JP2016221885A - Fiber-reinforced resin structure and manufacturing process thereof - Google Patents

Fiber-reinforced resin structure and manufacturing process thereof Download PDF

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JP2016221885A
JP2016221885A JP2015111735A JP2015111735A JP2016221885A JP 2016221885 A JP2016221885 A JP 2016221885A JP 2015111735 A JP2015111735 A JP 2015111735A JP 2015111735 A JP2015111735 A JP 2015111735A JP 2016221885 A JP2016221885 A JP 2016221885A
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reinforced resin
fiber reinforced
fiber
resin sheet
slit
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JP6574106B2 (en
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慧 吉澤
Satoshi Yoshizawa
慧 吉澤
忠士 岩沼
Tadashi Iwanuma
忠士 岩沼
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Subaru Corp
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Fuji Heavy Industries Ltd
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Abstract

PROBLEM TO BE SOLVED: To provide: a fiber-reinforced resin structure that has less warpage resulting from forming of convex parts, and has improved rigidity and strength of the convex parts; and a fiber-reinforced resin structure manufacturing process.SOLUTION: The fiber-reinforced resin structure is a fiber-reinforced resin structure formed by cold-press working a fiber-reinforced resin sheet in which plural pieces are laminated, and comprises: an inner layer that includes unidirectional fiber-reinforced resin sheet in which the reinforcing fibers are oriented along the uni-direction; a surface layer that includes reinforcing fibers oriented along a direction intersectant to the orientation direction of the inner layer reinforcing fibers; and a convex part formed by the inner layer swelling to the outside from a slit provided in the surface layer along the orientation direction of the inner layer reinforcing fiber.SELECTED DRAWING: Figure 2

Description

本発明は、強化繊維にマトリックス樹脂を含浸させた繊維強化樹脂シートを用いて繊維強化樹脂構造体を成形する繊維強化樹脂構造体及び繊維強化樹脂構造体の製造方法に関する。   The present invention relates to a fiber reinforced resin structure in which a fiber reinforced resin structure is molded using a fiber reinforced resin sheet obtained by impregnating a matrix resin into a reinforced fiber and a method for manufacturing the fiber reinforced resin structure.

自動車車体の構造部品は、従来、鋼材等の金属材料により構成されていた。近年、車体の軽量化のために、炭素繊維強化樹脂（ＣＦＲＰ）等の繊維強化樹脂からなる構成部品が使用されつつある。かかる繊維強化樹脂からなる構成部品は、例えば、強化繊維にマトリックス樹脂を含浸させた繊維強化樹脂シートを積層し、当該積層体を、金型を用いてプレス加工することにより成形される。繊維強化樹脂からなる構成部品では、その剛性を向上させるために、リブ等の凸状部が形成される場合がある。   Conventionally, structural parts of automobile bodies have been made of metal materials such as steel. In recent years, components made of fiber reinforced resin such as carbon fiber reinforced resin (CFRP) are being used to reduce the weight of the vehicle body. The component part which consists of this fiber reinforced resin is shape | molded, for example by laminating | stacking the fiber reinforced resin sheet which impregnated the matrix resin to the reinforced fiber, and pressing the said laminated body using a metal mold | die. In a component made of fiber reinforced resin, convex portions such as ribs may be formed in order to improve the rigidity.

例えば、特許文献１には、繊維強化樹脂からなるリブ付パネルにおいて、リブが取り付けられた表面と反対側のパネル表面に生じ得るヒケが効果的に解消され得るリブ付構造の繊維強化樹脂材の製造方法が開示されている。特許文献１に開示された繊維強化樹脂材は、パネル及びリブはともに熱可塑性樹脂の内部に繊維材が混合された素材からなり、リブを形成する素材の重量平均繊維長の割合はパネルを形成する素材の重量平均繊維長の割合に比して低くなっている。   For example, Patent Document 1 discloses a fiber reinforced resin material having a ribbed structure that can effectively eliminate sink marks that may occur on the panel surface opposite to the surface on which the rib is attached in a panel with ribs made of fiber reinforced resin. A manufacturing method is disclosed. In the fiber reinforced resin material disclosed in Patent Document 1, both the panel and the rib are made of a material in which a fiber material is mixed inside a thermoplastic resin, and the ratio of the weight average fiber length of the material forming the rib forms the panel. It is lower than the ratio of the weight average fiber length of the raw material.

