織物２１Ｃを配置し、さらに前記含浸済み熱硬化性樹脂発泡体１１Ｃの一方の側の面における前記含浸済み炭素繊維織物２１Ｃの表面に多孔性シート２５Ａを配置して積層体１０Ｃとする。前記多孔性シート２５Ａは前記繊維強化成形体１０において説明したとおりである。なお、前記積層作業は、次に行う（６−３）の圧縮加熱工程で用いるプレス成形用下型３１の上面に、前記含浸済み炭素繊維織物２１Ｃ、前記含浸済み熱硬化性樹脂発泡体１１Ｃ、前記含浸済み炭素繊維織物２１Ｃ、前記多孔性シート２５Ａの順に重ねて行ってもよい。また、前記含浸済み熱硬化性樹脂発泡体１１Ｃと含浸済み炭素繊維織物２１Ｃ及び多孔性シート２５Ａは、平面サイズが同サイズのものが好ましいが、異なっている場合には、後述の圧縮加熱工程後、最終的にトリミングすればよい。   In the step (6-2) shown in FIG. 6, the impregnated carbon fiber fabric 21C is disposed on both surfaces of the impregnated thermosetting resin foam 11C, and the impregnated thermosetting resin foam 11C is further disposed. A porous sheet 25A is arranged on the surface of the impregnated carbon fiber woven fabric 21C on the one side surface to form a laminate 10C. The porous sheet 25A is as described in the fiber-reinforced molded body 10. The laminating operation is performed on the upper surface of the press-molding lower mold 31 used in the compression heating step (6-3) to be performed next, the impregnated carbon fiber fabric 21C, the impregnated thermosetting resin foam 11C, The impregnated carbon fiber fabric 21C and the porous sheet 25A may be stacked in this order. Further, the impregnated thermosetting resin foam 11C, the impregnated carbon fiber fabric 21C, and the porous sheet 25A preferably have the same planar size, but if they are different, after the compression heating step described later, Finally, trimming is sufficient.

図６に示す（６−３）の圧縮加熱工程では、前記積層体１０Ｃをプレス成形用下型３１と上型３３により、圧縮すると共に加熱する。圧縮は、前記繊維強化成形体１０で説明した式（Ａ１）により得られる圧縮率が２００〜５０００％、特に好ましくは１０００〜２６００％となるようにする。前記圧縮加熱工程時、前記プレス成形用下型３１と上型３３間には適宜の位置にスペーサを設置して、前記プレス成形用下型３１と上型３３間が所定間隔（積層体の所定圧縮厚み）となるようにされる。また、加熱方法は特に限定されないが、前記プレス成形用下型３１と上型３３にヒータ等の加熱手段を設けて、前記プレス成形用下型３１と上型３３を介して行うのが簡単である。加熱温度は、前記含浸している熱硬化性樹脂の硬化反応温度以上とされる。   In the compression heating step (6-3) shown in FIG. 6, the laminated body 10C is compressed and heated by the press mold lower mold 31 and the upper mold 33. The compression is performed so that the compression ratio obtained by the formula (A1) described in the fiber reinforced molded body 10 is 200 to 5000%, particularly preferably 1000 to 2600%. During the compression heating step, a spacer is installed at an appropriate position between the press molding lower mold 31 and the upper mold 33, and a predetermined interval (predetermined of the laminate) is provided between the press molding lower mold 31 and the upper mold 33. Compression thickness). The heating method is not particularly limited, and it is easy to perform heating via the press molding lower mold 31 and the upper mold 33 by providing heating means such as a heater in the press molding lower mold 31 and the upper mold 33. is there. The heating temperature is set to be equal to or higher than the curing reaction temperature of the impregnated thermosetting resin.

前記圧縮加熱工程における圧縮により、前記含浸済み炭素繊維織物２１Ｃの熱硬化性樹脂と前記含浸済み熱硬化性樹脂発泡体１１Ｃの熱硬化性樹脂が確実に接触すると共に、前記含浸済み炭素繊維織物２１Ｃの熱硬化性樹脂が前記多孔性シート２５Ａに含浸し、前記積層体１０Ｃの全体に含浸する。また、前記多孔性シート２５Ａに含浸した前記熱硬化性樹脂は、前記多孔性シート２５Ａの表面に染み出し（滲出し）、露出して均一な樹脂層を形成する。その際、圧縮後の熱硬化性樹脂発泡体、炭素繊維織物、多孔性シートの空間容積を上回る過剰な熱硬化性樹脂は、型外部へ押し出されて、熱硬化性樹脂中に存在する微小なボイドや意図せずにできた微小な空隙は除いて、実質的に空隙が存在していない積層体となる。そして前記圧縮加熱工程における加熱により、前記積層体１０Ｃの全体に含浸した熱硬化性樹脂は硬化反応を開始し、前記積層体１０Ｃの圧縮状態、すなわち前記含浸済み熱硬化性樹脂発泡体１１Ｃが圧縮された状態で硬化する。なお、前記多孔性シート２５Ａがウレタン樹脂発泡体からなる場合には前記多孔性シートも圧縮された状態で前記熱硬化性樹脂が硬化する。それにより、前記含浸済み熱構成樹脂発泡体１１Ｃから前記芯材１１が形成され、また、前記含浸済み炭素繊維織物２１Ｃから前記繊維補強材２１が形成され、前記多孔性シート２５Ａから表面材２５が形成され、前記芯材１１と前記繊維補強材２１及び前記表面材２５が一体化して前記第１実施形態の繊維強化成形体１０が形成される。その後、加熱圧縮を解除して前記繊維強化成形体１０を得る。このようにして得られた繊維強化成形体１０は、前記表面材２５の表面が、前記多孔性シート２５Ａの表面に染み出した熱硬化性樹脂の硬化によって平滑な樹脂層となっている。   The compression in the compression heating step ensures that the thermosetting resin of the impregnated carbon fiber fabric 21C and the thermosetting resin of the impregnated thermosetting resin foam 11C are in contact with each other and the impregnated carbon fiber fabric 21C. The porous sheet 25A is impregnated with the thermosetting resin, and the entire laminate 10C is impregnated. Further, the thermosetting resin impregnated in the porous sheet 25A oozes out (exudes) on the surface of the porous sheet 25A and is exposed to form a uniform resin layer. At that time, excessive thermosetting resin exceeding the space volume of the thermosetting resin foam, the carbon fiber woven fabric, and the porous sheet after being compressed is pushed out of the mold, and the minute amount existing in the thermosetting resin. Except for voids and unintentional fine voids, the laminate is substantially free of voids. Then, the thermosetting resin impregnated in the entire laminate 10C starts a curing reaction by the heating in the compression heating step, and the compression state of the laminate 10C, that is, the impregnated thermosetting resin foam 11C is compressed. It cures in the finished state. When the porous sheet 25A is made of a urethane resin foam, the thermosetting resin is cured while the porous sheet is also compressed. Thereby, the core material 11 is formed from the impregnated thermal constituent resin foam 11C, the fiber reinforcing material 21 is formed from the impregnated carbon fiber fabric 21C, and the surface material 25 is formed from the porous sheet 25A. The core material 11, the fiber reinforcing material 21, and the surface material 25 are integrated to form the fiber reinforced molded body 10 of the first embodiment. Thereafter, the heat compression is released to obtain the fiber reinforced molded body 10. In the fiber reinforced molded body 10 thus obtained, the surface of the surface material 25 is a smooth resin layer by curing of the thermosetting resin that has oozed out on the surface of the porous sheet 25A.

なお、前記製造方法の第３実施形態における積層工程で、前記含浸済み熱硬化性樹脂発泡体１１Ｃの両面に、前記含浸済み炭素繊維織物２１Ｃを配置し、さらに前記含浸済み熱硬化性樹脂発泡体１１Ｃの両側の含浸済み炭素繊維織物２１Ｃの表面にそれぞれ多孔性シート２５Ａを配置して積層体を作成し、その後に前記圧縮加熱工程を行えば、表面材を両面に有する前記第２実施形態の繊維強化成形体１０Ｗを製造することができる。   In the lamination step in the third embodiment of the manufacturing method, the impregnated carbon fiber fabric 21C is disposed on both surfaces of the impregnated thermosetting resin foam 11C, and the impregnated thermosetting resin foam is further disposed. If the porous sheet 25A is respectively disposed on the surface of the impregnated carbon fiber fabric 21C on both sides of 11C to form a laminate, and then the compression heating step is performed, the surface material on both sides of the second embodiment is provided. The fiber reinforced molded body 10W can be manufactured.

製造方法の第４実施形態では、含浸工程後にプリプレグ作成工程を行い、作成したプリプレグを用いて積層工程と圧縮加熱工程を順に行う。
図７に示す（７−１）の含浸工程では、前記製造方法の第１実施形態における含浸工程と同様にして、前記炭素繊維織物２１Ａに前記熱硬化性樹脂２１Ｂを含浸させ、含浸済み炭素繊維織物２１Ｃを形成する。前記含浸工程では、前記炭素繊維織物２１Ａに、前記式（Ｂ１）で規定する樹脂比率が、５０〜８０％、特には５５〜７０％となるように熱硬化性樹脂２１Ｂを含浸させることが好ましい。また、前記炭素繊維織物２１Ａに含浸した熱硬化性樹脂２１Ｂは、圧縮加熱工程で熱硬化性樹脂発泡体１１Ａ及び多孔性シート２５Ａに含浸するため、前記樹脂比率の式（Ｂ１）におけるＷｂ（＝熱硬化性樹脂含浸後の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）−Ｗａ（＝熱硬化性樹脂含浸前の熱硬化性樹脂発泡体と炭素繊維織物と多孔性シートの合計重量）は、含浸工程において炭素繊維織物２１Ａに含浸した熱硬化性樹脂２１Ｂの重量と等しい値である。また、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量である。前記炭素繊維織物２１Ａ及び前記熱硬化性樹脂２１Ｂは、製造方法の第１実施形態で説明したとおりである。 In 4th Embodiment of a manufacturing method, a prepreg creation process is performed after an impregnation process, and a lamination process and a compression heating process are performed in order using the created prepreg.
In the impregnation step (7-1) shown in FIG. 7, the carbon fiber fabric 21A is impregnated with the thermosetting resin 21B in the same manner as the impregnation step in the first embodiment of the manufacturing method, and the impregnated carbon fiber is impregnated. A fabric 21C is formed. In the impregnation step, the carbon fiber fabric 21A is preferably impregnated with the thermosetting resin 21B so that the resin ratio defined by the formula (B1) is 50 to 80%, particularly 55 to 70%. . Further, since the thermosetting resin 21B impregnated in the carbon fiber fabric 21A is impregnated in the thermosetting resin foam 11A and the porous sheet 25A in the compression heating process, Wb in the resin ratio formula (B1) (= Total weight of thermosetting resin foam, carbon fiber fabric and porous sheet after impregnation of thermosetting resin) -Wa (= thermosetting resin foam, carbon fiber fabric and porous sheet before impregnation of thermosetting resin) Is a value equal to the weight of the thermosetting resin 21B impregnated in the carbon fiber fabric 21A in the impregnation step. Further, the weight after impregnation in the formula of the resin ratio is the weight after removing the solvent by drying after impregnation when the thermosetting resin is used in a solvent. The carbon fiber fabric 21A and the thermosetting resin 21B are as described in the first embodiment of the manufacturing method.

（７−２）のプリプレグ作成工程では、前記含浸済み炭素繊維織物２１Ｃに前記多孔性シート２５Ａを積層し、更に、前記含浸済み炭素繊維織物２１Ｃの熱硬化性樹脂２１Ｂに含まれている溶剤を除去させるため、前記熱硬化性樹脂２１Ｂが硬化しない温度で乾燥させ、プリプレグ２０Ａを半硬化状態で作成する。半硬化状態のプリプレグ２０Ａは、前記炭素繊維織物２１Ａと多孔性シート２５Ａとが前記熱硬化性樹脂２１Ｂにより、ある程度の強度で接着されており、取り扱いが容易である。前記多孔性シート２５Ａは、製造方法の第１実施形態で説明したとおりである。
また、前記炭素繊維織物２１Ａに前記多孔性シート２５Ａを積層した状態で、前記炭素繊維織物２１Ａに、塗布スプレーや塗布ローラーによって熱硬化性樹脂２１Ｂを塗布・含浸させ、前記含浸済み炭素繊維織物２１Ｃを成形すると同時に、プリプレグ２０Ａを作成しても良い。 In the prepreg creating step of (7-2), the porous sheet 25A is laminated on the impregnated carbon fiber fabric 21C, and the solvent contained in the thermosetting resin 21B of the impregnated carbon fiber fabric 21C is further removed. In order to remove it, the thermosetting resin 21B is dried at a temperature at which it is not cured, and the prepreg 20A is made in a semi-cured state. The semi-cured prepreg 20A is easy to handle because the carbon fiber fabric 21A and the porous sheet 25A are bonded to each other with a certain degree of strength by the thermosetting resin 21B. The porous sheet 25A is as described in the first embodiment of the manufacturing method.
Further, in the state where the porous sheet 25A is laminated on the carbon fiber fabric 21A, the carbon fiber fabric 21A is coated and impregnated with a thermosetting resin 21B by a coating spray or a coating roller, and the impregnated carbon fiber fabric 21C. The prepreg 20A may be formed simultaneously with the molding.

なお、前記炭素繊維織物２１Ａの他に、前記熱硬化性樹脂発泡体１１Ａにも前記熱硬化性樹脂１１Ｂを含浸させて、含浸済み熱硬化性樹脂発泡体１１Ｃを作成しておいても良い。このとき、前記熱硬化性樹脂２１Ｂ及び熱硬化性樹脂１１Ｂを同一材料とすると、前記芯材１１と繊維補強材２１との密着性が高まるので好ましい。この場合も、前記樹脂比率の式（Ｂ１）における樹脂比率が、５０〜８０％、特には５５〜７０％となるように熱硬化性樹脂を含浸させることが好ましく、記樹脂比率の式（Ｂ１）におけるＷｂ−Ｗａは、含浸工程において前記炭素繊維織物２１Ａおよび前記熱硬化性樹脂発泡体１１Ａの各々に含浸した熱硬化性樹脂の合計量と等しい値である。また、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量である。   In addition to the carbon fiber woven fabric 21A, the thermosetting resin foam 11A may be impregnated with the thermosetting resin 11B to prepare the impregnated thermosetting resin foam 11C. At this time, it is preferable that the thermosetting resin 21 </ b> B and the thermosetting resin 11 </ b> B are made of the same material because adhesion between the core material 11 and the fiber reinforcing material 21 is increased. Also in this case, it is preferable to impregnate the thermosetting resin so that the resin ratio in the resin ratio formula (B1) is 50 to 80%, particularly 55 to 70%, and the resin ratio formula (B1 ) Is equal to the total amount of the thermosetting resin impregnated in each of the carbon fiber fabric 21A and the thermosetting resin foam 11A in the impregnation step. Further, the weight after impregnation in the formula of the resin ratio is the weight after removing the solvent by drying after impregnation when the thermosetting resin is used in a solvent.

（７−３）の積層工程では、連続気泡を有する熱硬化性樹脂発泡体１１Ａの両面に、前記プリプレグ２０Ａを前記含浸済み炭素繊維織物２１Ｃが前記連続気泡を有する熱硬化性樹脂発泡体１１Ａに接するように配置し、積層体１０Ｄとする。前記連続気泡を有する熱硬化性樹脂発泡体１１Ａは、製造方法の第１実施形態で説明したとおりである。なお、前記積層作業は、次に行う（７−４）の圧縮加熱工程で用いるプレス成形用下型３１の上面に、前記プリプレグ２０Ａ、前記熱硬化性樹脂発泡体１１Ａ、前記プリプレグ２０Ａの順に重ねて行ってもよい。また、前記プリプレグ２０Ａと連続気泡を有する熱硬化性樹脂発泡体１１Ａは、平面サイズが同サイズのものが好ましいが、異なっている場合には、後述の圧縮加熱工程後にトリミングすればよい。   In the laminating step (7-3), the carbon fiber fabric 21C impregnated with the prepreg 20A is formed on the thermosetting resin foam 11A having the open cells on both surfaces of the thermoset resin foam 11A having open cells. It arrange | positions so that it may contact | connect and is set as laminated body 10D. The thermosetting resin foam 11A having the open cells is as described in the first embodiment of the manufacturing method. In the stacking operation, the prepreg 20A, the thermosetting resin foam 11A, and the prepreg 20A are stacked in this order on the upper surface of the press molding lower mold 31 used in the compression heating step (7-4) to be performed next. You may go. The prepreg 20A and the thermosetting resin foam 11A having open cells preferably have the same plane size, but if they are different, they may be trimmed after the compression heating step described later.

