JP2014031015A - Long fiber-reinforced resin molding and production method of the same - Google Patents

Long fiber-reinforced resin molding and production method of the same Download PDF

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JP2014031015A
JP2014031015A JP2013204848A JP2013204848A JP2014031015A JP 2014031015 A JP2014031015 A JP 2014031015A JP 2013204848 A JP2013204848 A JP 2013204848A JP 2013204848 A JP2013204848 A JP 2013204848A JP 2014031015 A JP2014031015 A JP 2014031015A
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filler
molded body
reinforced resin
long fiber
edge
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JP5682843B2 (en
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Noriyoshi Terasawa
知徳 寺澤
Tsuneo Takano
恒男 高野
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Mitsubishi Rayon Co Ltd
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
    • B29C70/302—Details of the edges of fibre composites, e.g. edge finishing or means to avoid delamination
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
    • B29C70/28—Shaping operations therefor
    • B29C70/40—Shaping or impregnating by compression not applied
    • B29C70/42—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles
    • B29C70/46—Shaping or impregnating by compression not applied for producing articles of definite length, i.e. discrete articles using matched moulds, e.g. for deforming sheet moulding compounds [SMC] or prepregs

Abstract

PROBLEM TO BE SOLVED: To provide a long fiber-reinforced resin molding that has a marginal part without a corner part, in which physical properties and appearance are favorable, and that is excellent in productivity; and a production method of the same.SOLUTION: A fiber-reinforced resin molding 10A is that a marginal part includes a filler 12a, and is performed by integral molding so that an edge face 13 of the marginal part may make a convex surface shape. SMC is suitably used as the filler 12a. Concretely, a marginal part material 12 having the filler 12a is integrated in the marginal part of the planar long fiber-reinforced resin molding body 10A. A prepreg in which the marginal part 12 includes the filler 12a is performed by compression molding to perform integral molding of the fiber-reinforced resin molding 10A in which the edge face 13 of the marginal part is a convex surface shape to be produced.

Description

本発明は、長繊維強化樹脂成形体とその製造方法に関する。   The present invention relates to a long fiber reinforced resin molded article and a method for producing the same.

従来、炭素繊維などの長繊維を強化繊維として用いた長繊維強化樹脂成形体を製造する際には、長繊維に熱硬化性樹脂を含浸したプリプレグが中間材として使用されている。このようなプリプレグとしては、具体的には、一方向に引きそろえられた長繊維に熱硬化性樹脂を含浸した一方向プリプレグ、長繊維の織物に熱硬化性樹脂を含浸したクロスプリプレグなどがある。
プリプレグを所望の形状に成形する方法としては、相対移動自在な上型と下型とを有する圧縮成形用型を使用して、加熱下で成形する圧縮成形法がある。
図６は、面状の長繊維強化樹脂成形体を製造するための従来の圧縮成形用型の一例を示す図である。図７は、図６の圧縮成形用型を用いて成形された面状の成形体を示す図である。図６の圧縮成形用型は、上型３１と下型３２とが上下に相対接近してキャビティ３３を形成し、キャビティ３３内でプリプレグを圧縮成形するようになっている（例えば特許文献１の図２参照。）。 Conventionally, when producing a long fiber reinforced resin molded article using long fibers such as carbon fibers as reinforcing fibers, a prepreg obtained by impregnating the long fibers with a thermosetting resin has been used as an intermediate material. Specific examples of such a prepreg include a unidirectional prepreg in which long fibers arranged in one direction are impregnated with a thermosetting resin, and a cross prepreg in which a woven fabric of long fibers is impregnated with a thermosetting resin. .
As a method of forming the prepreg into a desired shape, there is a compression molding method in which a compression molding die having an upper mold and a lower mold that are relatively movable is used and molded under heating.
FIG. 6 is a view showing an example of a conventional compression molding die for producing a planar long fiber reinforced resin molded body. FIG. 7 is a diagram showing a planar molded body formed using the compression molding die of FIG. In the compression molding die of FIG. 6, the upper die 31 and the lower die 32 are relatively close to each other to form a cavity 33, and the prepreg is compression molded in the cavity 33 (for example, in Patent Document 1). (See FIG. 2).

このような圧縮成形用型３０では、上型３１と下型３２は、これらが上下に相対接近してキャビティ３３を形成した際に、キャビティ３３の外周縁部において上型３１と下型３２とが上下方向に延びるガス抜き用の間隔３４を形成しつつ、嵌合されるようになっている。この間隙３４は、通常、加熱により流動性が高くなった樹脂材料ははみ出さず、例えば熱硬化反応によりキャビティ３３内で発生したガスが抜ける程度の距離Ｃ’（例えば、０．０５〜０．１ｍｍ）に設定されている。このような間隙３４が形成される部分はシェアエッジ部と呼ばれている。   In such a compression molding die 30, the upper die 31 and the lower die 32 are formed so that the upper die 31, the lower die 32 and the lower die 32 are formed at the outer peripheral edge of the cavity 33 when they are relatively close to each other to form the cavity 33. Are fitted while forming a degassing interval 34 extending in the vertical direction. The gap 34 does not normally protrude from the resin material whose fluidity has been increased by heating, and for example, a distance C ′ (for example, 0.05 to 0.00) that allows gas generated in the cavity 33 to escape due to a thermosetting reaction. 1 mm). A portion where such a gap 34 is formed is called a shear edge portion.