また、特許文献２には、プレス成形におけるプレス圧を適切に抑えつつ、リブ等の立設部分を備えた所望の３次元形状を有する成形体を成形できる繊維強化熱可塑性樹脂成形体の製造方法が開示されている。特許文献２に開示された繊維強化熱可塑性樹脂成形体は、強化樹脂がランダムに配向された第１の強化繊維層を有する第１の繊維強化熱可塑性樹脂層と、その少なくとも片面に積層され第２の強化繊維層を有する第２の繊維強化熱可塑性樹脂層とから構成される。そして、繊維強化熱可塑性樹脂成形体は、立設部分において第２の繊維強化熱可塑性樹脂層が破断されているとともに第１の強化繊維層が面形状形成部分と立設部分の内部との間で連続して延在している。   Patent Document 2 discloses a method for producing a fiber-reinforced thermoplastic resin molded body capable of molding a molded body having a desired three-dimensional shape having standing portions such as ribs while appropriately suppressing the pressing pressure in press molding. Is disclosed. The fiber-reinforced thermoplastic resin molded article disclosed in Patent Document 2 is laminated on at least one surface of a first fiber-reinforced thermoplastic resin layer having a first reinforcing fiber layer in which the reinforcing resin is randomly oriented. And a second fiber-reinforced thermoplastic resin layer having two reinforcing fiber layers. In the fiber reinforced thermoplastic resin molded body, the second fiber reinforced thermoplastic resin layer is broken at the standing portion and the first reinforcing fiber layer is between the surface shape forming portion and the inside of the standing portion. It is extended continuously.

特開２０１２−１４８４４３号公報JP 2012-148443 A 特開２０１４−１７２２４１号公報JP 2014-172241 A

しかしながら、特許文献１に記載の繊維強化樹脂材は、表層の繊維強化樹脂層によりリブが形成されるため、当該リブは、同一方向に配列された繊維のみを含んで形成される。そのため、リブは、ある一方向に沿って剛性や強度が高くなるものの、それ以外の方向については、剛性や強度が低くなるおそれがある。   However, in the fiber reinforced resin material described in Patent Document 1, since the rib is formed by the surface fiber reinforced resin layer, the rib is formed including only fibers arranged in the same direction. For this reason, the rib has higher rigidity and strength along a certain direction, but the rigidity and strength may be lowered in the other directions.

また、特許文献２に記載の繊維強化熱可塑性樹脂成形体では、表層として位置する第２の繊維強化熱可塑性樹脂層の破断部分を介して、内層として位置する第１の繊維強化熱可塑性樹脂層の第１の強化繊維層が面形状形成部分と立設部分との間で連続して延在するようにリブが形成される。したがって、第１の強化繊維層が一方向に配向された連続繊維からなる場合、当該連続繊維を膨出させにくく、局所的なリブを形成することが困難である。また、連続繊維を膨出させてリブを形成した場合、連続繊維が引っ張られて、成形品に反りが生じるおそれがある。   Moreover, in the fiber reinforced thermoplastic resin molded article described in Patent Document 2, the first fiber reinforced thermoplastic resin layer positioned as the inner layer through the fracture portion of the second fiber reinforced thermoplastic resin layer positioned as the surface layer. The ribs are formed so that the first reinforcing fiber layer continuously extends between the surface shape forming portion and the standing portion. Therefore, when the first reinforcing fiber layer is made of continuous fibers oriented in one direction, it is difficult to bulge the continuous fibers and it is difficult to form local ribs. Moreover, when a continuous fiber is expanded and a rib is formed, there is a possibility that the continuous fiber is pulled and warps the molded product.