（７−４）の圧縮加熱工程では、前記積層体１０Ｄをプレス成形用下型３１と上型３３により圧縮すると共に加熱する。圧縮は、前記繊維強化成形体１０で説明した式（Ａ１）により得られる圧縮率が２００〜５０００％、特に好ましくは１０００〜２６００％となるように調整する。前記圧縮加熱工程時、前記プレス成形用下型３１と上型３３間には適宜の位置にスペーサを設置して、前記プレス成形用下型３１と上型３３間が所定間隔（積層体の所定圧縮厚み）となるようにされる。また、積層体の加熱方法は特に限定されないが、前記プレス成形用下型３１と上型３３にヒータ等の加熱手段を設けて、前記プレス成形用下型３１と上型３３を介して加熱するのが簡単である。加熱温度は、前記含浸している熱硬化性樹脂の硬化反応温度以上とされる。   In the compression heating step (7-4), the laminate 10D is compressed and heated by the lower mold 31 for press molding and the upper mold 33. The compression is adjusted so that the compression ratio obtained by the formula (A1) described in the fiber reinforced molded body 10 is 200 to 5000%, particularly preferably 1000 to 2600%. During the compression heating step, a spacer is installed at an appropriate position between the press molding lower mold 31 and the upper mold 33, and a predetermined interval (predetermined of the laminate) is provided between the press molding lower mold 31 and the upper mold 33. Compression thickness). The heating method of the laminated body is not particularly limited, but heating means such as a heater is provided in the lower mold 31 for press molding and the upper mold 33, and heating is performed via the lower mold 31 for press molding and the upper mold 33. It's easy. The heating temperature is set to be equal to or higher than the curing reaction temperature of the impregnated thermosetting resin.

前記圧縮加熱工程時に前記積層体１０Ａが圧縮されると、前記積層体１０Ｄのプリプレグ２０Ａから熱硬化性樹脂が押し出され、前記プリプレグ２０Ａと接している前記熱硬化性樹脂発泡体１１Ａに含浸し、前記積層体１０Ｄの全体に含浸する。さらに前記プリプレグ２０Ａに含浸している前記熱硬化性樹脂は、前記多孔性シート２５Ａの表面に染み出し（滲出し）、露出して均一な樹脂層を形成する。その際、圧縮後の熱硬化性樹脂発泡体、炭素繊維織物、多孔性シートの空間容積を上回る過剰な熱硬化性樹脂は、型外部へ押し出されて、熱硬化性樹脂中に存在する微小なボイドや意図せずにできた微小な空隙は除いて、実質的に空隙が存在していない積層体となる。前記積層体１０Ｄの全体に含浸した熱硬化性樹脂は、加熱により硬化反応を開始し、前記積層体１０Ｄが圧縮された状態で硬化する。なお、前記多孔性シート２５Ａがウレタン樹脂発泡体からなる場合には前記多孔性シート２５Ａも圧縮された状態で前記熱硬化性樹脂が硬化する。前記熱硬化性樹脂発泡体１１Ａから前記芯材１１が形成され、また、前記含浸済み炭素繊維織物２１Ｃから前記繊維補強材２１が形成され、前記多孔性シート２５Ａから表面材２５が形成され、前記芯材１１と前記繊維補強材２１及び前記表面材２５が一体化して前記第２実施形態の繊維強化成形体１０Ｗが形成される。その後、加熱圧縮を解除して前記繊維強化成形体１０Ｗを得る。このようにして得られた繊維強化成形体１０Ｗは、前記表面材２５の表面が、前記多孔性シート２５Ａの表面に染み出して付着（露出）した熱硬化性樹脂の硬化によって平滑な樹脂層となっている。   When the laminate 10A is compressed during the compression heating step, a thermosetting resin is extruded from the prepreg 20A of the laminate 10D, and the thermosetting resin foam 11A in contact with the prepreg 20A is impregnated, The entire laminate 10D is impregnated. Further, the thermosetting resin impregnated in the prepreg 20A exudes (exudes) to the surface of the porous sheet 25A and is exposed to form a uniform resin layer. At that time, excessive thermosetting resin exceeding the space volume of the thermosetting resin foam, the carbon fiber woven fabric, and the porous sheet after being compressed is pushed out of the mold, and the minute amount existing in the thermosetting resin. Except for voids and unintentional fine voids, the laminate is substantially free of voids. The thermosetting resin impregnated in the entire laminate 10D starts a curing reaction by heating, and is cured in a state where the laminate 10D is compressed. When the porous sheet 25A is made of a urethane resin foam, the thermosetting resin is cured while the porous sheet 25A is also compressed. The core material 11 is formed from the thermosetting resin foam 11A, the fiber reinforcing material 21 is formed from the impregnated carbon fiber fabric 21C, and the surface material 25 is formed from the porous sheet 25A. The core material 11, the fiber reinforcing material 21, and the surface material 25 are integrated to form the fiber reinforced molded body 10W of the second embodiment. Thereafter, the heat compression is released to obtain the fiber-reinforced molded body 10W. The fiber reinforced molded body 10W thus obtained has a smooth resin layer by curing the thermosetting resin in which the surface of the surface material 25 exudes to and adheres to (exposes) the surface of the porous sheet 25A. It has become.

前記製造方法の第４実施形態によれば、前記芯材の両面に繊維補強材が積層され、さらに芯材両面の繊維補強材の表面にそれぞれ表面材が積層されて一体化した繊維強化成形体を容易に製造できるので、前記製造方法の第４実施形態は、両面を意匠面として用いる繊維強化成形体の製造に好適である。更に、前記多孔性シート２５Ａと含浸済み炭素繊維織物２１Ｃを別々に前記連続気泡を有する熱硬化性樹脂発泡体１１Ａの両面に積層する必要がないため、製造作業の煩わしさ及び製造コストを低減することができる。   According to the fourth embodiment of the manufacturing method, a fiber reinforced molded body in which fiber reinforcing materials are laminated on both surfaces of the core material, and further, surface materials are laminated on the surfaces of the fiber reinforcing materials on both surfaces of the core material, respectively. Therefore, the fourth embodiment of the manufacturing method is suitable for manufacturing a fiber-reinforced molded body using both surfaces as a design surface. Furthermore, since it is not necessary to separately laminate the porous sheet 25A and the impregnated carbon fiber fabric 21C on both surfaces of the thermosetting resin foam 11A having the open cells, the troublesome manufacturing process and the manufacturing cost are reduced. be able to.

前記製造方法の第４実施形態における積層工程及び圧縮加熱工程に代えて、図８に示す（８−１）の積層工程及び（８−２）の圧縮加熱工程を行う製造方法の第５実施形態により、前記第３実施形態の繊維強化成形体１０Ｚを容易に製造することができる。
（８−１）の積層工程では、前記連続気泡を有する熱硬化性樹脂発泡体１１Ａの一側の面に、前記プリプレグ２０Ａを前記含浸済み炭素繊維織物２１Ｃが前記連続気泡を有する熱硬化性樹脂発泡体１１Ａに接するように配置し、一方、前記連続気泡を有する熱硬化性樹脂発泡体１１Ａの他側の面には、前記プリプレグ２０Ａを前記多孔性シート２５Ａが前記連続気泡を有する熱硬化性樹脂発泡体１１Ａに接するように配置して積層体１０Ｅとする。前記積層体１０Ｅは、一側の外面が前記多孔性シート２５Ａで構成され、他側の外面が前記含浸済み炭素繊維織物２１Ｃで構成されている。なお、前記積層作業は、次に行う（８−２）の圧縮加熱工程で用いるプレス成形用下型３１の上面に、前記プリプレグ２０Ａ、前記連続気泡を有する熱硬化性樹脂発泡体１１Ａ、前記プリプレグ２０Ａの順に重ねて行ってもよい。また、前記プリプレグ２０Ａと連続気泡を有する熱硬化性樹脂発泡体１１Ａは、平面サイズが同サイズのものが好ましいが、異なっている場合には、後述の圧縮加熱工程後にトリミングすればよい。 8th Embodiment of the manufacturing method which replaces with the lamination process and compression heating process in 4th Embodiment of the said manufacturing method, and performs the lamination process of (8-1) and the compression heating process of (8-2) shown in FIG. Thus, the fiber-reinforced molded body 10Z of the third embodiment can be easily manufactured.
In the laminating step (8-1), the carbon fiber fabric 21C impregnated with the prepreg 20A on the one side surface of the thermosetting resin foam 11A having the open cells has the open cells. On the other side of the thermosetting resin foam 11A having the open cells, the prepreg 20A is disposed on the other surface of the foam 11A, and the porous sheet 25A has the open cells. It arrange | positions so that the resin foam 11A may be contacted, and it is set as the laminated body 10E. The laminated body 10E has one outer surface made of the porous sheet 25A and the other outer surface made of the impregnated carbon fiber fabric 21C. The lamination operation is performed on the upper surface of the press molding lower mold 31 used in the compression heating step (8-2) to be performed next, the prepreg 20A, the thermosetting resin foam 11A having the open cells, and the prepreg. You may superimpose in order of 20A. The prepreg 20A and the thermosetting resin foam 11A having open cells preferably have the same plane size, but if they are different, they may be trimmed after the compression heating step described later.

（８−２）の圧縮加熱工程では、前記積層体１０Ｅを、製造方法の第４実施形態における圧縮加熱工程と同様にしてプレス成形用下型３１と上型３３により圧縮すると共に加熱する。これにより、前記第３実施形態の繊維強化成形体１０Ｚが得られる。前記繊維強化成形体１０Ｚにおける一側外面の表面材２５は、一方のプリプレグ２０Ａの多孔性シート２５Ａから形成され、それに対して前記芯材１１と接する硬化層２６は他方のプリプレグ２０Ａの多孔性シート２５Ａから形成されている。前記樹脂比率Ｒ及び圧縮率Ｃは、前記製造方法の第４実施形態と同様である。   In the compression heating step (8-2), the laminate 10E is compressed and heated by the lower die 31 for press molding and the upper die 33 in the same manner as the compression heating step in the fourth embodiment of the manufacturing method. Thereby, the fiber reinforced molded product 10Z of the third embodiment is obtained. The surface material 25 on one outer surface of the fiber-reinforced molded body 10Z is formed from a porous sheet 25A of one prepreg 20A, while the cured layer 26 in contact with the core material 11 is a porous sheet of the other prepreg 20A. 25A. The resin ratio R and the compression rate C are the same as in the fourth embodiment of the manufacturing method.

なお、前記製造方法の第４実施形態と同様に、前記炭素繊維織物２１Ａの他に、前記熱硬化性樹脂発泡体１１Ａにも前記熱硬化性樹脂１１Ｂを含浸させて、含浸済み熱硬化性樹脂発泡体１１Ｃを作成しておいても良い。このとき、前記熱硬化性樹脂２１Ｂ及び熱硬化性樹脂１１Ｂを同一材料とすると、前記芯材１１と繊維補強材２１との密着性が高まるので好ましい。また、この場合も、前記樹脂比率の式（Ｂ１）における樹脂比率が、５０〜８０％、特には５５〜７０％となるように熱硬化性樹脂を含浸させることが好ましく、記樹脂比率の式（Ｂ１）におけるＷｂ−Ｗａは、含浸工程において前記炭素繊維織物２１Ａおよび前記熱硬化性樹脂発泡体１１Ａの各々に含浸した熱硬化性樹脂の合計量と等しい値である。また、前記樹脂比率の式における含浸後の重量は、熱硬化性樹脂を溶剤に溶かして使用した場合には、含浸後に乾燥させて溶剤を除去した後の重量である。   As in the fourth embodiment of the manufacturing method, in addition to the carbon fiber fabric 21A, the thermosetting resin foam 11A is impregnated with the thermosetting resin 11B, and the impregnated thermosetting resin is impregnated. The foam 11C may be created. At this time, it is preferable that the thermosetting resin 21 </ b> B and the thermosetting resin 11 </ b> B are made of the same material because adhesion between the core material 11 and the fiber reinforcing material 21 is increased. Also in this case, it is preferable to impregnate the thermosetting resin so that the resin ratio in the formula (B1) of the resin ratio is 50 to 80%, particularly 55 to 70%. Wb-Wa in (B1) is a value equal to the total amount of the thermosetting resin impregnated in each of the carbon fiber fabric 21A and the thermosetting resin foam 11A in the impregnation step. Further, the weight after impregnation in the formula of the resin ratio is the weight after removing the solvent by drying after impregnation when the thermosetting resin is used in a solvent.

前記製造方法の第５実施形態は、片側表面のみを意匠面として用いる繊維強化成形体の製造に好適である。更に、前記多孔性シート２５Ａと含浸済み炭素繊維織物２１Ｃを別々に前記連続気泡を有する熱硬化性樹脂発泡体１１Ａの両面に積層する必要がないため、製造作業の煩わしさ及び製造コストを低減することができる。   5th Embodiment of the said manufacturing method is suitable for manufacture of the fiber reinforced molded object which uses only one side surface as a design surface. Furthermore, since it is not necessary to separately laminate the porous sheet 25A and the impregnated carbon fiber fabric 21C on both surfaces of the thermosetting resin foam 11A having the open cells, the troublesome manufacturing process and the manufacturing cost are reduced. be able to.

前記製造方法の第１実施形態により実施例８の繊維強化成形体を製造し、前記製造方法の第２実施形態により実施例９の繊維強化成形体を製造し、前記製造方法の第３実施形態により実施例１〜７、１０〜１４の繊維強化成形体を製造し、前記製造方法の第４実施形態によりに実施例１６の繊維強化成形体を作成し、前記製造方法の第５実施形態により実施例１５の繊維強化成形体を作成し、比較例１〜１０の繊維強化成形体と比較した。
・実施例１
熱硬化性樹脂としてフェノール樹脂（旭有機材料株式会社製、品名；ＰＡＰＳ−４と旭有機材料株式会社製、品名；ヘキサメチレンテトラミンを１００：１２で混合したもの）をメタノールに３０ｗｔ％の濃度となるように溶解した。このフェノール樹脂溶液中に平織の炭素繊維織物（東邦テナックス株式会社製、品名；Ｗ−３１０１、繊維重さ２００ｇ／ｍ２）を漬け、取り出した後に２５℃の室温にて２時間自然乾燥し、更に６０℃の雰囲気下にて１時間乾燥させて含浸済み炭素繊維織物を２枚形成した。炭素繊維織物は、２００×３００ｍｍの平面サイズに裁断したもの（重量１２ｇ／枚）を使用した。乾燥後の含浸済み炭素繊維織物は１枚あたり２８ｇであった。 The fiber-reinforced molded body of Example 8 is manufactured by the first embodiment of the manufacturing method, the fiber-reinforced molded body of Example 9 is manufactured by the second embodiment of the manufacturing method, and the third embodiment of the manufacturing method is manufactured. The fiber-reinforced molded bodies of Examples 1 to 7 and 10 to 14 are manufactured, the fiber-reinforced molded body of Example 16 is created according to the fourth embodiment of the manufacturing method, and the fifth embodiment of the manufacturing method is used. The fiber reinforced molded body of Example 15 was created and compared with the fiber reinforced molded bodies of Comparative Examples 1-10.
Example 1
As a thermosetting resin, phenol resin (Asahi Organic Materials Co., Ltd., product name: PAPS-4 and Asahi Organic Materials Co., Ltd., product name: hexamethylenetetramine mixed at 100: 12) in methanol with a concentration of 30 wt% It dissolved so that it might become. A plain-woven carbon fiber woven fabric (manufactured by Toho Tenax Co., Ltd., product name: W-3101, fiber weight 200 g / m 2 ) is dipped in this phenol resin solution, taken out, and naturally dried at room temperature of 25 ° C. for 2 hours Further, it was dried in an atmosphere at 60 ° C. for 1 hour to form two impregnated carbon fiber fabrics. The carbon fiber fabric used was cut into a plane size of 200 × 300 mm (weight 12 g / sheet). The impregnated carbon fiber fabric after drying was 28 g per sheet.