国際公開第０４／０４８４３５号International Publication No. 04/048435

しかしながら、図７に示すように、このような圧縮成形用型３０を用いて成形された成形体４０の縁部は、角部４１ａ、４１ｂを有する形状となる。
このような角部４１ａ、４１ｂを有する形状は、この成形体４０が人の手などに触れるものである場合には、角部４１ａ、４１ｂが怪我の原因となる可能性がある点や、角部４１ａ、４１ｂが製造時に欠損しやすい点などから、好適ではない。 However, as shown in FIG. 7, the edge part of the molded object 40 shape | molded using such a mold 30 for compression molding becomes a shape which has the corner | angular parts 41a and 41b.
Such a shape having the corners 41a and 41b has a possibility that the corners 41a and 41b may cause injury when the molded body 40 touches a human hand or the like. The portions 41a and 41b are not preferable because they are easily lost during manufacturing.

このような問題を解決するために、成形体４０の角部４１ａ、４１ｂを切削加工などの後処理で削り落とし、丸めることも考えられるが、このような切削加工は非常に手間がかかり、生産性の点で問題がある。   In order to solve such a problem, the corners 41a and 41b of the molded body 40 may be scraped off and rounded by post-processing such as cutting, but such cutting is very laborious and production. There is a problem in terms of sex.

本発明は上記事情に鑑みてなされたもので、角部のない縁部を備え、物性や外観が良好で、生産性にも優れた長繊維強化樹脂成形体とその製造方法の提供を課題とする。   The present invention has been made in view of the above circumstances, and it is an object to provide a long fiber reinforced resin molded article having an edge without corners, good physical properties and appearance, and excellent productivity, and a method for producing the same. To do.

本発明の長繊維強化樹脂成形体は、縁部が充填材を内包し、かつ、前記縁部の端面が凸曲面状をなすように一体成形されている。
前記充填材は、ＳＭＣからなることが好ましい。
本発明の長繊維強化樹脂成形体としては、長繊維強化樹脂成形体本体の縁部に、前記充填材を備えた縁部材が一体化されている形態が好ましい。
その他には、縁部が前記充填材を内包するように巻き込まれている形態も例示できる。
本発明の長繊維強化樹脂成形体の製造方法は、縁部が充填材を内包するプリプレグを圧縮成形して、前記縁部の端面が凸曲面状である長繊維強化樹脂成形体を一体成形するものである。 The long fiber reinforced resin molded body of the present invention is integrally molded so that the edge portion contains the filler and the end surface of the edge portion has a convex curved surface shape.
The filler is preferably made of SMC.
The long fiber reinforced resin molded body of the present invention preferably has a form in which an edge member provided with the filler is integrated with the edge of the long fiber reinforced resin molded body.
In addition, the form by which the edge part is wound so that the said filler may be included can also be illustrated.
In the method for producing a long fiber reinforced resin molded article of the present invention, a prepreg having an edge containing a filler is compression-molded, and a long fiber reinforced resin molded article having an end surface of a convex curved surface is integrally formed. Is.

本発明によれば、角部のない縁部を備え、物性や外観が良好で、生産性にも優れた長繊維強化樹脂成形体とその製造方法を提供できる。   ADVANTAGE OF THE INVENTION According to this invention, the long fiber reinforced resin molded object which was provided with the edge part without a corner | angular part, was excellent in the physical property and external appearance, and was excellent also in productivity, and its manufacturing method can be provided.

第１実施形態例の長繊維強化樹脂成形体を示す部分断面図である。It is a fragmentary sectional view which shows the long fiber reinforced resin molding of the example of 1st Embodiment. 図１の長繊維強化樹脂成形体の圧縮成形に好適に使用される圧縮成形用型の（ａ）部分縦断面図と、（ｂ）（ａ）の一部を拡大した拡大図である。It is the (a) partial longitudinal cross-sectional view of the mold for compression molding used suitably for the compression molding of the long fiber reinforced resin molding of FIG. 1, and the enlarged view which expanded a part of (b) (a). 第２実施形態例の長繊維強化樹脂成形体を示す部分断面図である。It is a fragmentary sectional view which shows the long fiber reinforced resin molding of the example of 2nd Embodiment. 第３実施形態例の長繊維強化樹脂成形体を示す部分断面図である。It is a fragmentary sectional view which shows the long fiber reinforced resin molding of the example of 3rd Embodiment. 第４実施形態例の長繊維強化樹脂成形体を示す部分断面図である。It is a fragmentary sectional view which shows the long fiber reinforced resin molding of the example of 4th Embodiment. 圧縮成形用型の一例を示す部分縦断面図である。It is a fragmentary longitudinal cross-section which shows an example of the die for compression molding. 図６の圧縮成形型で成形された成形体の部分断面図である。It is a fragmentary sectional view of the molded object shape | molded with the compression mold of FIG.