そこで、本発明は、上記問題に鑑みてなされたものであり、本発明の目的とするところは、凸状部の形成に起因する反りが少なく、凸状部の剛性や強度が向上された、繊維強化樹脂構造体、及び繊維強化樹脂構造体の製造方法を提供することにある。   Therefore, the present invention has been made in view of the above problems, and the object of the present invention is less warp due to the formation of the convex portion, and the rigidity and strength of the convex portion are improved. It is providing the manufacturing method of a fiber reinforced resin structure and a fiber reinforced resin structure.

上記課題を解決するために、本発明のある観点によれば、複数枚積層された繊維強化樹脂シートを冷間プレス加工して成形された繊維強化樹脂構造体であって、強化繊維が一方向に沿って配向した一方向繊維強化樹脂シートを含む内部層と、内部層の強化繊維の配向方向に交差する方向に沿って配向した強化繊維を含む表層と、内部層の強化繊維の配向方向に沿って表層に設けられたスリットから内部層が外部に膨出して形成された凸状部と、を備える、繊維強化樹脂構造体が提供される。   In order to solve the above-described problem, according to one aspect of the present invention, a fiber-reinforced resin structure formed by cold pressing a plurality of laminated fiber-reinforced resin sheets, the reinforcing fibers are unidirectional An inner layer containing a unidirectional fiber-reinforced resin sheet oriented along the surface, a surface layer containing reinforcing fibers oriented along a direction intersecting the orientation direction of the reinforcing fibers in the inner layer, and an orientation direction of the reinforcing fibers in the inner layer A fiber-reinforced resin structure is provided that includes a convex portion formed by extending an inner layer outward from a slit provided in a surface layer along the outer surface.

表層の一部が、凸状部に沿って立ち上げられてもよい。   A part of the surface layer may be raised along the convex portion.

表層の繊維強化樹脂シートは一方向繊維強化樹脂シートからなり、当該表層の一方向繊維強化樹脂シートの強化繊維の配向方向が、内部層の強化繊維の配向方向と交差してもよい。   The fiber reinforced resin sheet of the surface layer is composed of a unidirectional fiber reinforced resin sheet, and the orientation direction of the reinforcing fibers of the surface unidirectional fiber reinforced resin sheet may intersect with the orientation direction of the reinforcing fibers of the inner layer.

表層の繊維強化樹脂シートは強化繊維が少なくとも２つの方向に沿って配向した繊維強化樹脂シートであり、少なくとも２つの方向が、内部層の強化繊維の配向方向と交差してもよい。   The fiber reinforced resin sheet of the surface layer is a fiber reinforced resin sheet in which reinforcing fibers are oriented along at least two directions, and at least two directions may intersect with the orientation directions of the reinforcing fibers of the inner layer.

凸状部の高さが０．１〜５．０ｍｍの範囲内の値であってもよい。   The height of the convex portion may be a value within the range of 0.1 to 5.0 mm.

また、上記課題を解決するために、本発明の別の観点によれば、強化繊維にマトリックス樹脂を含浸させた繊維強化樹脂シートを複数枚積層して繊維強化樹脂積層体を形成する工程と、繊維強化樹脂積層体を加熱する工程と、加熱した繊維強化樹脂積層体を、冷間プレス装置を用いてプレス加工し、繊維強化樹脂構造体を成形する工程と、を備え、繊維強化樹脂積層体の内部層の繊維強化樹脂シートは、強化繊維が一方向に沿って配向した一方向繊維強化樹脂シートを含み、内部層の一方向繊維強化樹脂シート中の強化繊維の配向方向に沿う一方、表層の繊維強化樹脂シート中の強化繊維に交差する方向に沿ってスリットを設けてプレス加工することにより、内部層の一方向繊維強化樹脂シートの強化繊維及びマトリックス樹脂を、スリットを介して表層から膨出させて、繊維強化樹脂構造体の表面に凸状部を形成する、繊維強化樹脂構造体の製造方法が提供される。   In order to solve the above problems, according to another aspect of the present invention, a step of laminating a plurality of fiber reinforced resin sheets impregnated with a matrix resin into reinforced fibers to form a fiber reinforced resin laminate, A step of heating the fiber reinforced resin laminate, and a step of pressing the heated fiber reinforced resin laminate using a cold press to form a fiber reinforced resin structure, and the fiber reinforced resin laminate. The fiber reinforced resin sheet of the inner layer includes a unidirectional fiber reinforced resin sheet in which the reinforced fibers are oriented along one direction, and the surface layer is along the orientation direction of the reinforced fibers in the unidirectional fiber reinforced resin sheet of the inner layer. By forming a slit along the direction intersecting the reinforcing fiber in the fiber reinforced resin sheet and pressing it, the reinforced fiber and matrix resin of the unidirectional fiber reinforced resin sheet in the inner layer are slit. And it swelled from the surface via, forming a convex portion on the surface of the fiber-reinforced resin structure, method for producing a fiber-reinforced resin structure is provided.