また、連続気泡を有する熱硬化性樹脂発泡体として、厚み１０ｍｍ、平面サイズ２００×３００ｍｍ（重量５．４ｇ）に切り出したメラミン樹脂発泡体（ＢＡＳＦ社製、品名：バソテクトＶ３０１２、密度９ｋｇ／ｍ３）を、炭素繊維織物と同様にしてフェノール樹脂溶液に漬け、取り出した後に２５℃の室温にて２時間自然乾燥し、更に６０℃の雰囲気下にて１時間乾燥させて含浸済み熱硬化性樹脂発泡体を形成した。乾燥後の含浸済み熱硬化樹脂発泡体の重量は２７ｇであった。また、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）は６５％であった。 In addition, as a thermosetting resin foam having open cells, a melamine resin foam cut out to a thickness of 10 mm and a planar size of 200 × 300 mm (weight 5.4 g) (manufactured by BASF, product name: Vasotect V3012, density 9 kg / m 3) ) Is immersed in a phenolic resin solution in the same manner as the carbon fiber fabric, taken out, dried naturally at room temperature of 25 ° C. for 2 hours, and further dried in an atmosphere of 60 ° C. for 1 hour to impregnate the thermosetting resin. A foam was formed. The weight of the impregnated thermosetting resin foam after drying was 27 g. Moreover, the resin ratio (value calculated by the formula (B1) of the resin ratio) contained in the entire carbon fiber fabric and the thermosetting foam was 65%.

次に、予め離型剤を表面に塗布したＳＵＳ製のプレス成形用の下型（平板状）の上に、含浸済み炭素繊維織物、含浸済み熱硬化性樹脂発泡体、含浸済み炭素繊維織物、多孔性シートの順に重ねて配置することにより、含浸済み熱硬化性樹脂発泡体の両面に含浸済み炭素繊維織物を配置し、さらに含浸済み熱硬化性樹脂発泡体の一側の面における含浸済み炭素繊維織物の表面に多孔性シートを配置した積層体をプレス成形用下型上にセットした。多孔性シートは、溶解処理によりセル膜を除去したウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名；ＭＦ−５０、嵩比重０．０３、セル数５０個／２５ｍｍ）を、非圧縮状態の厚み０．４ｍｍに裁断したものを用いた。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は４．０％である。なお、使用したウレタン樹脂発泡体の空隙率は９７．１％である。空隙率の計算式は次の通りである。空隙率＝（ウレタン樹脂真比重−嵩比重（≒ウレタン樹脂発泡体見かけ密度））／ウレタン樹脂真比重×１００   Next, an impregnated carbon fiber woven fabric, an impregnated thermosetting resin foam, an impregnated carbon fiber woven fabric, an SUS press-molded lower mold (flat plate shape) having a release agent coated on the surface in advance, By placing the porous sheets one after the other, the impregnated carbon fiber fabric is disposed on both sides of the impregnated thermosetting resin foam, and the impregnated carbon on one side of the impregnated thermosetting resin foam is further disposed. A laminate in which a porous sheet was arranged on the surface of a fiber fabric was set on a lower mold for press molding. The porous sheet is a non-compressed thickness of a urethane resin foam (product name: MF-50, bulk specific gravity 0.03, number of cells 50/25 mm, manufactured by Inoac Corporation) from which the cell membrane has been removed by dissolution treatment. What was cut into 0.4 mm was used. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 4.0%. In addition, the porosity of the used urethane resin foam is 97.1%. The formula for calculating the porosity is as follows. Porosity = (urethane resin true specific gravity−bulk specific gravity (≈appearance density of urethane resin foam)) / urethane resin true specific gravity × 100

前記積層体をプレス成形用下型上にセットした状態で、１８０℃で３分間、５ＭＰａの面圧をかけてプレス成形用上型（平板状）で前記積層体を押圧し、圧縮及び加熱を行ない、前記圧縮状態でフェノール樹脂を反応硬化させた。その際の積層体の加熱は、上下のプレス型に取り付けられた鋳込みヒーターにより行なった。また、プレス成形用下型と上型間には厚み０．９ｍｍのＳＵＳ製スペーサを介在させて下型と上型間の間隔、すなわち積層体の圧縮厚みを調整した。その後、プレス成形用下型と上型を室温で冷却させた後に下型と上型を開き、芯材の両面に繊維補強材が積層し、さらに一側の繊維補強材に多孔性シートから形成された表面材が積層一体化した繊維強化成形体を得た。この繊維強化成形体を１７０×２６０ｍｍにトリミングして実施例１の繊維強化成形体とした。   In a state where the laminate is set on the lower mold for press molding, the laminate is pressed with the upper mold for press molding (flat plate shape) by applying a surface pressure of 5 MPa at 180 ° C. for 3 minutes, and compressed and heated. Then, the phenol resin was reaction-cured in the compressed state. At that time, the laminate was heated by a casting heater attached to the upper and lower press dies. Further, a 0.9 mm thick SUS spacer was interposed between the lower mold for press molding and the upper mold to adjust the distance between the lower mold and the upper mold, that is, the compression thickness of the laminate. Then, after lowering the press mold lower mold and upper mold at room temperature, the lower mold and upper mold are opened, fiber reinforcing material is laminated on both sides of the core material, and a porous sheet is formed on one side fiber reinforcing material As a result, a fiber-reinforced molded body in which the finished surface material was laminated and integrated was obtained. This fiber reinforced molded body was trimmed to 170 × 260 mm to obtain a fiber reinforced molded body of Example 1.

実施例１の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２２５％であった。また、実施例１の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は、曲げ弾性率が５０ＧＰａ（繊維方向）であった。   About the fiber reinforced molded object of Example 1, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Was calculated to be 2225%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 1 was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus was 50 GPa (fiber direction).

・実施例２
連続気泡を有する熱硬化性樹脂発泡体の厚みを５ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例１と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は８．０％である。
実施例２の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２９、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（５ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると１０６２％であった。また、実施例２の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が４９ＧＰａ（繊維方向）であった。 Example 2
Resin contained in the carbon fiber fabric and the entire thermosetting foam by adjusting the amount of the thermosetting resin impregnated into the thermosetting resin foam by adjusting the thickness of the thermosetting resin foam having open cells to 5 mm. A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the ratio (value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 8.0%.
About the fiber reinforced molded object of Example 2, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (5 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Calculated to be 1062%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 2 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 49 GPa (fiber direction).

・実施例３
連続気泡を有する熱硬化性樹脂発泡体の厚みを１１．５ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例１と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は３．５％である。実施例３の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３２、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１１．５ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると２５１３％であった。また、実施例３の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が５１ＧＰａ（繊維方向）であった。 Example 3
The thickness of the thermosetting resin foam having open cells is 11.5 mm, and the amount of the thermosetting resin impregnated into the thermosetting resin foam is adjusted to be included in the entire carbon fiber fabric and the thermosetting foam. A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the resin ratio (value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 3.5%. About the fiber reinforced molded object of Example 3, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.32, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (11.5 mm) of the thermosetting resin foam before compression and the thickness (0.44 mm) of the core material. It was 25133% when calculated according to the formula of Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 3 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 51 GPa (fiber direction).

・実施例４
連続気泡を有する熱硬化性樹脂発泡体の厚みを１．４ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例１と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は２８．６％である。実施例４の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２８、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１．４ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２５％であった。また、実施例４の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が４６ＧＰａ（繊維方向）であった。 Example 4
The thickness of the thermosetting resin foam with open cells is 1.4mm, and the amount of thermosetting resin impregnated into the thermosetting resin foam is adjusted to be included in the entire carbon fiber fabric and thermosetting foam. A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the resin ratio (value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 28.6%. About the fiber reinforced molded object of Example 4, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.28, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (1.4 mm) of the thermosetting resin foam before compression and the thickness (0.43 mm) of the core material. It was 225% when calculated according to the formula of Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 4 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 46 GPa (fiber direction).

・実施例５
連続気泡を有する熱硬化性樹脂発泡体の厚みを２２ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例１と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１．８％である。実施例５の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３５、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（２２ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると４９００％であった。また、実施例５の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が５１ＧＰａ（繊維方向）であった。 Example 5
Resin contained in the entire carbon fiber fabric and the thermosetting foam by adjusting the amount of the thermosetting resin impregnated into the thermosetting resin foam by adjusting the thickness of the thermosetting resin foam having open cells to 22 mm. A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the ratio (value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 1.8%. About the fiber reinforced molded object of Example 5, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.35, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (22 mm) and the thickness of the core material (0.44 mm), and the compression rate formula It was 4900% when calculated according to the above. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 5 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 51 GPa (fiber direction).

・実施例６
乾燥後の含浸済み炭素繊維織物の重量が１枚あたり３５ｇ、乾燥後の含浸済み熱硬化樹脂発泡体の重量が４５ｇ、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を７４％とした以外は、実施例１と同様にして、繊維強化成形体を得た。実施例６の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．４５、全体の厚みは１．０ｍｍ、芯材の厚みは０．５２ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．５２ｍｍ）を用い、前記圧縮率の式に従って計算すると１８２３％であった。また、実施例６の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が５５ＧＰａ（繊維方向）であった。 Example 6
The weight of the impregnated carbon fiber fabric after drying is 35 g per sheet, the weight of the impregnated thermosetting resin foam after drying is 45 g, the resin ratio contained in the entire carbon fiber fabric and the thermosetting foam (the resin ratio) A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the value (calculated by the formula (B1)) was changed to 74%. About the fiber reinforced molded object of Example 6, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.45, the entire thickness was 1.0 mm, and the thickness of the core material was 0.52 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.52 mm), and the compression rate formula And calculated according to 182. In addition, the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 6 was measured in order to determine rigidity. The measurement result was a flexural modulus of 55 GPa (fiber direction).

・実施例７
乾燥後の含浸済み炭素繊維織物の重量が１枚あたり２２ｇ、乾燥後の含浸済み熱硬化樹脂発泡体の重量が１６ｇ、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を５１％とした以外は、実施例１と同様にして、繊維強化成形体を得た。実施例７の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２２５％であった。また、実施例７の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が４５ＧＰａ（繊維方向）であった。 -Example 7
The weight of the impregnated carbon fiber fabric after drying is 22 g per sheet, the weight of the impregnated thermosetting resin foam after drying is 16 g, and the resin ratio contained in the entire carbon fiber fabric and the thermosetting foam (the resin ratio) A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the value calculated by the formula (B1) was 51%. About the fiber reinforced molded object of Example 7, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Was calculated to be 2225%. In addition, the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 7 was measured in order to determine rigidity. The measurement result was a flexural modulus of 45 GPa (fiber direction).

・実施例８
乾燥後の含浸済み炭素繊維織物の重量が４０ｇ、熱硬化樹脂発泡体には樹脂を含浸させずに、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６６％とした以外は、実施例１と同様にして、繊維強化成形体を得た。実施例８の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２２５％であった。また、実施例８の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が５０ＧＰａ（繊維方向）であった。 Example 8
The weight of the impregnated carbon fiber woven fabric after drying is 40 g, the resin ratio contained in the entire carbon fiber woven fabric and the thermosetting foam without impregnating the resin in the thermosetting resin foam (the formula (B1 ) Was obtained in the same manner as in Example 1 except that the value calculated in (1) was 66%. About the fiber reinforced molded object of Example 8, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Was calculated to be 2225%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 8 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 50 GPa (fiber direction).

・実施例９
炭素繊維織物には樹脂を含浸せず、乾燥後の含浸済み熱硬化樹脂発泡体の重量が４０ｇ、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を５４％とした以外は、実施例１と同様にして、繊維強化成形体を得た。実施例９の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２２５％であった。また、実施例９の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が４６ＧＰａ（繊維方向）であった。 Example 9
The carbon fiber fabric is not impregnated with resin, and the weight of the impregnated thermosetting resin foam after drying is 40 g. The resin ratio contained in the entire carbon fiber fabric and the thermosetting foam (formula (B1) of the resin ratio) A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the value calculated in (1) was 54%. About the fiber reinforced molded object of Example 9, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Was calculated to be 2225%. In addition, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 9 was measured in order to determine rigidity. The measurement result was a flexural modulus of 46 GPa (fiber direction).

・実施例１０
連続気泡を有する熱硬化性樹脂発泡体としてウレタン樹脂発泡体（株式会社イノアックコーポレーション製モルトプレンＭＦ８０、密度７２ｋｇ／ｍ３）を用い、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例２と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は８．０％である。実施例１０の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３５、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（５ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると１０３６％であった。また、実施例１０の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が３５ＧＰａ（繊維方向）であった。 Example 10
The urethane resin foam (Mortoprene MF80 manufactured by Inoac Corporation, density 72 kg / m 3 ) is used as the thermosetting resin foam having open cells, and the amount of impregnation of the thermosetting resin into the thermosetting resin foam is adjusted. In the same manner as in Example 2, except that the resin ratio (value calculated by the formula (B1) of the resin ratio) contained in the entire carbon fiber fabric and the thermosetting foam is 65%, fiber reinforcement is performed. A molded body was obtained. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 8.0%. About the fiber reinforced molded object of Example 10, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.35, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (5 mm) and the thickness of the core material (0.44 mm), and the compression rate formula Was calculated to be 1036%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber-reinforced molded body of Example 10 was measured in order to determine rigidity. The measurement result was a flexural modulus of 35 GPa (fiber direction).

・実施例１１
熱硬化性樹脂としてエポキシ樹脂（ＤＩＣ株式会社製、品名；エピクロン８５０とＤＩＣ株式会社製、品名；ＷＨ−１０８Ｓを１００：３０で混合したもの）を用いた以外は、実施例１と同様にして、繊維強化成形体を得た。炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）は６５％である。実施例１１の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２２５％であった。また、実施例１１の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が４９ＧＰａ（繊維方向）であった。 Example 11
Example 1 was used except that an epoxy resin (manufactured by DIC Corporation, product name: Epicron 850 and DIC Corporation, product name: WH-108S mixed at 100: 30) was used as the thermosetting resin. A fiber-reinforced molded product was obtained. The resin ratio (value calculated by the formula (B1) of the resin ratio) contained in the entire carbon fiber fabric and the thermosetting foam is 65%. About the fiber reinforced molded object of Example 11, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Was calculated to be 2225%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 11 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 49 GPa (fiber direction).

・実施例１２
連続気泡を有する熱硬化性樹脂発泡体として、厚み２．２ｍｍ、平面サイズ２００×３００ｍｍ（重量１．２ｇ）に切り出したメラミン樹脂発泡体（ＢＡＳＦ社製、品名：バソテクトＶ３０１２、密度９ｋｇ／ｍ３）を用いた以外は実施例１と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１８．２％である。なお、乾燥後の含浸済み熱硬化樹脂発泡体の重量は１６ｇであった。また、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）は６５％であった。実施例１２の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２８、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（２．２ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると４１１％であった。また、実施例１２の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は、曲げ弾性率が４６ＧＰａ（繊維方向）であった。 Example 12
As a thermosetting resin foam having open cells, a melamine resin foam cut out to a thickness of 2.2 mm and a planar size of 200 × 300 mm (weight 1.2 g) (manufactured by BASF, product name: Vasotect V3012, density 9 kg / m 3 ) Was used in the same manner as in Example 1 to obtain a fiber-reinforced molded body. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 18.2%. The weight of the impregnated thermosetting resin foam after drying was 16 g. Moreover, the resin ratio (value calculated by the formula (B1) of the resin ratio) contained in the entire carbon fiber fabric and the thermosetting foam was 65%. About the fiber reinforced molded object of Example 12, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.28, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (2.2 mm) of the thermosetting resin foam before compression and the thickness (0.43 mm) of the core material. It was 411% when calculated according to the formula of Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Example 12 was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus was 46 GPa (fiber direction).

・実施例１３
連続気泡を有する熱硬化性樹脂発泡体の厚みを３ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした以外は、実施例１２と同様にして、実施例１３の繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１３．３％である。実施例１３の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２９、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（３ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると５９７％であった。また、実施例１３の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が４７ＧＰａ（繊維方向）であった。 Example 13
Resin contained in carbon fiber fabric and thermosetting foam as a whole by adjusting the thickness of thermosetting resin foam having open cells to 3 mm and adjusting the amount of thermosetting resin impregnated into thermosetting resin foam A fiber-reinforced molded body of Example 13 was obtained in the same manner as Example 12 except that the ratio was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 13.3%. About the fiber reinforced molded object of Example 13, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness (3 mm) of the thermosetting resin foam before compression and the thickness (0.43 mm) of the core material, and the compression rate formula. And calculated to be 597%. Further, the flexural modulus (JIS K7074) of the fiber reinforced molded body of Example 13 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 47 GPa (fiber direction).