本発明の長繊維強化樹脂成形体は、縁部が充填材を内包し、かつ、この縁部を構成する端面が凸曲面状をなすように、一体成形（一括成形）されたものである。
ここで「充填材を内包する」とは、充填材が露出しないように被覆された状態のことを意味する。
以下本発明について、実施形態例を挙げて詳細に説明する。 The long fiber reinforced resin molded product of the present invention is integrally molded (collectively molded) so that the edge portion contains the filler and the end surface constituting the edge portion has a convex curved surface shape.
Here, “including the filler” means a state in which the filler is coated so as not to be exposed.
Hereinafter, the present invention will be described in detail with reference to embodiments.

［第１実施形態例］
図１は、第１実施形態例の長繊維強化樹脂成形体（以下、成形体という。）１０Ａについて、その縁部を含む要部を示した部分断面図である。
この例の成形体１０Ａは、面状に形成された長繊維強化樹脂成形体本体（以下、成形体本体という。）１１と、この成形体本体１１の縁部における一方の面１１ａに一体化された縁部材１２とを有して構成されている。成形体本体１１は、長繊維で熱硬化性樹脂が強化された長繊維強化樹脂からなっている。そして、縁部において、成形体本体１１と縁部材１２とで構成される端面１３は、凸曲面状に形成されている。
また、この例の縁部材１２は、充填材１２ａを備えるとともに、この充填材１２ａが露出しないように充填材１２ａの全周を覆う被覆材１２ｂを備えている。充填材１２ａはＳＭＣ（短繊維と熱硬化性樹脂からなるシートモールディングコンパウンド）からなり、被覆材１２ｂは、成形体本体１１と同じ種類の長繊維と同じ種類の熱硬化性樹脂とを備えた長繊維強化樹脂からなっている。 [First Embodiment]
FIG. 1 is a partial cross-sectional view showing a main part including an edge portion of a long fiber reinforced resin molded body (hereinafter referred to as a molded body) 10A of the first embodiment.
The molded body 10 </ b> A in this example is integrated with a long fiber reinforced resin molded body main body (hereinafter referred to as a molded body main body) 11 formed in a planar shape and one surface 11 a at the edge of the molded body main body 11. And an edge member 12. The molded body 11 is made of a long fiber reinforced resin in which a thermosetting resin is reinforced with long fibers. And in the edge part, the end surface 13 comprised by the molded object main body 11 and the edge member 12 is formed in the convex curve shape.
Further, the edge member 12 of this example includes a filler 12a and a covering material 12b that covers the entire circumference of the filler 12a so that the filler 12a is not exposed. The filler 12a is made of SMC (a sheet molding compound made of short fibers and a thermosetting resin), and the covering material 12b is a long material having the same type of long fibers as the molded body 11 and the same type of thermosetting resin. Made of fiber reinforced resin.

このような成形体１０Ａは、端面１３が凸曲面状に形成されているため、端面１３が平面状に形成されている場合のような角部が存在しない。そのため、この成形体１０Ａが人の手などに触れるものであっても、怪我の原因となる可能性が低く、製造時における角部の欠損も起こらない。
また、このような成形体１０Ａは、縁部が充填材１２ａを内包している。そのため、成形時の樹脂流れによって熱硬化性樹脂が過剰になり、強度が低下して欠けやすい傾向にある成形体本体１１の縁部を充填材１２ａで補強することができ、物性に優れた成形体１０Ａとすることができる。加えて、充填材１２ａは露出しないように内包されているため、樹脂流れが起こりやすいＳＭＣなどが充填材１２ａとして使用されている場合であっても、ＳＭＣ中の熱硬化性樹脂が成形時に成形体本体１１側へと移動してしまう現象を効果的に防ぐことができる。よって、このような樹脂流れに起因して、成形体本体１１の繊維配向が乱れて物性が変化してしまうという問題や、外観が低下するという問題を防止することができる。
また、このような成形体１０Ａは、後述の圧縮成形用型を使用した圧縮成形により、一体成形されたものであって、縁部を切削加工するなどの後処理工程や、成形体本体１１と縁部材１２とを別々に製造して接着剤で接着する工程などを必要としないため、少ない工程数で製造でき、生産性に優れる。 In such a molded body 10A, since the end face 13 is formed in a convex curved surface shape, there is no corner as in the case where the end face 13 is formed in a flat shape. For this reason, even if the molded body 10A touches a human hand or the like, there is a low possibility of causing injury, and no corners are lost during manufacture.
In addition, such a molded body 10A includes the filler 12a at the edge. Therefore, the thermosetting resin becomes excessive due to the resin flow at the time of molding, and the edge of the molded body 11 that tends to be chipped due to a decrease in strength can be reinforced with the filler 12a, and molding with excellent physical properties. The body 10A can be obtained. In addition, since the filler 12a is included so as not to be exposed, the thermosetting resin in the SMC is molded at the time of molding even when SMC or the like that easily causes resin flow is used as the filler 12a. The phenomenon of moving to the body main body 11 side can be effectively prevented. Therefore, it is possible to prevent the problem that the fiber orientation of the molded body 11 is disturbed and the physical properties are changed due to such a resin flow, and the appearance is deteriorated.
Further, such a molded body 10A is integrally formed by compression molding using a compression molding die described later, and a post-processing step such as cutting an edge portion, Since the step of separately manufacturing the edge member 12 and bonding it with an adhesive is not required, it can be manufactured with a small number of steps, and the productivity is excellent.