冷間プレス装置の金型のプレス面における、スリットに対向する位置に凹部が設けられ、スリットから膨出させる一方向繊維強化樹脂シートの強化繊維及びマトリックス樹脂を凹部に進入させて凸状部を成形してもよい。   A concave portion is provided at a position facing the slit on the pressing surface of the die of the cold press apparatus, and the reinforced fiber and matrix resin of the unidirectional fiber reinforced resin sheet that bulges from the slit is caused to enter the concave portion to form the convex portion You may shape | mold.

スリットの幅が５．０ｍｍ以下の値であってもよい。   The slit width may be a value of 5.0 mm or less.

あらかじめスリットを設けた繊維強化樹脂シートを表層に配置して繊維強化樹脂積層体を形成してもよい。   A fiber reinforced resin laminate may be formed by disposing a fiber reinforced resin sheet provided with slits in advance on the surface layer.

繊維強化樹脂積層体を形成した後、表層側からスリットを形成し、繊維強化樹脂積層体を冷間プレス装置に設置してもよい。   After forming the fiber reinforced resin laminate, a slit may be formed from the surface layer side, and the fiber reinforced resin laminate may be installed in a cold press apparatus.

以上説明したように本発明によれば、繊維強化樹脂構造体において、凸状部の形成に起因する反りが少なく、凸状部の剛性や強度を向上させることができる。   As described above, according to the present invention, in the fiber reinforced resin structure, there is little warpage due to the formation of the convex portion, and the rigidity and strength of the convex portion can be improved.

繊維強化樹脂構造体の一例を示す斜視図である。It is a perspective view which shows an example of a fiber reinforced resin structure. 繊維強化樹脂構造体の凸状部を示す断面図である。It is sectional drawing which shows the convex-shaped part of a fiber reinforced resin structure. 繊維強化樹脂構造体の製造方法を示す説明図である。It is explanatory drawing which shows the manufacturing method of a fiber reinforced resin structure. 冷間プレス工程の開始時の様子を示す説明図である。It is explanatory drawing which shows the mode at the time of the start of a cold press process. 冷間プレス工程のプレス中の様子を示す説明図である。It is explanatory drawing which shows the mode during the press of a cold press process. 冷間プレス工程の終了時の様子を示す説明図である。It is explanatory drawing which shows the mode at the time of completion | finish of a cold press process.

以下に添付図面を参照しながら、本発明の好適な実施の形態について詳細に説明する。なお、本明細書及び図面において、実質的に同一の機能構成を有する構成要素については、同一の符号を付することにより重複説明を省略する。また、本明細書及び図面において、実質的に同一の機能構成を有する複数の構成要素を、同一の符号の後に異なるアルファベットを付して区別する場合もある。ただし、実質的に同一の機能構成を有する複数の構成要素の各々を特に区別する必要がない場合、同一符号のみを付する。   Exemplary embodiments of the present invention will be described below in detail with reference to the accompanying drawings. In addition, in this specification and drawing, about the component which has the substantially same function structure, duplication description is abbreviate | omitted by attaching | subjecting the same code | symbol. In the present specification and drawings, a plurality of components having substantially the same functional configuration may be distinguished by adding different alphabets after the same reference numeral. However, when it is not necessary to particularly distinguish each of a plurality of constituent elements having substantially the same functional configuration, only the same reference numerals are given.