・実施例１４
連続気泡を有する熱硬化性樹脂発泡体の厚みを４ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした以外は、実施例１２と同様にして、実施例１４の繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１０．０％である。実施例１４の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２９、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（４ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると８３０％であった。また、実施例１４の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が４９ＧＰａ（繊維方向）であった。 Example 14
Resin contained in carbon fiber fabric and thermosetting foam as a whole by adjusting the thickness of thermosetting resin foam having open cells to 4 mm and adjusting the amount of thermosetting resin impregnated in thermosetting resin foam A fiber-reinforced molded body of Example 14 was obtained in the same manner as Example 12 except that the ratio was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 10.0%. About the fiber reinforced molded object of Example 14, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (4 mm) and the thickness of the core material (0.43 mm), and the compression rate formula Was calculated to be 830%. Further, the flexural modulus (JIS K7074) of the fiber-reinforced molded body of Example 14 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 49 GPa (fiber direction).

・実施例１５
フェノール樹脂（ＤＩＣ株式会社製、品名；フェノライト５０１０、固形分６０％）をエタノールに５０ｗｔ％となるように混合した。このフェノール樹脂溶液を平織の炭素繊維織物（東邦テナックス株式会社製、品名；Ｗ−３１０１、繊維重さ２００ｇ／ｍ２）に浸漬させ、その上に多孔性シート（株式会社イノアックコーポレーション製、品名；ＭＦ−５０ＬＥ、嵩比重０．０３、セル数５０個／２５ｍｍ）を設置してプリプレグを得た。 Example 15
Phenol resin (manufactured by DIC Corporation, product name: Phenolite 5010, solid content 60%) was mixed with ethanol so as to be 50 wt%. This phenolic resin solution is immersed in a plain-woven carbon fiber fabric (manufactured by Toho Tenax Co., Ltd., product name; W-3101, fiber weight 200 g / m 2 ), and a porous sheet (manufactured by Inoac Corporation, product name) is placed thereon. MF-50LE, bulk specific gravity 0.03, 50 cells / 25 mm) were installed to obtain a prepreg.

多孔性シートは、溶解処理によりセル膜を除去したウレタン樹脂発泡体を非圧縮状態の厚み０．７ｍｍに裁断したものを用いた。なお、使用したウレタン樹脂発泡体の空隙率は９７．１％であった。空隙率の計算式は次の通りである。
空隙率＝（ウレタン樹脂真比重−嵩比重（≒ウレタン樹脂発泡体見かけ密度）/ウレタン樹脂真比重×１００ As the porous sheet, a urethane resin foam from which the cell membrane was removed by dissolution treatment was cut into a non-compressed thickness of 0.7 mm. In addition, the porosity of the used urethane resin foam was 97.1%. The formula for calculating the porosity is as follows.
Porosity = (Urethane resin true specific gravity-Bulk specific gravity (≒ Apparent density of urethane resin foam) / Urethane resin true specific gravity x 100

なお、炭素繊維織物は、３８０×２６０ｍｍ（重量１９．８ｇ／枚）を使用した。乾燥後の含浸済み炭素繊維織物は1枚あたり３６ｇであった。このようにして得られた２枚のプリプレグを８７℃の雰囲気下にて５分乾燥させた。   The carbon fiber fabric used was 380 × 260 mm (weight 19.8 g / sheet). The impregnated carbon fiber fabric after drying was 36 g per sheet. The two prepregs thus obtained were dried at 87 ° C. for 5 minutes.

連続気泡を有する熱硬化性樹脂発泡体として、厚み７．５ｍｍ、平面サイズ３８０×２６０ｍｍ（重量６．０ｇ/枚）に切り出した連続気泡を有するメラミン樹脂発泡体（ＢＡＳＦ社製、品名；バソテクトＶ３０１２、密度９ｋｇ／ｍ３）を、炭素繊維織物と同様にしてフェノール樹脂溶液に浸漬させ、取り出した後に１００℃の雰囲気下にて３１分乾燥し、乾燥後の含浸済み熱硬化樹脂発泡体を形成した。乾燥後の含浸済み熱硬化性樹脂発泡体の重量は６７ｇであった。また、炭素繊維織物と熱硬化性樹脂発泡体に含まれる樹脂比率は６４％であった。 As a thermosetting resin foam having open cells, a melamine resin foam having a continuous cell cut to a thickness of 7.5 mm and a planar size of 380 × 260 mm (weight: 6.0 g / sheet) (manufactured by BASF, product name: Bazotect V3012) , A density of 9 kg / m 3 ) is immersed in a phenolic resin solution in the same manner as the carbon fiber fabric, taken out and dried in an atmosphere of 100 ° C. for 31 minutes to form an impregnated thermosetting resin foam after drying. did. The weight of the impregnated thermosetting resin foam after drying was 67 g. Moreover, the resin ratio contained in the carbon fiber fabric and the thermosetting resin foam was 64%.

次に、予め離型剤を表面に塗布したＳＵＳ製のプレス成形用の平板状の下型の上に、多孔性シート面を上側にしたプリプレグ、含浸済み熱硬化性樹脂発泡体、多孔性シート面を上側にしたプリプレグの順に積層し積層体を得た。すなわちこの積層体は、下から順に炭素繊維織物、多孔性シート、熱硬化性樹脂発泡体、炭素繊維織物、多孔性シートが積層されている。この積層体をプレス成形用下型上にセットした。芯材となる熱硬化性樹脂発泡体と多孔シートの合計厚みに対する表面材となる多孔性シートの厚みの比は８．５％である。   Next, a prepreg having a porous sheet surface on the upper side, a SUS press-molded flat mold with a release agent applied on the surface in advance, an impregnated thermosetting resin foam, and a porous sheet Laminates were obtained by laminating in order of prepregs with the surface facing up. That is, in this laminate, a carbon fiber fabric, a porous sheet, a thermosetting resin foam, a carbon fiber fabric, and a porous sheet are laminated in order from the bottom. This laminate was set on a lower mold for press molding. The ratio of the thickness of the porous sheet serving as the surface material to the total thickness of the thermosetting resin foam serving as the core material and the porous sheet is 8.5%.

前記積層体をプレス成形用下型上にセットした状態で、１４５℃で８分間、５ＭＰａの面圧をかけてプレス成形用上型（平板状）で積層体を押圧し、圧縮及び加熱を行い、圧縮状態でフェノール樹脂を反応硬化させた。   With the laminate set on the lower mold for press molding, pressurize the laminate with the upper mold for press molding (flat plate shape) at 145 ° C. for 8 minutes, applying a surface pressure of 5 MPa, and compress and heat The phenol resin was reaction-cured in a compressed state.

その際の積層体の加熱は上下のプレス型に取り付けられた鋳込みヒータにより行った。また、プレス成形用下型と上型の間には１．０ｍｍの間隔を設けて積層体の圧縮厚みを調整した。その後下型と上型を開き、芯材の一側には多孔性シートから形成された硬化層が積層し、さらに前記硬化層に繊維補強材が積層一体化し、一方、芯材の他側には繊維維補強材が積層し、さらに繊維補強材に多孔性シートから形成された表面材が積層一体化した繊維強化成形体を得た。   At that time, the laminate was heated by a cast heater attached to the upper and lower press dies. Further, the compressed thickness of the laminate was adjusted by providing a gap of 1.0 mm between the lower mold for press molding and the upper mold. Thereafter, the lower mold and the upper mold are opened, and a cured layer formed of a porous sheet is laminated on one side of the core material, and a fiber reinforcing material is laminated and integrated on the cured layer, while on the other side of the core material Obtained a fiber reinforced molded body in which fiber fiber reinforcing materials were laminated and a surface material formed from a porous sheet was laminated and integrated on the fiber reinforcing material.

実施例１５の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．４０、全体の厚みは１．０ｍｍ、芯材の厚みは０．４８ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、圧縮前の芯材用熱硬化性樹脂発泡体の厚み（７．５ｍｍ）と芯材の厚み（０．４８ｍｍ）を用い、圧縮率の式に従って計算すると１４６２％であった。また、実施例１５の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定したところ、４８ＧＰａであった。   About the fiber reinforced molded object of Example 15, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.40, the overall thickness was 1.0 mm, and the thickness of the core material was 0.48 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (7.5 mm) of the thermosetting resin foam for the core material before compression and the thickness (0.48 mm) of the core material. It was 1462% when calculated according to the formula of Moreover, it was 48 GPa when the bending elastic modulus (JIS K7074-1988 A method) was measured about the fiber reinforced molded object of Example 15 in order to judge rigidity.

・実施例１６
実施例１５と同様にして得られたプリプレグを用い、予め離型剤を表面に塗布したＳＵＳ製のプレス成形用の下型（平板状）の上に、多孔性シート面を下側としたプリプレグ、含浸済み熱硬化性樹脂発泡体、多孔性シート面を上側としたプリプレグの順に積層させて積層体を得た。すなわちこの積層体は、下から順に多孔性シート、炭素繊維織物、熱硬化性樹脂発泡体、炭素繊維織物、多孔性シートが積層されている。この積層体をプレス成形用下型上にセットした。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚み（両面の合計）の比は１８．７％である。 Example 16
Using a prepreg obtained in the same manner as in Example 15, a prepreg having a porous sheet surface on the lower side on a lower mold (flat plate) made of SUS and having a release agent applied in advance to the surface. Then, the laminated body was obtained by laminating the impregnated thermosetting resin foam and the prepreg with the porous sheet surface facing upward. That is, in this laminate, a porous sheet, a carbon fiber fabric, a thermosetting resin foam, a carbon fiber fabric, and a porous sheet are laminated in order from the bottom. This laminate was set on a lower mold for press molding. The ratio of the thickness of the porous sheet (total of both surfaces) to the thickness of the thermosetting resin foam having open cells is 18.7%.

この積層体をプレス成形用下型上にセットした状態で、１４５℃で８分間、５ＭＰａの面圧をかけてプレス成形用上型（平板状）で積層体を圧縮及び加熱し、圧縮状態でフェノール樹脂を反応硬化させた。その際の積層体の加熱は上下のプレス型に取り付けられた鋳込みヒータにより行った。また、プレス成形用下型と上型の間には１．０ｍｍの間隔を設けて積層体の圧縮厚みを調整した。その後下型と上型を開き、芯材の両面に繊維補強材が積層し、さらに繊維補強材の両面に多孔性シートから形成された表面材が積層一体化した繊維強化成形体を得た。   In a state where the laminate is set on the lower mold for press molding, the laminate is compressed and heated with an upper mold for press molding (flat plate shape) at 145 ° C. for 8 minutes and a surface pressure of 5 MPa. The phenolic resin was reaction cured. At that time, the laminate was heated by a cast heater attached to the upper and lower press dies. Further, the compressed thickness of the laminate was adjusted by providing a gap of 1.0 mm between the lower mold for press molding and the upper mold. Thereafter, the lower mold and the upper mold were opened to obtain a fiber-reinforced molded body in which fiber reinforcing materials were laminated on both surfaces of the core material, and surface materials formed from porous sheets were laminated and integrated on both surfaces of the fiber reinforcing material.

実施例１６の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．４０、全体の厚みは１．０ｍｍ、芯材の厚みは０．４８ｍｍであった。芯材用樹脂発泡体の圧縮率は、圧縮前の芯材用樹脂発泡体の厚み（７．５ｍｍ）と芯材の厚み（０．４８ｍｍ）を用い、圧縮率の式に従って計算すると１４６２％であった。また、実施例１６の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定したところ、４２ＧＰａであった。   About the fiber reinforced molded object of Example 16, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.40, the overall thickness was 1.0 mm, and the thickness of the core material was 0.48 mm. The compression ratio of the core resin foam is 1462% when calculated according to the compression ratio formula using the thickness (7.5 mm) of the core resin foam before compression and the thickness of the core (0.48 mm). there were. Moreover, when the bending elastic modulus (JIS K7074-1988 A method) was measured about the fiber reinforced molded object of Example 16 in order to judge rigidity, it was 42 GPa.

・比較例１
連続気泡を有する熱硬化性樹脂発泡体の厚みを０．９５ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例１と同様にして、繊維強化成形体を得た。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は４２．１％である。比較例１の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２８、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（０．９５ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると１２１％であった。また、比較例１の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が２５ＧＰａ（繊維方向）であり、各実施例と比べると前記圧縮率が低いことにより、曲げ弾性率（剛性）が低いものであった。 Comparative example 1
The thickness of the thermosetting resin foam having open cells is 0.95 mm, and the amount of thermosetting resin impregnated into the thermosetting resin foam is adjusted to be included in the entire carbon fiber fabric and thermosetting foam. A fiber-reinforced molded body was obtained in the same manner as in Example 1 except that the resin ratio (value calculated by the formula (B1) of the resin ratio) was 65%. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 42.1%. About the fiber reinforced molded object of the comparative example 1, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.28, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (0.95 mm) of the thermosetting resin foam before compression and the thickness (0.43 mm) of the core material. It was 121% when calculated according to the formula of Further, the flexural modulus (JIS K7074-1988 A method) was measured for the fiber reinforced molded body of Comparative Example 1 in order to determine the rigidity. As a result of the measurement, the bending elastic modulus was 25 GPa (fiber direction), and the bending elastic modulus (rigidity) was low due to the low compression rate compared to each example.

・比較例２
連続気泡を有する熱硬化性樹脂発泡体の厚みを３０ｍｍとし、熱硬化性樹脂発泡体への熱硬化性樹脂の含浸量を調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を６５％とした以外は、実施例１と同様にして、繊維強化成形体の成形を行ったが、十分に圧縮できず厚みムラの大きい成形体しか得られなかった。比較例２における圧縮率は、得られる芯材の厚みが実施例１と同じ厚み（０．４３ｍｍ）になると仮定した場合、前記圧縮前の熱硬化性樹脂発泡体の厚み（３０ｍｍ）を用いて前記圧縮率の式に従って計算すると６８７７％となり、圧縮率が５０００％を超えるために、比較例２では良好な成形体が得られなかった。 Comparative example 2
Resin contained in the entire carbon fiber fabric and thermosetting foam by adjusting the amount of thermosetting resin impregnated into the thermosetting resin foam by adjusting the thickness of the thermosetting resin foam having open cells to 30 mm. Except that the ratio (value calculated by the formula (B1) of the resin ratio) was 65%, the fiber reinforced molded body was molded in the same manner as in Example 1, but it could not be compressed sufficiently and the thickness unevenness was Only large compacts were obtained. Assuming that the thickness of the core material obtained in Comparative Example 2 is the same as that of Example 1 (0.43 mm), the thickness (30 mm) of the thermosetting resin foam before compression is used. When calculated according to the compression rate formula, it was 6877%, and the compression rate exceeded 5000%. Therefore, in Comparative Example 2, a good molded product could not be obtained.

・比較例３
連続気泡を有する熱硬化性樹脂発泡体の代わりに、独立気泡を有するウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名：サーマックス、密度３０ｋｇ／ｍ３）を２００×３００×厚み５ｍｍに加工したもの（重量９ｇ）を使用し、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を５７％とした以外は実施例８と同様の方法にて繊維強化成形体を得た。比較例３の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２９、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（５ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると１０３６％であった。また、比較例３の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が２２ＧＰａ（繊維方向）であり、芯材に独立気泡の発泡体を用いたことにより、各実施例と比べて熱硬化性樹脂が芯材内に均一に分散保持されず、曲げ弾性率（剛性）が低いものであった。 Comparative example 3
Instead of a thermosetting resin foam having open cells, a urethane resin foam (made by Inoac Corporation, product name: Thermax, density 30 kg / m 3 ) having closed cells was processed to 200 × 300 × thickness 5 mm. Example (weight 9 g) is the same as Example 8 except that the resin ratio (value calculated by the formula (B1) of the resin ratio) contained in the entire carbon fiber fabric and the thermosetting foam is 57%. A fiber-reinforced molded body was obtained by the method described above. About the fiber reinforced molded object of the comparative example 3, specific gravity, the whole thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (5 mm) and the thickness of the core material (0.44 mm), and the compression rate formula Was calculated to be 1036%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Comparative Example 3 was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus is 22 GPa (fiber direction), and the use of closed cell foam for the core material prevents the thermosetting resin from being uniformly dispersed and held in the core material. The bending elastic modulus (rigidity) was low.