また、この例では、充填材１２ａが露出しないようにあらかじめ被覆材１２ｂで全周が覆われたうえで、縁部材１２が成形体本体１１に一体化されている。そのため、より効果的に上述の樹脂流れを防ぐことができる。加えて、成形体本体１１と縁部材１２との接着部分では、成形体本体１１と充填材１２ａではなく、成形体本体１１と被覆材１２ｂとが接着している。よって、成形体本体１１と被覆材１２ｂとを同じ種類の長繊維と同じ種類の熱硬化性樹脂とで構成することによって、成形体本体１１と縁部材１２との接着性も優れる。   In this example, the entire periphery is covered with the covering material 12b in advance so that the filler 12a is not exposed, and the edge member 12 is integrated with the molded body 11. Therefore, the above-mentioned resin flow can be prevented more effectively. In addition, in the bonded portion between the molded body 11 and the edge member 12, the molded body 11 and the covering material 12b are bonded instead of the molded body 11 and the filler 12a. Therefore, the adhesiveness of the molded body main body 11 and the edge member 12 is excellent by comprising the molded body main body 11 and the covering material 12b with the same type of long fibers and the same type of thermosetting resin.

この例の成形体１０Ａは、例えば次のようにして製造することができる。
まず、充填材用のＳＭＣと、被覆材用のシート状プリプレグとを用意する。ついで、シート状プリプレグでＳＭＣの全周を覆い、プリプレグ縁部材を製造する。一方、成形体本体用の面状のプリプレグ本体を用意し、このプリプレグ本体の縁部における一方の面にプリプレグ縁部材を配置して、縁部が充填材を内包するプリプレグを製造する。
ついで、このプリプレグを図２に示すような圧縮成形用型２０で圧縮成形する。
または、シート状プリプレグでＳＭＣの全周を覆ったものを圧縮成形型２０に装填後、引き続き、成形体本体用の面状のプリプレグ本体を圧縮成形型２０に装填することにより、縁部が充填材を内包するプリプレグを圧縮成形型２０内において製造し、これを引き続き圧縮成形してもよい。
圧縮成形の前には、予備成形と脱気とを行ってもよい。 The molded body 10A of this example can be manufactured as follows, for example.
First, an SMC for a filler and a sheet-like prepreg for a coating material are prepared. Next, the entire circumference of the SMC is covered with a sheet-like prepreg to manufacture a prepreg edge member. On the other hand, a planar prepreg body for a molded body is prepared, and a prepreg edge member is disposed on one surface of the edge of the prepreg body to produce a prepreg in which the edge includes a filler.
Next, this prepreg is compression molded with a compression molding die 20 as shown in FIG.
Alternatively, the sheet-shaped prepreg covering the entire circumference of the SMC is loaded into the compression mold 20, and then the planar prepreg body for the molded body is loaded into the compression mold 20 to fill the edges. A prepreg containing the material may be produced in the compression mold 20 and subsequently compression molded.
Prior to compression molding, preforming and degassing may be performed.

この圧縮成形用型２０は、一対の型として上型２１と下型２２とを備え、この例では、下型２２に対して上型２１が鉛直方向に昇降することで、相対移動自在、すなわち相対接近または相対離間が可能とされている。上型２１と下型２２には、成形面２３、２４がそれぞれ形成され、上型２１と下型２２とが相対接近することにより、これら成形面２３、２４で囲まれたキャビティ２５が形成される。キャビティ２５内では、プリプレグが加熱されながら圧縮され、図１の成形体１０Ａが圧縮成形される。なお、この例では、プリプレグを加熱する手段は図示していない。   The compression mold 20 includes an upper mold 21 and a lower mold 22 as a pair of molds. In this example, the upper mold 21 is moved up and down in the vertical direction with respect to the lower mold 22. Relative approach or relative separation is possible. Molding surfaces 23 and 24 are formed on the upper die 21 and the lower die 22, respectively, and a cavity 25 surrounded by the molding surfaces 23 and 24 is formed by relatively approaching the upper die 21 and the lower die 22. The In the cavity 25, the prepreg is compressed while being heated, and the molded body 10A of FIG. 1 is compression-molded. In this example, means for heating the prepreg is not shown.