＜１．繊維強化樹脂構造体＞
図１は、本実施形態にかかる繊維強化樹脂構造体２０の一例を示す斜視図である。繊維強化樹脂構造体２０は、繊維強化樹脂を用いて成形され、鋼板からなる構造体と比較して軽量でありつつ、高い強度を有している。繊維強化樹脂構造体２０の用途は特に限定されないが、繊維強化樹脂構造体２０は、例えば、自動車車体用の構造部品として使用される。なお、繊維強化樹脂構造体２０は、構成面が折れ曲がった屈曲部Ｒを有していればよく、図１に例示した形状に限られない。 <1. Fiber Reinforced Resin Structure>
FIG. 1 is a perspective view showing an example of a fiber reinforced resin structure 20 according to the present embodiment. The fiber reinforced resin structure 20 is formed using a fiber reinforced resin, and has high strength while being lighter than a structure made of a steel plate. Although the use of the fiber reinforced resin structure 20 is not particularly limited, the fiber reinforced resin structure 20 is used, for example, as a structural component for an automobile body. In addition, the fiber reinforced resin structure 20 should just have the bending part R in which the structure surface was bent, and is not restricted to the shape illustrated in FIG.

（１−１．繊維強化樹脂シート）
繊維強化樹脂構造体２０の成形素材となる繊維強化樹脂シートは、強化繊維にマトリックス樹脂を含浸させて形成される。使用される強化繊維は、特に限定されるものではなく、例えば、炭素繊維やガラス繊維、アラミド繊維等であってもよく、さらにはこれらの強化繊維を組み合わせて使用してもよい。中でも、炭素繊維は、機械特性が高く、強度設計を行いやすいことから、強化繊維が炭素繊維を含むことが好ましい。 (1-1. Fiber reinforced resin sheet)
The fiber reinforced resin sheet as a molding material of the fiber reinforced resin structure 20 is formed by impregnating a matrix resin into a reinforced fiber. The reinforcing fiber used is not particularly limited, and may be, for example, carbon fiber, glass fiber, aramid fiber, or the like, or may be used in combination of these reinforcing fibers. Among these, carbon fibers have high mechanical properties and are easy to design for strength. Therefore, it is preferable that the reinforcing fibers include carbon fibers.

強化繊維としては、繊維強化樹脂シートの一端から他端まで連続する連続繊維が用いられる。また、繊維強化樹脂シートとしては、強化繊維が一方向に沿って配向した一方向繊維強化樹脂シートや、強化繊維が複数方向に沿って配向した繊維強化樹脂シートが用いられる。ただし、繊維強化樹脂構造体２０の内部層を構成する繊維強化樹脂シートは、少なくとも一つの一方向繊維強化樹脂シートを含む。一方、繊維強化樹脂構造体２０の表層を構成する繊維強化樹脂シートは、一方向繊維強化樹脂シートであってもよいし、強化繊維が複数方向に沿って配向した繊維強化樹脂シートであってもよい。   As the reinforcing fiber, a continuous fiber continuous from one end to the other end of the fiber reinforced resin sheet is used. Moreover, as a fiber reinforced resin sheet, the unidirectional fiber reinforced resin sheet in which the reinforced fiber orientated along one direction, and the fiber reinforced resin sheet in which the reinforced fiber orientated in several directions are used. However, the fiber reinforced resin sheet constituting the inner layer of the fiber reinforced resin structure 20 includes at least one unidirectional fiber reinforced resin sheet. On the other hand, the fiber reinforced resin sheet constituting the surface layer of the fiber reinforced resin structure 20 may be a unidirectional fiber reinforced resin sheet, or may be a fiber reinforced resin sheet in which reinforced fibers are oriented in a plurality of directions. Good.