・比較例４
炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率（前記樹脂比率の式（Ｂ１）で計算した値）を４５％とした以外は、実施例１と同様にして、繊維強化成形体を得た。比較例４の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２８、全体の厚みは０．９ｍｍ、芯材の厚みは０．４３ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１０ｍｍ）と前記芯材の厚み（０．４３ｍｍ）を用い、前記圧縮率の式に従って計算すると２２２５％であった。また、比較例４の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法）を測定した。測定結果は曲げ弾性率が２７ＧＰａ（繊維方向）であり、樹脂比率が低すぎることにより、各実施例と比べて含まれる熱硬化性樹脂が少なく、曲げ弾性率（剛性）が低いものであった。 Comparative example 4
A fiber reinforced molded body was obtained in the same manner as in Example 1 except that the resin ratio (value calculated by the formula (B1) of the resin ratio) contained in the entire carbon fiber fabric and the thermosetting foam was 45%. Obtained. For the fiber-reinforced molded body of Comparative Example 4, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity was 1.28, the overall thickness was 0.9 mm, and the core material thickness was 0.43 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (10 mm) and the thickness of the core material (0.43 mm), and the expression of the compression rate. Was calculated to be 2225%. Further, the flexural modulus (JIS K7074-1988 A method) of the fiber reinforced molded body of Comparative Example 4 was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus was 27 GPa (fiber direction), and the resin ratio was too low, so that less thermosetting resin was contained compared to each example, and the flexural modulus (rigidity) was low. .

・比較例５
炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を８５％とした以外は、実施例１と同様にして、繊維強化成形体の成形を行ったが、樹脂比率が高すぎることにより、炭素繊維織物及び熱硬化性発泡体に含まれる熱硬化性樹脂が過剰に多くなって十分に圧縮できず、厚みムラの大きい成形体しか得られなかった。 Comparative example 5
Except that the resin ratio contained in the entire carbon fiber fabric and the thermosetting foam was 85%, the fiber reinforced molded body was molded in the same manner as in Example 1, but the resin ratio was too high. The thermosetting resin contained in the carbon fiber woven fabric and the thermosetting foam was excessively large and could not be sufficiently compressed, and only a molded product having large thickness unevenness was obtained.

・比較例６
連続気泡を有する熱硬化性樹脂発泡体の代わりに、独立気泡を有する熱硬化性樹脂発泡体（株式会社イノアックコーポレーション製、品名：サーマックス、密度３０ｋｇ／ｍ３）を２００×３００×１．４ｍｍ厚みに加工したもの（重量２．５ｇ）を使用した。この発泡体は独立気泡であるので熱硬化性樹脂を含浸できないため、炭素繊維織物に熱硬化性樹脂を含浸させた。乾燥後の含浸済み炭素繊維織物の重量が１枚あたり３７ｇとなるように調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした。その他は実施例８と同様の方法にて比較例６の繊維強化成形体を得た。比較例６の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２８、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（１．４ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると２１８％であった。また、比較例６の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が１８ＧＰａ（繊維方向）であった。 Comparative Example 6
Instead of the thermosetting resin foam having open cells, a thermosetting resin foam having closed cells (manufactured by Inoac Corporation, product name: Thermax, density 30 kg / m 3 ) is 200 × 300 × 1.4 mm. What was processed into thickness (weight 2.5g) was used. Since this foam is a closed cell and cannot be impregnated with the thermosetting resin, the carbon fiber fabric was impregnated with the thermosetting resin. The weight ratio of the impregnated carbon fiber woven fabric after drying was adjusted to 37 g per sheet, so that the resin ratio contained in the entire carbon fiber woven fabric and the thermosetting foam was 65%. Otherwise, a fiber-reinforced molded body of Comparative Example 6 was obtained in the same manner as in Example 8. For the fiber-reinforced molded body of Comparative Example 6, the specific gravity, the entire thickness, and the thickness of the core material were measured. The specific gravity was 1.28, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (1.4 mm) of the thermosetting resin foam before compression and the thickness (0.44 mm) of the core material. It was 218% when calculated according to the formula of Further, the flexural modulus (JIS K7074) of the fiber reinforced molded body of Comparative Example 6 was measured in order to determine the rigidity. The measurement result was a bending elastic modulus of 18 GPa (fiber direction).

・比較例７
独立気泡を有する熱硬化性樹脂発泡体（株式会社イノアックコーポレーション製、品名：サーマックス、密度３０ｋｇ／ｍ３）を２００×３００×２．３ｍｍ厚みに加工したもの（重量４．１ｇ）を使用し、乾燥後の含浸済み炭素繊維織物の一枚あたりの重量が３８ｇとなるよう調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした。それ以外は比較例６と同様の方法にて比較例７の繊維強化成形体を得た。比較例７の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２９、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（２．３ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると４２２％であった。また、比較例７の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が２０ＧＰａ（繊維方向）であった。 Comparative example 7
Using a thermosetting resin foam having closed cells (product name: Thermax, density 30 kg / m 3 ) processed to 200 × 300 × 2.3 mm thickness (weight: 4.1 g) having closed cells. The weight ratio of the impregnated carbon fiber woven fabric after drying was adjusted to 38 g so that the resin ratio contained in the entire carbon fiber woven fabric and the thermosetting foam was 65%. Otherwise, a fiber-reinforced molded article of Comparative Example 7 was obtained in the same manner as Comparative Example 6. For the fiber-reinforced molded body of Comparative Example 7, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness (2.3 mm) of the thermosetting resin foam before compression and the thickness (0.44 mm) of the core material. It was 422% when calculated according to the formula of Further, the flexural modulus (JIS K7074) of the fiber reinforced molded body of Comparative Example 7 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 20 GPa (fiber direction).

・比較例８
独立気泡を有する熱硬化性樹脂発泡体（株式会社イノアックコーポレーション製、品名：サーマックス、密度３０ｋｇ／ｍ３）を２００×３００×３ｍｍ厚みに加工したもの（重量５．４ｇ）を使用し、乾燥後の含浸済み炭素繊維織物の一枚あたりの重量が３９ｇとなるように調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした。それ以外は比較例６と同様の方法にて繊維強化成形体を得た。比較例８の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．２９、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（３ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると５８１％であった。また、比較例８の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が２１ＧＰａ（繊維方向）であった。 Comparative Example 8
A thermosetting resin foam having closed cells (product of Inoac Corporation, product name: Thermax, density 30 kg / m 3 ) processed to a thickness of 200 × 300 × 3 mm (weight 5.4 g) is used and dried. Adjustment was made so that the weight per sheet of the impregnated carbon fiber woven fabric was 39 g, and the resin ratio contained in the entire carbon fiber woven fabric and the thermosetting foam was 65%. Otherwise, a fiber-reinforced molded body was obtained in the same manner as in Comparative Example 6. For the fiber-reinforced molded body of Comparative Example 8, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity was 1.29, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is determined by using the thickness of the thermosetting resin foam before compression (3 mm) and the thickness of the core material (0.44 mm), and the expression of the compression rate. Was calculated to be 581%. Further, the flexural modulus (JIS K7074) of the fiber-reinforced molded body of Comparative Example 8 was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus was 21 GPa (fiber direction).

・比較例９
独立気泡を有する熱硬化性樹脂発泡体（株式会社イノアックコーポレーション製、品名：サーマックス、密度３０ｋｇ／ｍ３）を２００×３００×４ｍｍ厚みに加工したもの（重量７．２ｇ）を使用し、乾燥後の含浸済み炭素繊維織物の１枚あたりの重量が４１ｇとなるよう調整し、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした。それ以外は比較例６と同様の方法にて比較例９の繊維強化成形体を得た。比較例９の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（４ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると８０９％であった。また、比較例９の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が２１ＧＰａ（繊維方向）であった。 Comparative Example 9
A thermosetting resin foam having closed cells (product of Inoac Corporation, product name: Thermax, density 30 kg / m 3 ) processed to a thickness of 200 × 300 × 4 mm (weight 7.2 g) is used and dried. The weight of one post-impregnated carbon fiber fabric was adjusted to 41 g, and the resin ratio contained in the entire carbon fiber fabric and the thermosetting foam was 65%. Otherwise, a fiber-reinforced molded article of Comparative Example 9 was obtained in the same manner as in Comparative Example 6. For the fiber-reinforced molded body of Comparative Example 9, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is calculated by using the thickness (4 mm) of the thermosetting resin foam before compression and the thickness (0.44 mm) of the core material, and the compression rate formula. And calculated to be 809%. Further, the flexural modulus (JIS K7074) of the fiber reinforced molded body of Comparative Example 9 was measured in order to determine the rigidity. As a result of the measurement, the flexural modulus was 21 GPa (fiber direction).

・比較例１０
独立気泡を有する熱硬化性樹脂発泡体（株式会社イノアックコーポレーション製、品名：サーマックス、密度３０ｋｇ／ｍ３）を２００×３００×５ｍｍ厚みに加工したもの（重量９ｇ）を使用し、乾燥後の含浸済み炭素繊維織物の一枚あたりの重量が４３ｇとなるよう調整して、炭素繊維織物と熱硬化性発泡体全体に含まれる樹脂比率を６５％とした。それ以外は比較例６と同様の方法にて比較例１０の繊維強化成形体を得た。比較例１０の繊維強化成形体について、比重、全体の厚み及び芯材の厚みを測定した。比重は１．３０、全体の厚みは０．９ｍｍ、芯材の厚みは０．４４ｍｍであった。芯材を構成する熱硬化性樹脂発泡体の圧縮率は、前記圧縮前の熱硬化性樹脂発泡体の厚み（５ｍｍ）と前記芯材の厚み（０．４４ｍｍ）を用い、前記圧縮率の式に従って計算すると１０３６％であった。また、比較例１０の繊維強化成形体について、剛性を判断するために曲げ弾性率（ＪＩＳ Ｋ７０７４）を測定した。測定結果は曲げ弾性率が２２ＧＰａ（繊維方向）であった。 Comparative Example 10
Using a thermosetting resin foam having closed cells (product of Inoac Corporation, product name: Thermax, density 30 kg / m 3 ) processed to a thickness of 200 × 300 × 5 mm (weight 9 g), and after drying The weight ratio of the impregnated carbon fiber woven fabric was adjusted to 43 g so that the resin ratio contained in the entire carbon fiber woven fabric and the thermosetting foam was 65%. Otherwise, a fiber-reinforced molded article of Comparative Example 10 was obtained in the same manner as in Comparative Example 6. For the fiber-reinforced molded body of Comparative Example 10, the specific gravity, the overall thickness, and the thickness of the core material were measured. The specific gravity was 1.30, the overall thickness was 0.9 mm, and the core material thickness was 0.44 mm. The compression rate of the thermosetting resin foam constituting the core material is obtained by using the thickness of the thermosetting resin foam before compression (5 mm) and the thickness of the core material (0.44 mm), and the compression rate formula Was calculated to be 1036%. Further, the flexural modulus (JIS K7074) of the fiber reinforced molded body of Comparative Example 10 was measured in order to determine the rigidity. The measurement result was a flexural modulus of 22 GPa (fiber direction).

前記各実施例及び比較例における圧縮率、樹脂比率、比重、厚み、曲げ弾性率を表１に示す。   Table 1 shows the compression ratio, resin ratio, specific gravity, thickness, and flexural modulus in each of the examples and comparative examples.

Figure 2012071591
Figure 2012071591

表１において、熱硬化性樹脂発泡体と炭素繊維織物がそれぞれ同種類であり、かつ樹脂比率が同一の実施例１〜５及び実施例１２〜１４において、圧縮率が２２５％と低い実施例４は、他の実施例と比べて曲げ弾性率（剛性）が低く、一方、圧縮率が４９００％と高い実施例５は比重が高く（重く）なっている。このように、圧縮率が低くなると曲げ弾性率（剛性）が低下する傾向があり、一方、圧縮率が高くなると比重が高く（重く）なる傾向がある。これらの点から、圧縮率は２００〜５０００％、より好ましくは１０００〜２６００％である。   In Table 1, in Examples 1 to 5 and Examples 12 to 14 in which the thermosetting resin foam and the carbon fiber woven fabric are of the same type and the resin ratio is the same, the compression rate is as low as 225% in Example 4. Is lower in flexural modulus (rigidity) than the other examples, while Example 5 with a high compression rate of 4900% has a higher specific gravity (heavy). As described above, when the compressibility is low, the flexural modulus (rigidity) tends to decrease, and when the compressibility is high, the specific gravity tends to be high (heavy). From these points, the compression rate is 200 to 5000%, more preferably 1000 to 2600%.

また、熱硬化性樹脂発泡体と炭素繊維織物がそれぞれ同種類からなり、かつ圧縮率が同一の実施例１、７〜９及び比較例４において、樹脂比率４５％の比較例４では曲げ弾性率が２７ＧＰａと低いのに対し、樹脂比率６６％の実施例８では曲げ弾性率が５０ＧＰａと高く、樹脂比率が高くなると曲げ弾性率（剛性）が高くなることがわかる。また、実施例１、７〜９及び比較例４と圧縮比率がほぼ等しく、樹脂比率が７４％と高い実施例６は比重が１．４５であり、一方、樹脂比率４５％の比較例４は比重が１．２８、樹脂比率５１％の実施例７は比重が１．３０であることから、樹脂比率が高くなると比重が高くなる傾向にあることがわかる。これらの点から、樹脂比率は、５０〜８０％、より好ましくは５５〜７０％である。   Further, in Examples 1, 7 to 9 and Comparative Example 4 in which the thermosetting resin foam and the carbon fiber fabric are of the same kind and the compression ratio is the same, in Comparative Example 4 in which the resin ratio is 45%, the flexural modulus is Is low at 27 GPa, whereas in Example 8 where the resin ratio is 66%, the bending elastic modulus is as high as 50 GPa, and as the resin ratio increases, the bending elastic modulus (rigidity) increases. Moreover, compression ratio is substantially equal to Examples 1, 7-9, and Comparative Example 4, and Example 6 with a high resin ratio of 74% has a specific gravity of 1.45, while Comparative Example 4 with a resin ratio of 45% Since Example 7 with a specific gravity of 1.28 and a resin ratio of 51% has a specific gravity of 1.30, it can be seen that the specific gravity tends to increase as the resin ratio increases. From these points, the resin ratio is 50 to 80%, more preferably 55 to 70%.

熱硬化性樹脂発泡体が独立気泡を有するものからなる比較例３及び比較例６〜１０は、熱硬化性樹脂発泡体が連続気泡を有するものからなる実施例及び他の比較例と比べて曲げ弾性率が極端に低くなっている。   Comparative Example 3 and Comparative Examples 6 to 10 in which the thermosetting resin foam has closed cells are bent as compared with Examples and other Comparative Examples in which the thermosetting resin foam has open cells. The elastic modulus is extremely low.

また、繊維強化成形体の片面のみが多孔性シートで覆われた実施例１５と、繊維強化成形体の両面が多孔性シートで覆われた実施例１６とを比較すると、実施例１６は実施例１５より低下するが、高い曲げ弾性率を示すことが確認された。すなわち、芯材に用いる熱硬化性樹脂発泡体よりも薄い多孔性シートを両面に配置して意匠性を向上させても、これにより曲げ弾性率（剛性）が充分に維持される。したがって、本発明に係る繊維強化成形体によれば、美観性と強度とを両立させることができる。さらに、芯材は、連続気泡を有する複数の熱硬化性樹脂発泡体層に熱硬化性樹脂が含浸して圧縮した状態で硬化一体化したもの（実施例１５）でも、単層の場合（実施例１、実施例２、実施例１６）と同程度の効果が得られることがわかる。   Further, when Example 15 in which only one surface of the fiber reinforced molded body was covered with a porous sheet was compared with Example 16 in which both surfaces of the fiber reinforced molded body were covered with a porous sheet, Example 16 was an example. Although it was lower than 15, it was confirmed that a high flexural modulus was exhibited. That is, even if a porous sheet thinner than the thermosetting resin foam used for the core material is arranged on both sides to improve the design, the bending elastic modulus (rigidity) is sufficiently maintained. Therefore, according to the fiber reinforced molded body according to the present invention, it is possible to achieve both aesthetics and strength. Further, the core material may be one in which a plurality of thermosetting resin foam layers having open cells are cured and integrated while being impregnated with a thermosetting resin and compressed (Example 15). It can be seen that the same effects as those of Example 1, Example 2, and Example 16) can be obtained.