そして、この圧縮成形用型２０は、上型２１と下型２２とがそれぞれ対向面２１ａ、２２ａを有しており、上型２１と下型２２とが相対接近してキャビティ２５を形成した際には、この一対の対向面２１ａ、２２ａが対向するようになっている。
具体的には、この対向面２１ａ、２２ａは、相対移動の方向に対して垂直な面（この例では水平面）であり、キャビティ２５の外周縁部において、相対移動の方向に対して垂直方向（この例では水平方向）に延びる間隙２６を介して、互いに対向するように形成されている。対向面２１ａ、２２ａの間に形成された間隙２６は、プリプレグが加熱されて、プリプレグを構成する熱硬化性樹脂の流動性が高くなったとしてもはみ出さず、熱硬化反応などによりキャビティ２５内で発生したガスが抜ける程度の距離Ｃ（例えば、０．０５〜０．１ｍｍ）に設定されている。
なお、この例の圧縮成形用型２０では、間隙２６は、対向面２１ａ、２２ａにおいて水平方向に延びた後、垂下して、型外に通じるように形成されている。 In the compression molding die 20, the upper die 21 and the lower die 22 have opposing surfaces 21 a and 22 a, respectively, and the upper die 21 and the lower die 22 are relatively close to form a cavity 25. The pair of opposed surfaces 21a and 22a are opposed to each other.
Specifically, the facing surfaces 21a and 22a are surfaces (horizontal planes in this example) perpendicular to the direction of relative movement, and the outer peripheral edge of the cavity 25 is perpendicular to the direction of relative movement ( In this example, they are formed so as to face each other via a gap 26 extending in the horizontal direction). The gap 26 formed between the opposing surfaces 21a and 22a does not protrude even if the fluidity of the thermosetting resin constituting the prepreg is increased due to the heating of the prepreg. The distance C (for example, 0.05 to 0.1 mm) is set such that the gas generated in step 3 can escape.
In the compression molding die 20 of this example, the gap 26 extends in the horizontal direction on the opposing surfaces 21a and 22a and then hangs down so as to communicate with the outside of the die.

圧縮成形では、まず、予め上型２１と下型２２とを所定の温度（成形温度）まで加熱しておく。ついで、プリプレグを下型２２の成形面２４上に配置した後、上型２１を下型２２の方に降下させて圧縮成形用型２０を型締めし、上型２１および下型２２により形成されるキャビティ２５内で、プリプレグを加熱しながら圧縮する。
こうして圧縮成形した後、上型２１を上昇させて圧縮成形型２０を型開きし、成形された成形体１０Ａを取り出す。
取り出された成形体１０Ａには、圧縮成形中に間隙２６の部分に熱硬化性樹脂がはみ出したことによるバリが形成されていることがあるが、その場合には、バリを落とすための研磨などを必要に応じて行う。
上型２１と下型２２の材質としては、圧縮成形時に溶融したり変形したりしないものであればよく、好ましくは金属が用いられるが、場合によっては樹脂であってもよい。
このような圧縮成形用型２０を使用することによって、縁部が充填材１２ａを内包し、かつ、凸曲面状であって角部のない端面１３を備えた図１のような成形体１０Ａを一体成形することができる。 In compression molding, first, the upper mold 21 and the lower mold 22 are heated in advance to a predetermined temperature (molding temperature). Next, after the prepreg is disposed on the molding surface 24 of the lower die 22, the upper die 21 is lowered toward the lower die 22 to clamp the compression molding die 20, and the upper die 21 and the lower die 22 are formed. In the cavity 25, the prepreg is compressed while being heated.
After compression molding in this way, the upper mold 21 is raised, the compression mold 20 is opened, and the molded body 10A is taken out.
The molded body 10A that has been taken out may have burrs formed due to the thermosetting resin protruding into the gaps 26 during compression molding. In such a case, polishing or the like is used to remove the burrs. As necessary.
The material of the upper mold 21 and the lower mold 22 may be any material that does not melt or deform during compression molding, and a metal is preferably used, but a resin may be used in some cases.
By using such a compression molding die 20, the molded body 10 </ b> A as shown in FIG. 1 having an end surface 13 that includes a filler 12 a at the edge and is convex and has no corners. Can be integrally molded.

成形体本体１１を構成する長繊維強化樹脂としては、一方向に引きそろえられた長繊維に熱硬化性樹脂を含浸した一方向プリプレグ、長繊維の織物に熱硬化性樹脂を含浸したクロスプリプレグなどから製造されるものが例示できる。成形体本体１１は、このようなプリプレグを適宜複数枚重ねた積層体から形成されてもよい。
長繊維としては、例えば炭素繊維、ガラス繊維、アラミド繊維、ボロン繊維、炭化珪素繊維、高強度ポリエチレン、ＰＢＯ繊維、ステンレススチール繊維等が挙げられ、熱硬化性樹脂としては、例えばエポキシ樹脂、ビニルエステル樹脂、不飽和ポリエステル樹脂、ポリイミド樹脂、マレイミド樹脂、フェノール樹脂等が挙げられる。 The long fiber reinforced resin constituting the molded body 11 includes a unidirectional prepreg in which a long fiber aligned in one direction is impregnated with a thermosetting resin, a cross prepreg in which a long fiber fabric is impregnated with a thermosetting resin, and the like. Can be exemplified. The molded body 11 may be formed from a laminate in which a plurality of such prepregs are appropriately stacked.
Examples of long fibers include carbon fibers, glass fibers, aramid fibers, boron fibers, silicon carbide fibers, high-strength polyethylene, PBO fibers, and stainless steel fibers. Thermosetting resins include, for example, epoxy resins and vinyl esters. Examples thereof include resins, unsaturated polyester resins, polyimide resins, maleimide resins, phenol resins, and the like.