また、本発明の繊維強化成形品における良好な塗装外観及び塗装密着性（塗膜の剥がれ難さ）を確認するため、以下の実施例品及び比較例品を作成し、それぞれ表面材の表面に塗装を行って塗装外観、塗装表面の凹凸度合（表面粗さ）、塗装密着性を調べた。塗装外観は、乾燥後の塗膜表面を目視で観察し、凹凸が全く分からない場合を◎、僅かに凹凸が分かる場合を○、明確に凹凸が分かる場合を×と判定した。塗装表面の凹凸度合は、乾燥後の塗膜表面に対し、表面粗さ計（東京精密製、品名；Ｓｕｒｆｃｏｍ）を用いてＲｚ；１０点測定し、その平均値で表した。塗装密着性は、乾燥後の塗膜表面に、カッターを用いて間隔１ｍｍで格子状の切り込み（クロスカット）を１００升形成し、その切り込みを形成した１００升部分に、幅２５ｍｍ、長さ７５ｍｍのセロハンテープを接着し、その後セロハンテープを剥がして塗膜が剥がれなかった升の数（密着数）によって塗装密着性を表した。また、実施例品及び比較例品について、塗装後の全体厚み及び曲げ弾性率（ＪＩＳ Ｋ７０７４−１９８８ Ａ法、繊維方向）を測定した。   In addition, in order to confirm the good coating appearance and coating adhesion (difficult to peel off the coating film) in the fiber reinforced molded product of the present invention, the following Example products and Comparative Example products were prepared, respectively, on the surface of the surface material. After painting, the appearance of the paint, the degree of unevenness (surface roughness) of the paint surface, and the paint adhesion were examined. The appearance of the coating was determined by visually observing the surface of the coated film after drying, ◎ when the irregularities were not known at all, ◯ when the irregularities were slightly known, and x when the irregularities were clearly known. The degree of unevenness on the coating surface was measured by measuring 10 Rz using a surface roughness meter (manufactured by Tokyo Seimitsu, product name: Surfcom) on the surface of the coating film after drying, and expressed as an average value thereof. The coating adhesion is such that 100 mm of grid-like cuts (cross cuts) are formed on the surface of the coated film after drying at intervals of 1 mm using a cutter, and a width of 25 mm and a length of 75 mm are formed on the 100 mm portions where the cuts are formed. The cellophane tape was adhered, and then the cellophane tape was peeled off, and the coating adhesion was expressed by the number of wrinkles (number of adhesion) that the coating film was not peeled off. Moreover, about the Example goods and the comparative example goods, the whole thickness after coating and a bending elastic modulus (JIS K7074-1988 A method, fiber direction) were measured.

・実施例Ａ
前記実施例１の繊維強化成形体における表面材の表面に、２液硬化型ウレタン系塗料を用いて、スプレー塗装により、膜厚２０μｍになるように塗装を施し、実施例Ａの繊維強化成形体（塗装品）を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は４．０％である。
・実施例Ｂ
前記実施例１における多孔性シートの厚み（非圧縮状態の厚み）を０．６ｍｍにした以外は実施例Ａと同様にして実施例Ｂの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は６．０％である。 Example A
The surface of the surface material in the fiber reinforced molded body of Example 1 was coated by spray coating so as to have a film thickness of 20 μm using a two-component curable urethane coating, and the fiber reinforced molded body of Example A (Painted product) was created. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 4.0%.
Example B
A fiber-reinforced molded body (painted product) of Example B was prepared in the same manner as in Example A except that the thickness of the porous sheet in Example 1 (thickness in an uncompressed state) was 0.6 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 6.0%.

・実施例Ｃ
前記実施例１における多孔性シートの厚み（非圧縮状態の厚み）を１．０ｍｍにした以外は実施例Ａと同様にして実施例Ｃの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１０．０％である。
・実施例Ｄ
前記実施例１における多孔性シートの厚み（非圧縮状態の厚み）を２．０ｍｍにした以外は実施例Ａと同様にして実施例Ｄの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は２０．０％である。
・実施例Ｅ
前記実施例１における多孔性シートの厚み（非圧縮状態の厚み）を３．０ｍｍにした以外は実施例Ａと同様にして実施例Ｅの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は３０．０％である。 Example C
A fiber-reinforced molded article (painted product) of Example C was prepared in the same manner as in Example A except that the thickness of the porous sheet in Example 1 (thickness in an uncompressed state) was 1.0 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 10.0%.
Example D
A fiber-reinforced molded article (painted product) of Example D was prepared in the same manner as Example A, except that the thickness of the porous sheet in Example 1 (thickness in an uncompressed state) was 2.0 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 20.0%.
Example E
A fiber-reinforced molded article (painted product) of Example E was prepared in the same manner as in Example A except that the thickness of the porous sheet in Example 1 (thickness in an uncompressed state) was set to 3.0 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 30.0%.

・実施例Ｆ
前記実施例１における多孔性シートに代えて、溶解処理によりセル膜を除去したウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名；ＭＦ−８０、嵩比重０．０５、セル数８０個／２５ｍｍ）、空隙率９５．２％、非圧縮時の厚み１．０ｍｍを用い、他は実施例Ａと同様にして実施例Ｆの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１０．０％である。
・実施例Ｇ
前記実施例１における多孔性シートに代えて、溶解処理によりセル膜を除去したウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名；ＭＦ−１０、嵩比重０．０２８、セル数１０個／２５ｍｍ）、空隙率９７．３％、非圧縮時の厚み１．０ｍｍを用い、他は実施例Ａと同様にして実施例Ｇの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１０．０％である。
・実施例Ｈ
前記実施例１における多孔性シートに代えて、溶解処理によりセル膜を除去したウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名；ＭＦ−８、嵩比重０．０２７、セル数８個／２５ｍｍ）、空隙率９７．４％、非圧縮時の厚み１．０ｍｍを用い、他は実施例Ａと同様にして実施例Ｈの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１０．０％である。
・実施例Ｉ
前記実施例１における多孔性シートに代えて、セル膜除去処理が行われていないセル膜有りのウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名；ＳＰ−５０、嵩比重０．０３１、セル数５０個／２５ｍｍ）、空隙率９７．０％、非圧縮時の厚み１．０ｍｍを用い、他は実施例Ａと同様にして実施例Ｉの繊維強化成形体(塗装品)を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は１０．０％である。 -Example F
Instead of the porous sheet in Example 1, a urethane resin foam from which the cell membrane was removed by dissolution treatment (product name: MF-80, bulk specific gravity 0.05, number of cells 80/25 mm, manufactured by Inoac Corporation) A fiber reinforced molded article (painted product) of Example F was prepared in the same manner as in Example A except that the porosity was 95.2% and the non-compressed thickness was 1.0 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 10.0%.
Example G
In place of the porous sheet in Example 1, a urethane resin foam from which the cell membrane was removed by dissolution treatment (manufactured by Inoac Corporation, product name: MF-10, bulk specific gravity 0.028, number of cells 10/25 mm) A fiber reinforced molded article (painted product) of Example G was prepared in the same manner as in Example A except that the porosity was 97.3% and the thickness at non-compression was 1.0 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 10.0%.
Example H
Instead of the porous sheet in Example 1, the urethane resin foam from which the cell membrane was removed by dissolution treatment (manufactured by Inoac Corporation, product name: MF-8, bulk specific gravity 0.027, number of cells 8/25 mm) A fiber reinforced molded article (painted product) of Example H was prepared in the same manner as in Example A except that the porosity was 97.4% and the non-compressed thickness was 1.0 mm. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 10.0%.
Example I
In place of the porous sheet in Example 1, a urethane resin foam with a cell membrane that has not been subjected to cell membrane removal treatment (product name: SP-50, bulk specific gravity 0.031, number of cells, manufactured by Inoac Corporation) 50/25 mm), a porosity of 97.0%, and a non-compressed thickness of 1.0 mm were used, and a fiber-reinforced molded article (painted product) of Example I was prepared in the same manner as in Example A. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 10.0%.

・実施例Ｊ
補強材用熱硬化性樹脂としてフェノール樹脂（ＤＩＣ株式会社製、品名；フェノライト５０１０、固形分６０％）をエタノールに５０ｗｔ％となるように混合した。このフェノール樹脂溶液を平織の炭素繊維織物（東邦テナックス株式会社製、品名；Ｗ−３１０１、繊維重さ２００ｇ／ｍ２）に浸漬させ、その上に多孔性シート（株式会社イノアックコーポレーション製、品名；ＭＦ−５０ＬＥ、嵩比重０．０３、セル数５０個／２５mm）を設置してプリプレグを得た。 ・ Example J
Phenol resin (manufactured by DIC Corporation, product name: Phenolite 5010, solid content 60%) was mixed with ethanol so as to be 50 wt% as a thermosetting resin for reinforcing material. This phenolic resin solution is immersed in a plain-woven carbon fiber fabric (manufactured by Toho Tenax Co., Ltd., product name; W-3101, fiber weight 200 g / m 2 ), and a porous sheet (manufactured by Inoac Corporation, product name) is placed thereon. MF-50LE, bulk specific gravity 0.03, 50 cells / 25 mm) were installed to obtain a prepreg.

多孔性シートは、溶解処理によりセル膜を除去したウレタン樹脂発泡体を非圧縮状態の厚み０．７ｍｍに裁断したものを用いた。なお、使用したウレタン樹脂発泡体の空隙率は９７．１％であった。空隙率の計算式は次の通りである。
空隙率＝（ウレタン樹脂真比重−嵩比重（≒ウレタン樹脂発泡体見かけ密度）／ウレタン樹脂真比重×１００ As the porous sheet, a urethane resin foam from which the cell membrane was removed by dissolution treatment was cut into a non-compressed thickness of 0.7 mm. In addition, the porosity of the used urethane resin foam was 97.1%. The formula for calculating the porosity is as follows.
Porosity = (Urethane resin true specific gravity-Bulk specific gravity (≒ Apparent density of urethane resin foam) / Urethane resin true specific gravity x 100

なお、炭素繊維織物は、３８０×２６０ｍｍ（重量１９．８ｇ／枚）を使用した。乾燥後の含浸済み炭素繊維織物は1枚あたり３６ｇであった。このようにして得られた２枚のプリプレグを８７℃の雰囲気下にて５分乾燥させた。   The carbon fiber fabric used was 380 × 260 mm (weight 19.8 g / sheet). The impregnated carbon fiber fabric after drying was 36 g per sheet. The two prepregs thus obtained were dried at 87 ° C. for 5 minutes.

芯材用として、厚み７．５ｍｍ、平面サイズ３８０×２６０ｍｍ（重量６．０ｇ／枚）に切り出した連続気泡を有するメラミン樹脂発泡体（ＢＡＳＦ社製、品名；バソテクトＶ３０１２、密度９ｋｇ／ｍ３）を炭素繊維織物と同様にしてフェノール樹脂溶液に浸漬させ、取り出した後に１００℃の雰囲気下にて３１分乾燥し、含浸済み熱硬化性樹脂発泡体を形成した。乾燥後の含浸済み熱硬化性樹脂発泡体の重量は６７ｇであった。また、炭素繊維織物と熱硬化性樹脂発泡体に含まれる樹脂比率は６４％であった。 Melamine resin foam having open cells cut into a thickness of 7.5 mm and a planar size of 380 × 260 mm (weight: 6.0 g / sheet) for the core material (manufactured by BASF, product name: Bazotect V3012, density 9 kg / m 3 ) Was immersed in a phenolic resin solution in the same manner as the carbon fiber fabric, taken out, and dried in an atmosphere at 100 ° C. for 31 minutes to form an impregnated thermosetting resin foam. The weight of the impregnated thermosetting resin foam after drying was 67 g. Moreover, the resin ratio contained in the carbon fiber fabric and the thermosetting resin foam was 64%.

次に、予め離型剤を表面に塗布したＳＵＳ製のプレス成形用の平板状の下型の上に、多孔性シート面を上側にしたプリプレグ、含浸済み熱硬化性樹脂発泡体、多孔性シート面を上側にしたプリプレグの順に積層し積層体を得た。すなわちこの積層体は、下から順に炭素繊維織物、多孔性シート、芯材用部材（連続気泡を有する熱硬化性樹脂発泡体）、炭素繊維織物、多孔性シートが積層されている。この積層体をプレス成形用下型上にセットした。芯材となる連続気泡を有する熱硬化性樹脂発泡体と多孔シートの合計厚みに対する表面材となる多孔性シートの厚みの比は８．５％である。   Next, a prepreg having a porous sheet surface on the upper side, a SUS press-molded flat mold with a release agent applied on the surface in advance, an impregnated thermosetting resin foam, and a porous sheet Laminates were obtained by laminating in order of prepregs with the surface facing up. That is, in this laminate, a carbon fiber fabric, a porous sheet, a core member (thermosetting resin foam having open cells), a carbon fiber fabric, and a porous sheet are laminated in order from the bottom. This laminate was set on a lower mold for press molding. The ratio of the thickness of the porous sheet as the surface material to the total thickness of the thermosetting resin foam having open cells as the core material and the porous sheet is 8.5%.

この積層体をプレス成形用下型上にセットした状態で、１４５℃で８分間、５ＭＰａの面圧をかけてプレス成形用上型（平板状）で前記積層体を押圧し、圧縮及び加熱を行い、前記圧縮状態でフェノール樹脂を反応硬化させた。   With this laminated body set on the lower mold for press molding, pressurize the laminated body with the upper mold for press molding (flat plate shape) by applying a surface pressure of 5 MPa at 145 ° C. for 8 minutes, and compress and heat And the phenolic resin was reaction cured in the compressed state.

その際の積層体の加熱は上下のプレス方に取り付けられた鋳込みヒータにより行った。また、プレス成形用下型と上型の間には１．０ｍｍの間隔を設けて積層体の圧縮厚みを調整した。その後下型と上型を開き、芯材の両面に繊維補強材が積層し、さらに一方の繊維補強材に多孔性シートから形成された表面材が積層一体化した繊維強化成形体を得た。他は実施例Ａと同様にして実施例Ｊの繊維強化成形体(塗装品)を作成した。   At that time, the laminate was heated by a cast-in heater attached to the upper and lower presses. Further, the compressed thickness of the laminate was adjusted by providing a gap of 1.0 mm between the lower mold for press molding and the upper mold. Thereafter, the lower mold and the upper mold were opened to obtain a fiber reinforced molded body in which a fiber reinforcing material was laminated on both surfaces of a core material, and a surface material formed from a porous sheet was laminated and integrated on one fiber reinforcing material. The fiber reinforced molded body (painted product) of Example J was prepared in the same manner as Example A except for the above.

・実施例Ｋ
実施例Ｊと同様にして得られたプリプレグを用いて、予め離型剤を表面に塗布したＳＵＳ製のプレス成形用の下型（平板状）の上に、多孔性シート面を下側としたプリプレグ、含浸済み熱硬化性樹脂発泡体、多孔性シート面を上側としたプリプレグの順に積層させて積層体を得た。すなわちこの積層体は、下から順に多孔性シート、繊維織物、芯材用部材（連続気泡を有する熱硬化性樹脂発泡体）、繊維織物、多孔性シートが積層されている。この積層体をプレス成形用下型上にセットした。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シート（両面の合計）の厚みの比は１８．７％である。 -Example K
Using the prepreg obtained in the same manner as in Example J, the porous sheet surface was placed on the lower side of a SUS press-molding lower die (flat plate shape) previously coated with a release agent on the surface. A laminate was obtained by laminating a prepreg, an impregnated thermosetting resin foam, and a prepreg with the porous sheet surface facing upward. That is, in this laminate, a porous sheet, a fiber fabric, a core member (thermosetting resin foam having open cells), a fiber fabric, and a porous sheet are laminated in order from the bottom. This laminate was set on a lower mold for press molding. The ratio of the thickness of the porous sheet (total of both surfaces) to the thickness of the thermosetting resin foam having open cells is 18.7%.

この積層体をプレス成形用下型上にセットした状態で、１４５℃で８分間、５ＭＰａの面圧をかけてプレス成形用上型（平板状）で前記積層体を圧縮及び加熱し、圧縮状態でフェノール樹脂を反応硬化させた。その際の積層体の加熱は上下のプレス方に取り付けられた鋳込みヒータにより行った。また、プレス成形用下型と上型の間には１．０ｍｍの間隔を設けて積層体の圧縮厚みを調整した。
その後下型と上型を開き、芯材の両面に繊維補強材が積層され、さらに繊維補強材に多孔性シートから形成された表面材が積層一体化された繊維強化成形体を得た。他は実施例Ａと同様にして実施例Ｋの繊維強化成形体(塗装品)を作成した。 In a state where this laminate is set on the lower mold for press molding, the laminate is compressed and heated by applying a surface pressure of 5 MPa at 145 ° C. for 8 minutes with the upper mold for press molding (flat plate shape). The phenolic resin was reacted and cured. At that time, the laminate was heated by a cast-in heater attached to the upper and lower presses. Further, the compressed thickness of the laminate was adjusted by providing a gap of 1.0 mm between the lower mold for press molding and the upper mold.
Thereafter, the lower mold and the upper mold were opened to obtain a fiber reinforced molded body in which a fiber reinforcing material was laminated on both surfaces of the core material, and a surface material formed from a porous sheet was laminated and integrated on the fiber reinforcing material. The fiber reinforced molded body (painted product) of Example K was prepared in the same manner as Example A except for the above.