縁部材１２を構成する充填材１２ａとしては、成形性に優れるとともに、縁部をより効果的に補強できる点から、強化繊維として短繊維を用いたＳＭＣが好適であるが、例えば、強化繊維を含まない熱硬化性樹脂を使用してもよい。また、軽量な金属、樹脂が発泡剤により発泡した発泡体、プリフォームされた樹脂成形体などを使用してもよい。ＳＭＣを使用する場合には、成形体本体１１に使用された長繊維と同じ材質の短繊維と、成形体本体１１と同じ種類の熱硬化性樹脂とから構成されるものを使用することが好ましい。
充填材１２ａを被覆する被覆材１２ｂとしては、成形体本体１１と同じ種類の長繊維と熱硬化性樹脂とを備えたクロスプリプレグや、スクリムクロスプリプレグなどから製造される長繊維強化樹脂を使用すると、成形体本体１１との接着性が優れるとともに、充填材１２ａがＳＭＣ、熱硬化性樹脂などの場合にも、硬化前の熱硬化性樹脂が外側に漏れにくく好ましい。 As the filler 12a constituting the edge member 12, SMC using short fibers as the reinforcing fibers is preferable from the viewpoint of excellent moldability and the ability to reinforce the edge more effectively. You may use the thermosetting resin which does not contain. Further, a lightweight metal, a foam in which a resin is foamed with a foaming agent, a preformed resin molded body, or the like may be used. When using SMC, it is preferable to use what is comprised from the short fiber of the same material as the long fiber used for the molded object main body 11, and the thermosetting resin of the same kind as the molded object main body 11. .
As the covering material 12b for covering the filler 12a, a long fiber reinforced resin produced from a cross prepreg having the same type of long fibers and thermosetting resin as the molded body 11 or a scrim cloth prepreg is used. In addition, the adhesiveness with the molded body 11 is excellent, and even when the filler 12a is SMC, thermosetting resin or the like, it is preferable that the thermosetting resin before curing hardly leaks to the outside.

［第２実施形態例］
図３は、第２実施形態例の成形体１０Ｂについて、その縁部を含む要部を示した部分断面図である。
この例の成形体１０Ｂの縁部材１２は、充填材１２ａが露出しないように、被覆材１２ｂが充填材１２ａを覆っているだけでなく、成形体本体１１の一方の面（縁部材１２が一体化された側の面）１１ａに沿って端面１３側とは反対側に延出し、この延出した延出部１２ｃも成形体本体１１の一方の面１１ａと接着している点で、第１実施形態例の成形体１０Ａと異なっている。
このような成形体１０Ｂによれば、延出部１２ｃの分だけ、第１実施形態例の成形体１０Ａよりも成形体本体１１と縁部材１２との接着面積が大きくなるため、成形体本体１１と縁部材１２とがより良好に接着する。
この成形体１０Ｂも、第１実施形態例の場合と同様の方法により、一体成形することができる。 [Second Embodiment]
FIG. 3 is a partial cross-sectional view showing the main part including the edge of the molded body 10B of the second embodiment.
In the edge member 12 of the molded body 10B of this example, not only the covering material 12b covers the filler 12a so that the filler 12a is not exposed, but also one surface of the molded body main body 11 (the edge member 12 is integrated). The first surface 11a extends in the direction opposite to the end surface 13 side along the surface 11a, and this extended portion 12c is also bonded to the one surface 11a of the molded body 11. This is different from the molded body 10A of the embodiment.
According to such a molded body 10B, the adhesion area of the molded body main body 11 and the edge member 12 is larger than the molded body 10A of the first embodiment by the amount of the extending portion 12c. And the edge member 12 adhere more favorably.
This molded body 10B can also be integrally molded by the same method as in the first embodiment.

［第３実施形態例］
図４は、第３実施形態例の成形体１０Ｃについて、その縁部を含む要部を示した部分断面図である。
この例の成形体１０Ｃの縁部材１２は、充填材１２ａが露出しないように、被覆材１２ｂが充填材１２ａを覆っている点では第１および第２実施形態例の成形体１０Ａ、１０Ｂと同様である。ただし、被覆材１２ｂが充填材１２ａの全周を覆っているのではなく、充填材１２ａにおいて成形体本体１１の一方の面１１ａとは接触していない非接触面のみを覆っている。そして、縁部材１２が成形体本体１１と一体化されることで、充填材１２ａが露出せず内包されるように構成されている点で、第１および第２実施形態例の成形体１０Ａ、１０Ｂとは異なっている。そして、被覆材１２ｂは、成形体本体１１の一方の面１１ａに沿って端面１３側とは反対側に延出するとともに、成形体本体１１の端面１３側にも延出し、これら延出した延出部１２ｃが成形体本体１１と接着することで、成形体本体１１と縁部材１２とが一体化されている。
この際、被覆材１２ｂと、この被覆材１２ｂと接着する成形体本体１１の表面とで、同じ種類のプリプレグが使用されていると、被覆材１２ｂの延出部１２ｃが成形体本体１１と良好に接着し、好適である。 [Third Embodiment]
FIG. 4 is a partial cross-sectional view showing the main part including the edge part of the molded body 10C of the third embodiment.
The edge member 12 of the molded body 10C of this example is the same as the molded bodies 10A and 10B of the first and second embodiments in that the covering material 12b covers the filler 12a so that the filler 12a is not exposed. It is. However, the covering material 12b does not cover the entire circumference of the filler 12a, but covers only the non-contact surface that is not in contact with the one surface 11a of the molded body 11 in the filler 12a. Then, the edge member 12 is integrated with the molded body main body 11 so that the filler 12a is not exposed and is included, and the molded body 10A of the first and second embodiments is provided. It is different from 10B. The covering material 12b extends along the one surface 11a of the molded body 11 to the side opposite to the end surface 13 side, and also extends to the end surface 13 side of the molded body 11 and these extended extensions. The molded body main body 11 and the edge member 12 are integrated by the protruding portion 12c being bonded to the molded body main body 11.
At this time, when the same kind of prepreg is used for the covering material 12b and the surface of the molded body 11 that adheres to the covering material 12b, the extended portion 12c of the covering material 12b is good with the molded body 11 Adhering to is suitable.

この成形体１０Ｃも、第１および第２実施形態例の場合と同様の方法により、一体成形することができる。ただし、この例の場合には、シート状プリプレグでＳＭＣの全周を覆ったプリプレグ縁部材を製造する必要はなく、面状のプリプレグ本体の縁部における一方の面に、充填材用のＳＭＣを配置してから、これを覆うように被覆材用のシート状プリプレグを配置して、これを圧縮成形用型２０で圧縮成形すればよい。   This molded body 10C can also be integrally molded by the same method as in the first and second embodiments. However, in the case of this example, it is not necessary to manufacture a prepreg edge member that covers the entire circumference of the SMC with the sheet-like prepreg, and the SMC for the filler is formed on one surface of the edge of the planar prepreg body. After the arrangement, a sheet-like prepreg for the covering material is arranged so as to cover it, and this is compression-molded by the compression molding die 20.

［第４実施形態例］
図５は、第４実施形態例の成形体１０Ｄについて、その縁部を含む要部を示した部分断面図である。
この例の成形体１０Ｄは、成形体本体と充填材を有する縁部材とが一体化された構成ではなく、面状の成形体１４の縁部が充填材１２ａを内包するように巻き込まれている点で、第１〜３実施形態例の成形体１０Ａ〜１０Ｃと異なっている。
この例の成形体１０Ｄによれば、第１〜３実施形態例のように、被覆材１２ｂを使用する必要がないため、少ない材料で構成でき、コストを抑制することができる。
この成形体１０Ｄを製造する場合には、面状の長繊維強化樹脂からなるプリプレグを圧縮成形型２０内に配置し、さらにその縁部に充填材１２ａを配置し、充填材１２ａが露出しないように縁部を内側に巻き込んだ状態として、圧縮成形すればよい。 [Fourth Embodiment]
FIG. 5 is a partial cross-sectional view showing the main part including the edge of the molded body 10D of the fourth embodiment.
The molded body 10D of this example is not a structure in which the molded body main body and the edge member having the filler are integrated, but is wound so that the edge of the planar molded body 14 includes the filler 12a. This is different from the molded bodies 10A to 10C of the first to third embodiments.
According to the molded body 10D of this example, since it is not necessary to use the covering material 12b as in the first to third embodiments, it can be configured with a small amount of material and the cost can be suppressed.
When this molded body 10D is manufactured, a prepreg made of a sheet-like long fiber reinforced resin is disposed in the compression mold 20, and further, a filler 12a is disposed at an edge thereof so that the filler 12a is not exposed. What is necessary is just to carry out compression molding as the state which wound the edge part inside.

以上説明したように、各例の成形体１０Ａ〜１０Ｄによれば、端面１３が凸曲面状に形成されている。そのため、この成形体１０Ａ〜１０Ｄが人の手などに触れるものであっても、怪我の原因となる可能性が低く、製造時における角部の欠損も起こらない。
また、このような成形体１０Ａ〜１０Ｄは、縁部が充填材１２ａを内包している。そのため、強度が低下しやすい傾向にある縁部を充填材１２ａで補強することができ、物性に優れた成形体１０Ａ〜１０Ｄとすることができる。加えて、樹脂流れが起こりやすいＳＭＣなどが充填材１２ａとして使用されている場合であっても、ＳＭＣ中の熱硬化性樹脂の移動を防ぎ、物性変化や外観低下を抑制することができる。
また、このような成形体１０Ａ〜１０Ｄは、一体成形されたものであって、縁部１３を切削加工するなどの後処理工程や、成形体本体１１と縁部材１２とを別々に製造して接着剤で接着する工程などを必要としないため、少ない工程数で製造でき、生産性に優れる。
なお、成形体１０Ａ〜１０Ｄは、その縁部の全部、すなわち全周縁部が充填材を内包し、かつ、全周端面が凸曲面状をなすものであってもよいし、必要に応じて部分的に充填材を内包し、その部分を構成する端面が凸曲面状をなすものであってもよい。 As described above, according to the molded bodies 10A to 10D of the respective examples, the end surface 13 is formed in a convex curved shape. For this reason, even if the molded bodies 10A to 10D touch a human hand or the like, there is a low possibility of causing injury, and no corners are lost during manufacture.
In addition, such molded bodies 10 </ b> A to 10 </ b> D include the filler 12 a at the edges. Therefore, the edge part in which an intensity | strength tends to fall can be reinforced with the filler 12a, and it can be set as the molded object 10A-10D excellent in the physical property. In addition, even when SMC or the like in which resin flow easily occurs is used as the filler 12a, the movement of the thermosetting resin in the SMC can be prevented, and changes in physical properties and appearance deterioration can be suppressed.
Further, such molded bodies 10A to 10D are integrally molded, and a post-processing step such as cutting the edge portion 13 or the molded body main body 11 and the edge member 12 are separately manufactured. Since a process of bonding with an adhesive is not required, it can be manufactured with a small number of processes and is excellent in productivity.
In addition, as for molded object 10A-10D, the whole edge part, ie, all the peripheral parts, may include a filler, and all the peripheral end surfaces may make a convex curve shape, and it is a part as needed. In particular, the filler may be included, and the end surface constituting the portion may be a convex curved surface.