・比較例Ａ
前記実施例１における表面の多孔性シートを無くした以外は実施例１及び実施例Ａと同様にして比較例Ａの繊維強化成形体(塗装品)を作成した。
・比較例Ｂ
実施例１における表面の多孔性シートの厚み（非圧縮状態の厚み）を４．０ｍｍにした以外は実施例１及び実施例Ａと同様にして比較例Ｂの繊維強化成形体（塗装品）を作成した。連続気泡を有する熱硬化性樹脂発泡体の厚みに対する多孔性シートの厚みの比は４０．０％である。
・比較例Ｃ
実施例１における多孔性シートに代えて、溶解処理によりセル膜を除去したウレタン樹脂発泡体（株式会社イノアックコーポレーション製、品名；ＭＦ−１００、嵩比重０．０７５、セル数１００個／２５ｍｍ）、空隙率９２．８％、非圧縮時の厚み１．０ｍｍを用い、他は実施例１及び実施例Ａと同様にして比較例Ｃの繊維強化成形体（塗装品）を作成した。 Comparative example A
A fiber-reinforced molded article (coating product) of Comparative Example A was prepared in the same manner as in Examples 1 and A except that the porous sheet on the surface in Example 1 was eliminated.
・ Comparative Example B
The fiber-reinforced molded article (coating product) of Comparative Example B was prepared in the same manner as in Example 1 and Example A, except that the thickness of the porous sheet on the surface in Example 1 (non-compressed thickness) was 4.0 mm. Created. The ratio of the thickness of the porous sheet to the thickness of the thermosetting resin foam having open cells is 40.0%.
Comparative example C
Instead of the porous sheet in Example 1, a urethane resin foam from which the cell membrane was removed by dissolution treatment (manufactured by Inoac Corporation, product name: MF-100, bulk specific gravity 0.075, number of cells 100/25 mm), A fiber-reinforced molded body (coating product) of Comparative Example C was prepared in the same manner as in Example 1 and Example A, except that the porosity was 92.8% and the thickness at non-compression was 1.0 mm.

前記実施例Ａ〜Ｋ及び比較例Ａ〜Ｃにおける曲げ弾性率、塗装外観、凹凸度合（表面粗さ）、塗装密着性（剥離しなかった升の数）の結果を表２に示す。なお、表２には、実施例Ａ〜Ｋ及び比較例Ａ〜Ｃにおける塗装前の凹凸度合い（表面粗さ）についても記載した。   Table 2 shows the results of bending elastic modulus, coating appearance, unevenness degree (surface roughness), and coating adhesion (number of wrinkles not peeled) in Examples A to K and Comparative Examples A to C. In Table 2, the unevenness degree (surface roughness) before coating in Examples A to K and Comparative Examples A to C is also described.

Figure 2012071591
Figure 2012071591

表２に示すように、表面に多孔性シート（表面材）を設けた実施例Ａ〜Ｉは、表面に多孔性シートを設けなかった比較例Ａと比べて塗装外観が良好で凹凸度合が小さく、しかも塗装密着性が良好であった。特に、多孔性シートの有無のみが異なる実施例Ａと比較例Ａを比べた場合、比較例Ａは、実施例Ａよりも凹凸度合が倍以上大きい値となる凹凸の大きいものであり、かつ塗装外観及び塗装密着においても実施例Ａより著しく劣っていた。   As shown in Table 2, Examples A to I provided with a porous sheet (surface material) on the surface had a better coating appearance and a lower degree of unevenness than Comparative Example A where a porous sheet was not provided on the surface. Moreover, the paint adhesion was good. In particular, when Example A and Comparative Example A, which differ only in the presence or absence of a porous sheet, are compared, Comparative Example A has large irregularities with a degree of irregularity that is twice or more larger than Example A, and is coated. The appearance and coating adhesion were also significantly inferior to Example A.

また、多孔性シートのセル膜が除去されている実施例Ｃと多孔性シートのセル膜が除去されていない点で互いに異なる実施例Ｉとを比べると、セル膜が除去されている実施例Ｃは、セル膜が除去されていない実施例Ｉよりも凹凸度合が半分以下の値となる凹凸の極めて小さいものであり、かつ塗装外観及び塗装密着においても実施例Ｉより良好であった。   Further, when Example C in which the cell membrane of the porous sheet is removed and Example I which is different from each other in that the cell membrane of the porous sheet is not removed are compared, Example C in which the cell membrane is removed The film has extremely small unevenness with a degree of unevenness of half or less than that of Example I from which the cell film was not removed, and was also better than Example I in coating appearance and coating adhesion.

また、多孔性シートの厚み（非圧縮状態の厚み）を、実施例Ａの０．４ｍｍの厚みから４．０ｍｍの厚みにした以外は実施例Ａと同じ比較例Ｂは、実施例Ａと比べて曲げ弾性率が半分ほどであると共に、塗装前及び塗装後の表面粗さが倍近い値となる凹凸の極めて大きいものであり、かつ塗装外観及び塗装密着性において実施例Ａよりも劣っていた。   In addition, Comparative Example B, which is the same as Example A, except that the thickness of the porous sheet (thickness in an uncompressed state) was changed from 0.4 mm in Example A to 4.0 mm, compared with Example A. The flexural modulus is about half, the surface roughness before and after coating is nearly double, and the coating appearance and coating adhesion are inferior to Example A. .

また、芯材となる連続気泡を有する熱硬化性樹脂発泡体および芯材となる多孔性シートの厚みの合計に対する、表面材となる多孔性シートの厚み合計の比が３０％以下である実施例Ａ〜Ｋにおいて、同比が４０％となる比較例Ｂと比べて曲げ弾性率が大きかった。   Further, the ratio of the total thickness of the porous sheet as the surface material to the total thickness of the thermosetting resin foam having open cells as the core material and the porous sheet as the core material is 30% or less. In A to K, the flexural modulus was large as compared with Comparative Example B in which the ratio was 40%.

多孔性シートのセル数を１００個／２５ｍｍとした比較例Ｃは、セル数以外が同じである実施例Ｃ（セル数５０個／２５ｍｍ）、実施例Ｆ（セル数８０個／２５ｍｍ）、実施例Ｇ（セル数１０個／２５ｍｍ）及び実施例Ｈ（セル数８個／２５ｍｍ）と比べて、塗装前及び塗装後の凹凸度合い（表面粗さ）が約２倍〜約４倍の値となる凹凸の極めて大きいものであり、かつ塗装外観及び塗装密着性においても実施例Ｃ、Ｆ、Ｇ及びＨよりも劣っていた。   Comparative Example C in which the number of cells of the porous sheet was 100/25 mm was the same as Example C (number of cells 50/25 mm), Example F (number of cells 80/25 mm), except for the number of cells. Compared to Example G (10 cells / 25 mm) and Example H (8 cells / 25 mm), the unevenness degree (surface roughness) before and after coating is about 2 to 4 times the value. It was inferior to Example C, F, G, and H also in the coating external appearance and coating adhesion.

また、実施例Ａ〜Ｉと実施例Ｊ，Ｋとで有意な差は確認できなかった。したがって、芯材用の熱硬化性樹脂発泡体と炭素繊維織物の少なくとも一方に熱硬化性樹脂を含浸させた後に各部材を積層させる方法、あるいは、炭素繊維織物と多孔性シートからプリプレグを作成してからプリプレグを芯材用の熱硬化性樹脂発泡体に積層させる方法のいずれの製造方法でも、塗装外観及び塗装密着性に優れた繊維強化成形体を得られることが確認できた。   In addition, a significant difference could not be confirmed between Examples A to I and Examples J and K. Therefore, a method of laminating each member after impregnating the thermosetting resin into at least one of the thermosetting resin foam for the core material and the carbon fiber fabric, or creating a prepreg from the carbon fiber fabric and the porous sheet. It was confirmed that a fiber-reinforced molded article excellent in coating appearance and coating adhesion can be obtained by any of the production methods of laminating a prepreg to a thermosetting resin foam for a core material.

このように、本発明の実施例品は、軽量、薄肉、高剛性を有し、かつ塗装した場合の外観が良好で塗膜が剥がれるおそれのないものであり、ノートパソコン等の携帯機器の筐体等して好適なものである。なお、本発明において、積層工程で用いる多孔性シートには予め熱硬化性樹脂を含浸させておいてもよい。その場合、その後の圧縮加熱工程における圧縮率が小さくても、表面に熱硬化性樹脂が配置されて均一な樹脂層が形成されやすくなり、繊維強化成形体の表面平滑性が良好になる。   As described above, the product of the example of the present invention has light weight, thin wall, and high rigidity, and has a good appearance when coated, and there is no fear of peeling off the coating film. It is suitable as a body. In the present invention, the porous sheet used in the lamination step may be impregnated with a thermosetting resin in advance. In that case, even if the compression rate in the subsequent compression heating step is small, the thermosetting resin is arranged on the surface and a uniform resin layer is easily formed, and the surface smoothness of the fiber-reinforced molded article is improved.

１０、１０Ｗ、１０Ｚ 繊維強化成形体
１０Ａ、１０Ｂ、１０Ｃ、１０Ｄ、１０Ｅ 積層体
１１ 芯材
１１Ａ 熱硬化性樹脂発泡体
１１Ｂ 熱硬化性樹脂
１１Ｃ 含浸済み熱硬化性樹脂発泡体
２０Ａ プリプレグ
２１ 繊維補強材
２１Ａ 炭素繊維織物
２１Ｂ 熱硬化性樹脂
２１Ｃ 含浸済み炭素繊維織物
２５ 表面材
２５Ａ 多孔性シート
２６ 硬化層 10, 10W, 10Z Fiber Reinforced Molded Body 10A, 10B, 10C, 10D, 10E Laminate 11 Core Material 11A Thermosetting Resin Foam 11B Thermosetting Resin 11C Impregnated Thermosetting Resin Foam 20A Prepreg 21 Fiber Reinforcement 21A carbon fiber fabric 21B thermosetting resin 21C impregnated carbon fiber fabric 25 surface material 25A porous sheet 26 cured layer

Claims (14)