１０Ａ〜１０Ｄ 長繊維強化樹脂成形体
１１ 長繊維強化樹脂成形体本体
１２ 縁部材
１２ａ 充填材
１２ｂ 被覆材
１２ｃ 延出部
１３ 端面
１４ 面状の成形体
２０ 圧縮成形用型
２１ 上型
２１ａ 対向面
２２ 下型
２２ａ 対向面
２３ 成形面
２４ 成形面
２５ キャビティ
２６ 間隙 10A to 10D Long fiber reinforced resin molded body 11 Long fiber reinforced resin molded body main body 12 Edge member 12a Filler 12b Covering material 12c Extension part 13 End surface 14 Planar molded body 20 Compression mold 21 Upper mold 21a Opposing surface 22 Lower mold 22a Opposing surface 23 Molding surface 24 Molding surface 25 Cavity 26 Gap

Claims (3)

縁部が充填材を内包し、かつ、前記縁部の端面が凸曲面状をなすように一体成形された面状の長繊維強化樹脂成形体であって、
面状の長繊維強化樹脂成形体本体の縁部に、前記充填材を備えた縁部材が一体化されている、長繊維強化樹脂成形体。 An edge is a sheet-like long fiber reinforced resin molded body that is integrally molded so as to enclose a filler, and an end surface of the edge has a convex curved shape,
A long fiber reinforced resin molded article in which an edge member provided with the filler is integrated with an edge of a planar long fiber reinforced resin molded body. 前記充填材は、ＳＭＣからなる請求項１に記載の長繊維強化樹脂成形体。   The long fiber reinforced resin molded product according to claim 1, wherein the filler is made of SMC. 縁部が充填材を内包するプリプレグを圧縮成形して、前記縁部の端面が凸曲面状である面状の長繊維強化樹脂成形体を一体成形する長繊維強化樹脂成形体の製造方法であって、
面状の長繊維強化樹脂成形体本体の縁部に、前記充填材を備えた縁部材を一体化する、長繊維強化樹脂成形体の製造方法。 This is a method for producing a long fiber reinforced resin molded body in which a prepreg in which an edge includes a filler is compression molded, and a planar long fiber reinforced resin molded body in which the end surface of the edge is a convex curved surface is integrally molded. And
A method for producing a long fiber reinforced resin molded body, wherein an edge member provided with the filler is integrated with an edge portion of a planar long fiber reinforced resin molded body.
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Cited By (6)

* Cited by examiner, † Cited by third party
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WO2018139062A1 (en) * 2017-01-27 2018-08-02 八千代工業株式会社 Method for molding fiber-reinforced resin product
JP2018176537A (en) * 2017-04-12 2018-11-15 トヨタ自動車株式会社 Method for producing resin molded article
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JP2020031690A (en) * 2018-08-27 2020-03-05 カシオ計算機株式会社 Band production method, band and watch
JP2021031591A (en) * 2019-08-26 2021-03-01 石川樹脂工業株式会社 Method for manufacturing carbon fiber-reinforced resin molding

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GB2547468A (en) * 2016-02-19 2017-08-23 Gurit (Uk) Ltd Laminated moulded parts and manufacture thereof
WO2017140911A1 (en) * 2016-02-19 2017-08-24 Gurit (Uk) Ltd Laminated moulded parts and manufacture thereof
US20190143611A1 (en) * 2016-02-19 2019-05-16 Gurit (Uk) Ltd. Laminated Moulded Parts and Manufacture Thereof
WO2018139062A1 (en) * 2017-01-27 2018-08-02 八千代工業株式会社 Method for molding fiber-reinforced resin product
JPWO2018139062A1 (en) * 2017-01-27 2019-11-07 八千代工業株式会社 Molding method of fiber reinforced resin products
JP2018176537A (en) * 2017-04-12 2018-11-15 トヨタ自動車株式会社 Method for producing resin molded article
WO2018227309A1 (en) * 2017-06-16 2018-12-20 Hutchinson Aéronautique & Industrie Ltée Process for manufacturing a composite panel
JP2020031690A (en) * 2018-08-27 2020-03-05 カシオ計算機株式会社 Band production method, band and watch
JP7159691B2 (en) 2018-08-27 2022-10-25 カシオ計算機株式会社 Band manufacturing method, band and watch
JP2021031591A (en) * 2019-08-26 2021-03-01 石川樹脂工業株式会社 Method for manufacturing carbon fiber-reinforced resin molding

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