芯材と、前記芯材の両面に積層された繊維補強材とを有する繊維強化成形体において、
前記芯材の少なくとも一側の面の前記繊維補強材の表面には表面材を積層し、
前記芯材は、連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸して前記熱硬化性樹脂発泡体を圧縮した状態で前記熱硬化性樹脂が硬化したものであって、以下の式（Ａ１）で規定される圧縮率Ｃが２００〜５０００％の範囲のものからなり、
前記繊維補強材は、炭素繊維織物に熱硬化性樹脂が含浸して硬化したものからなり、
前記表面材は、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着して硬化したものからなり、前記芯材と前記繊維補強材と前記表面材が、前記熱硬化性樹脂発泡体に含浸した前記熱硬化性樹脂と前記炭素繊維織物に含浸した前記熱硬化性樹脂と前記多孔性シートに含浸した前記熱硬化性樹脂の硬化により一体化され、
前記熱硬化性樹脂発泡体と前記炭素繊維織物と前記多孔性シートに含浸した熱硬化性樹脂は、以下の式（Ｂ１）で規定される樹脂比率Ｒが５０〜８０％の範囲にあり、
繊維強化成形体の曲げ弾性率が３０ＧＰａ以上であることを特徴とする繊維強化成形体。
Figure 2012071591
Figure 2012071591
 In a fiber reinforced molded body having a core material and a fiber reinforcing material laminated on both surfaces of the core material,
A surface material is laminated on the surface of the fiber reinforcing material on at least one side of the core material,
The core material is obtained by curing the thermosetting resin in a state where the thermosetting resin foam is impregnated with a thermosetting resin foam having open cells and the thermosetting resin foam is compressed. The compression rate C defined by the formula (A1) is in the range of 200 to 5000%,
The fiber reinforcing material consists of a carbon fiber fabric impregnated with a thermosetting resin and cured,
The surface material is formed by impregnating a porous sheet with a thermosetting resin, and the thermosetting resin adheres to the surface of the porous sheet and is cured, and the core material, the fiber reinforcing material, and the surface material. Is integrated by curing the thermosetting resin impregnated in the thermosetting resin foam, the thermosetting resin impregnated in the carbon fiber fabric, and the thermosetting resin impregnated in the porous sheet,
The thermosetting resin impregnated in the thermosetting resin foam, the carbon fiber fabric, and the porous sheet has a resin ratio R defined by the following formula (B1) in the range of 50 to 80%,
A fiber-reinforced molded body, wherein the fiber-reinforced molded body has a flexural modulus of 30 GPa or more.
Figure 2012071591
Figure 2012071591
 前記多孔性シートが、セル膜を除去したウレタン樹脂発泡体からなることを特徴とする請求項１に記載の繊維強化成形体。   The fiber-reinforced molded body according to claim 1, wherein the porous sheet is made of a urethane resin foam from which a cell membrane has been removed. 前記式（Ａ１）で規定される圧縮率Ｃが１０００〜２６００％であることを特徴とする請求項１又は２に記載の繊維強化成形体。   The fiber-reinforced molded body according to claim 1 or 2, wherein the compression ratio C defined by the formula (A1) is 1000 to 2600%. 連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着した状態で硬化した表面材とよりなって、前記芯材の両面に前記繊維補強材が積層され、前記芯材の少なくとも一側の面の前記繊維補強材の表面に前記表面材が積層されている繊維強化成形体の製造方法であって、
炭素繊維織物に熱硬化性樹脂を含浸させて含浸済み炭素繊維織物を得る含浸工程と、
連続気泡を有する熱硬化性樹脂発泡体の両面に、前記含浸済み炭素繊維織物を配置し、前記連続気泡を有する熱硬化性樹脂発泡体の少なくとも一側の面の前記含浸済み炭素繊維織物の表面に前記多孔性シートを配置して積層体を得る積層工程と、
前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、
前記含浸工程における含浸は、以下の式（Ｂ２）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、
前記圧縮加熱工程における圧縮は、以下の式（Ａ２）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、
前記圧縮加熱工程により、前記炭素繊維織物に含浸している熱硬化性樹脂を押し出して前記熱硬化性樹脂発泡体に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂を硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法。
Figure 2012071591
Figure 2012071591
 A thermosetting resin foam impregnated with open cells is impregnated with a thermosetting resin, and the thermosetting resin is cured in a state where the thermosetting resin foam is compressed, and a carbon fiber fabric is thermoset. A fiber reinforcing material impregnated and cured with a curable resin, and a surface material in which a porous sheet is impregnated with a thermosetting resin and cured with the thermosetting resin adhering to the surface of the porous sheet. The fiber reinforcing material is laminated on both surfaces of the material, and the method for producing a fiber reinforced molded article in which the surface material is laminated on the surface of the fiber reinforcing material on at least one side surface of the core material,
An impregnation step of impregnating a carbon fiber fabric with a thermosetting resin to obtain an impregnated carbon fiber fabric;
The impregnated carbon fiber woven fabric is disposed on both surfaces of a thermosetting resin foam having open cells, and the surface of the impregnated carbon fiber fabric on at least one side of the thermosetting resin foam having open cells. Laminating step of arranging the porous sheet to obtain a laminate,
A compression heating step of compressing and heating the laminate,
The impregnation in the impregnation step is performed such that the resin ratio R defined by the following formula (B2) is in the range of 50 to 80%,
The compression in the compression heating step is performed such that the compression rate C defined by the following formula (A2) is 200 to 5000%,
In the compression heating step, the thermosetting resin impregnated in the carbon fiber fabric is extruded to impregnate the thermosetting resin foam, and the porous sheet is impregnated to cause the thermosetting resin to undergo a curing reaction. And forming the core material, the fiber reinforcing material, and the surface material, and integrating the core material, the fiber reinforcing material, and the surface material.
Figure 2012071591
Figure 2012071591
 前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程を、前記含浸工程と平行して、または前記含浸工程後に行い、
前記積層工程において、前記含浸済み炭素繊維織物と前記多孔性シートの積層に代えて、前記プリプレグを前記含浸済み炭素繊維織物側が前記連続気泡を有する熱硬化性樹脂発泡体に接するように積層することを特徴とする請求項４に記載の繊維強化成形体の製造方法。 A prepreg creation step for creating a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated is performed in parallel with or after the impregnation step,
In the laminating step, instead of laminating the impregnated carbon fiber fabric and the porous sheet, the prepreg is laminated so that the impregnated carbon fiber fabric side is in contact with the thermosetting resin foam having the open cells. The manufacturing method of the fiber reinforced molded object of Claim 4 characterized by these. 連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着した状態で硬化した表面材とよりなって、前記芯材の両面に前記繊維補強材が積層され、前記芯材の少なくとも一側の面の前記繊維補強材の表面に前記表面材が積層されている繊維強化成形体の製造方法であって、
連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂を含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程と、
前記含浸済み熱硬化性樹脂発泡体の両面に炭素繊維織物を配置し、前記含浸済み熱硬化性樹脂発泡体の少なくとも一側の面の前記炭素繊維織物の表面に前記多孔性シートを配置して積層体を得る積層工程と、
前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、
前記含浸工程における含浸は、以下の式（Ｂ３）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、
前記圧縮加熱工程における圧縮は、以下の式（Ａ３）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、
前記圧縮加熱工程により、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂を押し出して前記炭素繊維織物に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂を硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法。
Figure 2012071591
Figure 2012071591
 A thermosetting resin foam impregnated with open cells is impregnated with a thermosetting resin, and the thermosetting resin is cured in a state where the thermosetting resin foam is compressed, and a carbon fiber fabric is thermoset. A fiber reinforcing material impregnated and cured with a curable resin, and a surface material in which a porous sheet is impregnated with a thermosetting resin and cured with the thermosetting resin adhering to the surface of the porous sheet. The fiber reinforcing material is laminated on both surfaces of the material, and the method for producing a fiber reinforced molded article in which the surface material is laminated on the surface of the fiber reinforcing material on at least one side surface of the core material,
An impregnation step of impregnating the thermosetting resin foam having open cells with the thermosetting resin to obtain an impregnated thermosetting resin foam;
A carbon fiber fabric is disposed on both surfaces of the impregnated thermosetting resin foam, and the porous sheet is disposed on the surface of the carbon fiber fabric on at least one side of the impregnated thermosetting resin foam. A lamination process for obtaining a laminate;
A compression heating step of compressing and heating the laminate,
The impregnation in the impregnation step is performed such that the resin ratio R defined by the following formula (B3) is in the range of 50 to 80%,
The compression in the compression heating step is performed such that the compression rate C defined by the following formula (A3) is 200 to 5000%,
In the compression heating step, the thermosetting resin impregnated in the thermosetting resin foam is extruded to impregnate the carbon fiber fabric and impregnated in the porous sheet to cause the thermosetting resin to cure. And forming the core material, the fiber reinforcing material, and the surface material, and integrating the core material, the fiber reinforcing material, and the surface material.
Figure 2012071591
Figure 2012071591
 連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に付着した状態で硬化した表面材とよりなって、前記芯材の両面に前記繊維補強材が積層され、前記芯材の少なくとも一側の面の前記繊維補強材の表面に前記表面材が積層されている繊維強化成形体の製造方法であって、
連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂Ａを含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程Ａと、
炭素繊維織物に熱硬化性樹脂Ｂを含浸させて含浸済み炭素繊維織物を得る含浸工程Ｂと、
前記含浸済み熱硬化性樹脂発泡体の両面に前記含浸済み炭素繊維織物を配置し、前記含浸済み熱硬化性樹脂発泡体の少なくとも一側の面の前記含浸済み炭素繊維織物の表面に前記多孔性シートを配置して積層体を得る積層工程と、
前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、
前記含浸工程Ａ及びＢにおける含浸は、以下の式（Ｂ４）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、
前記圧縮加熱工程における圧縮は、以下の式（Ａ４）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、
前記圧縮加熱工程により、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂Ａと前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを接触させると共に、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを前記多孔性シートに含浸させた状態で、前記熱硬化性樹脂Ａと前記熱硬化性樹脂Ｂをそれぞれ硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法。
Figure 2012071591
Figure 2012071591
 A thermosetting resin foam impregnated with open cells is impregnated with a thermosetting resin, and the thermosetting resin is cured in a state where the thermosetting resin foam is compressed, and a carbon fiber fabric is thermoset. A fiber reinforcing material impregnated and cured with a curable resin, and a surface material in which a porous sheet is impregnated with a thermosetting resin and cured with the thermosetting resin adhering to the surface of the porous sheet. The fiber reinforcing material is laminated on both surfaces of the material, and the method for producing a fiber reinforced molded article in which the surface material is laminated on the surface of the fiber reinforcing material on at least one side surface of the core material,
An impregnation step A in which a thermosetting resin foam having open cells is impregnated with the thermosetting resin A to obtain an impregnated thermosetting resin foam;
Impregnation step B of impregnating a carbon fiber fabric with a thermosetting resin B to obtain an impregnated carbon fiber fabric; and
The impregnated carbon fiber woven fabric is disposed on both surfaces of the impregnated thermosetting resin foam, and the porous surface is provided on the surface of the impregnated carbon fiber woven fabric on at least one side of the impregnated thermosetting resin foam. A laminating step of arranging a sheet to obtain a laminate;
A compression heating step of compressing and heating the laminate,
The impregnation in the impregnation steps A and B is performed such that the resin ratio R defined by the following formula (B4) is in the range of 50 to 80%,
The compression in the compression heating step is performed such that the compression rate C defined by the following formula (A4) is 200 to 5000%,
In the compression heating step, the thermosetting resin A impregnated in the thermosetting resin foam is brought into contact with the thermosetting resin B impregnated in the carbon fiber fabric, and the carbon fiber fabric is impregnated. In the state where the thermosetting resin B is impregnated in the porous sheet, the thermosetting resin A and the thermosetting resin B are respectively subjected to a curing reaction to cause the core material, the fiber reinforcing material, and the surface material. And manufacturing the fiber-reinforced molded body, wherein the core material, the fiber reinforcing material and the surface material are integrated.
Figure 2012071591
Figure 2012071591
 前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程を、前記含浸工程と平行して、または前記含浸工程後に行い、
前記積層工程において、前記含浸済み炭素繊維織物と前記多孔性シートの積層に代えて、前記プリプレグを前記含浸済み炭素繊維織物側が前記含浸済み熱硬化性樹脂発泡体に接するように積層することを特徴とする請求項７に記載の繊維強化成形体の製造方法。 A prepreg creation step for creating a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated is performed in parallel with or after the impregnation step,
In the laminating step, instead of laminating the impregnated carbon fiber fabric and the porous sheet, the prepreg is laminated so that the impregnated carbon fiber fabric side is in contact with the impregnated thermosetting resin foam. The manufacturing method of the fiber reinforced molded object of Claim 7. 連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体が圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に滲出して付着した状態で硬化した表面材とよりなって、前記芯材の両側の面にそれぞれ前記繊維補強材と前記表面材がこの順に積層されている繊維強化成形体の製造方法であって、
炭素繊維織物に熱硬化性樹脂Ｂを含浸させて含浸済み炭素繊維織物を得る含浸工程Ｂと、
前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程と、
前記連続気泡を有する熱硬化性樹脂発泡体の両側の面に、それぞれ前記プリプレグを前記含浸済み炭素繊維織物が前記連続気泡を有する熱硬化性樹脂発泡体と接するように配置して積層体を得る積層工程と、
前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、
前記含浸工程における含浸は、以下の式（Ｂ５）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、
前記圧縮加熱工程における圧縮は、以下の式（Ａ５）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、
前記圧縮加熱工程により、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを押し出して前記熱硬化性樹脂発泡体に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂Ｂを硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法。
Figure 2012071591
Figure 2012071591
 A thermosetting resin foam impregnated with open cells is impregnated with a thermosetting resin, and the thermosetting resin is cured in a state where the thermosetting resin foam is compressed, and a carbon fiber fabric is thermoset. A fiber reinforcing material impregnated and cured with a curable resin, and a surface material cured in a state where the porous sheet is impregnated with a thermosetting resin and the thermosetting resin oozes and adheres to the surface of the porous sheet. A method for producing a fiber-reinforced molded body in which the fiber reinforcing material and the surface material are respectively laminated in this order on both sides of the core material,
Impregnation step B of impregnating a carbon fiber fabric with a thermosetting resin B to obtain an impregnated carbon fiber fabric; and
A prepreg creation step of creating a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated;
The prepreg is disposed on both sides of the thermosetting resin foam having open cells so that the impregnated carbon fiber fabric is in contact with the thermosetting resin foam having open cells to obtain a laminate. Lamination process;
A compression heating step of compressing and heating the laminate,
The impregnation in the impregnation step is performed so that the resin ratio R defined by the following formula (B5) is in the range of 50 to 80%,
The compression in the compression heating step is performed such that the compression rate C defined by the following formula (A5) is 200 to 5000%,
In the compression heating process, the thermosetting resin B impregnated in the carbon fiber fabric is extruded to impregnate the thermosetting resin foam and impregnated in the porous sheet, and the thermosetting resin B is cured. A method for producing a fiber-reinforced molded body, comprising: reacting to form the core material, the fiber reinforcing material, and the surface material; and integrating the core material, the fiber reinforcing material, and the surface material.
Figure 2012071591
Figure 2012071591
 前記含浸工程Ｂに加えて、前記連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂Ａを含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程Ａを有し、
前記積層工程において、前記連続気泡を有する熱硬化性樹脂発泡体に代えて、前記含浸済み熱硬化性樹脂発泡体の両側の面に、それぞれ前記プリプレグを配置して積層し、
前記圧縮加熱工程において、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂Ａと前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを接触させると共に、前記熱硬化性樹脂Ｂを前記多孔性シートに含浸させた状態で、前記熱硬化性樹脂Ａと前記熱硬化性樹脂Ｂをそれぞれ硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする請求項９に記載の繊維強化成形体の製造方法。 In addition to the impregnation step B, the thermosetting resin foam having the open cells is impregnated with a thermosetting resin A to obtain an impregnated thermosetting resin foam,
In the laminating step, instead of the thermosetting resin foam having the open cells, the prepreg is disposed and laminated on both sides of the impregnated thermosetting resin foam, respectively,
In the compression heating step, the thermosetting resin A impregnated in the thermosetting resin foam is brought into contact with the thermosetting resin B impregnated in the carbon fiber fabric, and the thermosetting resin B is While the porous sheet is impregnated, the thermosetting resin A and the thermosetting resin B are respectively subjected to a curing reaction to form the core material, the fiber reinforcing material, and the surface material, and the core material The method for producing a fiber-reinforced molded body according to claim 9, wherein the fiber reinforcing material and the surface material are integrated. 連続気泡を有する熱硬化性樹脂発泡体と多孔性シートの積層体に熱硬化性樹脂が含浸し、前記熱硬化性樹脂発泡体と前記多孔性シートが圧縮された状態で前記熱硬化性樹脂が硬化した芯材と、炭素繊維織物に熱硬化性樹脂が含浸硬化した繊維補強材と、多孔性シートに熱硬化性樹脂が含浸し、かつ熱硬化性樹脂が前記多孔性シート表面に滲出して付着した状態で硬化した表面材とよりなって、前記芯材の両側の面に前記繊維補強材が積層され、前記芯材の一側の前記繊維補強材の表面に前記表面材が積層された繊維強化成形体の製造方法であって、
炭素繊維織物に熱硬化性樹脂Ｂを含浸させて含浸済み炭素繊維織物を得る含浸工程Ｂと、
前記含浸済み炭素繊維織物と前記多孔性シートとが積層されたプリプレグを作成するプリプレグ作成工程と、
連続気泡を有する熱硬化性樹脂発泡体の一側の面に、前記プリプレグを前記含浸済み炭素繊維織物が前記連続気泡を有する熱硬化性樹脂発泡体と接するように配置すると共に、前記連続気泡を有する熱硬化性樹脂発泡体の他側の面に、別の前記プリプレグを前記多孔性シートが前記連続気泡を有する熱硬化性樹脂発泡体と接するように配置して積層体を得る積層工程と、
前記積層体を圧縮及び加熱する圧縮加熱工程とからなり、
前記含浸工程における含浸は、以下の式（Ｂ６）で規定される樹脂比率Ｒが５０〜８０％の範囲となるように行い、
前記圧縮加熱工程における圧縮は、以下の式（Ａ６）で規定される圧縮率Ｃが２００〜５０００％となるように圧縮し、
前記圧縮加熱工程により、前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを押し出して前記熱硬化性樹脂発泡体に含浸させると共に前記多孔性シートに含浸させ、前記熱硬化性樹脂Ｂを硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする繊維強化成形体の製造方法。
Figure 2012071591
Figure 2012071591
 A laminate of a thermosetting resin foam and a porous sheet having open cells is impregnated with a thermosetting resin, and the thermosetting resin is compressed in a state where the thermosetting resin foam and the porous sheet are compressed. A cured core material, a fiber reinforcing material in which a carbon fiber fabric is impregnated and cured with a thermosetting resin, a porous sheet impregnated with a thermosetting resin, and the thermosetting resin oozes on the surface of the porous sheet. The fiber reinforcing material is laminated on both sides of the core material, and the surface material is laminated on the surface of the fiber reinforcing material on one side of the core material. A method for producing a fiber reinforced molded article,
Impregnation step B of impregnating a carbon fiber fabric with a thermosetting resin B to obtain an impregnated carbon fiber fabric; and
A prepreg creation step of creating a prepreg in which the impregnated carbon fiber fabric and the porous sheet are laminated;
The prepreg is disposed on one surface of a thermosetting resin foam having open cells so that the impregnated carbon fiber fabric is in contact with the thermosetting resin foam having open cells, and the open cells are Laminating step of obtaining a laminate by disposing another prepreg on the other surface of the thermosetting resin foam so that the porous sheet is in contact with the thermosetting resin foam having the open cells;
A compression heating step of compressing and heating the laminate,
The impregnation in the impregnation step is performed such that the resin ratio R defined by the following formula (B6) is in the range of 50 to 80%.
The compression in the compression heating step is performed such that the compression rate C defined by the following formula (A6) is 200 to 5000%,
In the compression heating process, the thermosetting resin B impregnated in the carbon fiber fabric is extruded to impregnate the thermosetting resin foam and impregnated in the porous sheet, and the thermosetting resin B is cured. A method for producing a fiber-reinforced molded body, comprising: reacting to form the core material, the fiber reinforcing material, and the surface material; and integrating the core material, the fiber reinforcing material, and the surface material.
Figure 2012071591
Figure 2012071591
 前記含浸工程Ｂに加えて、前記連続気泡を有する熱硬化性樹脂発泡体に熱硬化性樹脂Ａを含浸させて含浸済み熱硬化性樹脂発泡体を得る含浸工程Ａを有し、
前記積層工程において、前記連続気泡を有する熱硬化性樹脂発泡体に代えて、前記含浸済み熱硬化性樹脂発泡体の両側の面に、それぞれ前記プリプレグを配置して積層し、
前記圧縮加熱工程において、前記熱硬化性樹脂発泡体に含浸している熱硬化性樹脂Ａと前記炭素繊維織物に含浸している熱硬化性樹脂Ｂを接触させると共に、前記熱硬化性樹脂Ａまたは前記熱硬化性樹脂Ｂを前記多孔性シートに含浸させた状態で、前記熱硬化性樹脂Ａと前記前記熱硬化性樹脂Ｂをそれぞれ硬化反応させて前記芯材と前記繊維補強材及び前記表面材を形成すると共に、前記芯材と前記繊維補強材及び前記表面材を一体化することを特徴とする。 In addition to the impregnation step B, the thermosetting resin foam having the open cells is impregnated with a thermosetting resin A to obtain an impregnated thermosetting resin foam,
In the laminating step, instead of the thermosetting resin foam having the open cells, the prepreg is disposed and laminated on both sides of the impregnated thermosetting resin foam, respectively,
In the compression heating step, the thermosetting resin A impregnated in the thermosetting resin foam and the thermosetting resin B impregnated in the carbon fiber fabric are brought into contact with each other, and the thermosetting resin A or In the state where the thermosetting resin B is impregnated in the porous sheet, the thermosetting resin A and the thermosetting resin B are respectively subjected to a curing reaction to cause the core material, the fiber reinforcing material, and the surface material. And the core material, the fiber reinforcing material and the surface material are integrated. 前記熱硬化性樹脂発泡体の圧縮率が１０００〜２６００％であることを特徴とする請求項４から１２の何れか一項に記載の繊維強化成形体の製造方法。   The method for producing a fiber-reinforced molded body according to any one of claims 4 to 12, wherein the compression ratio of the thermosetting resin foam is 1000 to 2600%. 前記多孔性シートが、セル膜を除去したウレタン樹脂発泡体からなることを特徴とする請求項４から１３の何れか一項に記載の繊維強化成形体の製造方法。   The method for producing a fiber-reinforced molded body according to any one of claims 4 to 13, wherein the porous sheet is made of a urethane resin foam from which a cell membrane has been removed.
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