また、繊維強化樹脂シートのマトリックス樹脂には熱可塑性樹脂が用いられる。マトリックス樹脂としては、例えば、ポリエチレン樹脂、ポリプロピレン樹脂、ポリ塩化ビニル樹脂、ＡＢＳ樹脂、ポリスチレン樹脂、ＡＳ樹脂、ポリアミド樹脂、ポリアセタール樹脂、ポリカーボネート樹脂、熱可塑性ポリエステル樹脂、ＰＰＳ（ポリフェニレンサルファイド）樹脂、フッ素樹脂、ポリエーテルイミド樹脂、ポリエーテルケトン樹脂、ポリイミド樹脂などが例示される。これらの熱可塑性樹脂うちの１種類、あるいは２種類以上の混合物を使用することができる。これら熱可塑性樹脂は、単独でも、混合物でも、また共重合体であってもよい。混合物の場合には相溶化剤を併用してもよい。さらに、難燃剤として臭素系難燃剤、シリコン系難燃剤、赤燐などを加えてもよい。   A thermoplastic resin is used for the matrix resin of the fiber reinforced resin sheet. Examples of the matrix resin include polyethylene resin, polypropylene resin, polyvinyl chloride resin, ABS resin, polystyrene resin, AS resin, polyamide resin, polyacetal resin, polycarbonate resin, thermoplastic polyester resin, PPS (polyphenylene sulfide) resin, and fluorine resin. , Polyetherimide resin, polyetherketone resin, polyimide resin and the like. One type of these thermoplastic resins or a mixture of two or more types can be used. These thermoplastic resins may be used alone, as a mixture, or as a copolymer. In the case of a mixture, a compatibilizer may be used in combination. Further, brominated flame retardants, silicon-based flame retardants, red phosphorus and the like may be added as flame retardants.

この場合、使用される熱可塑性樹脂としては、例えば、ポリエチレン、ポリプロピレン等のポリオレフィン系樹脂、ナイロン６、ナイロン６６等のポリアミド系樹脂、ポリエチレンテレフタレート、ポリブチレンテレフタレート等のポリエステル系樹脂、ポリエーテルケトン、ポリエーテルスルフォン、芳香族ポリアミド等の樹脂が挙げられる。中でも可塑性マトリックス樹脂がポリアミド、ポリフェニレンスルフィド、ポリプロピレン、ポリエーテルエーテルケトン及びフェノキシ樹脂からなる群より選ばれる少なくとも１種であることが好ましい。   In this case, examples of the thermoplastic resin used include polyolefin resins such as polyethylene and polypropylene, polyamide resins such as nylon 6 and nylon 66, polyester resins such as polyethylene terephthalate and polybutylene terephthalate, polyether ketone, Examples of the resin include polyether sulfone and aromatic polyamide. Among them, the plastic matrix resin is preferably at least one selected from the group consisting of polyamide, polyphenylene sulfide, polypropylene, polyether ether ketone, and phenoxy resin.

なお、積層される複数の繊維強化樹脂シートは、それぞれ強化繊維の種類や含有率等が異なっていてもよい。また、積層される複数の繊維強化樹脂シートにおいて、マトリックス樹脂が相溶性を有する異なる材料同士であってもよく、あるいは、同一のマトリックス樹脂に対して異なる添加物等が混合されていてもよい。この場合においても、繊維強化樹脂シートの溶融及び硬化を効率的に行えるように、マトリックス樹脂の融点が近似することが好ましい。   The plurality of fiber reinforced resin sheets to be laminated may be different in the type and content of the reinforcing fibers. Moreover, in the some fiber reinforced resin sheet | seat laminated | stacked, the different materials in which matrix resin has compatibility may be sufficient, or different additives etc. may be mixed with respect to the same matrix resin. Even in this case, it is preferable that the melting point of the matrix resin is approximated so that the fiber-reinforced resin sheet can be efficiently melted and cured.

繊維強化樹脂シートは、例えば、一般的なフィルム含浸法や溶融含浸法等のプロセスにより、強化繊維を連続的に送り出しながらマトリックス樹脂を当該強化繊維に含浸させる方法により製造される。この繊維強化樹脂シートを所望のサイズに切断することにより、成形素材としての繊維強化樹脂シートが得られる。所望のサイズに切断した複数の繊維強化樹脂シートの幅方向の端部を接着剤等により互いに接合して、所望の幅及び長さの繊維強化樹脂シートを形成してもよい。繊維強化樹脂シートの厚さは、例えば、０．０３〜０．５０ｍｍの範囲内の値とすることができる。   The fiber reinforced resin sheet is manufactured by, for example, a method of impregnating the reinforcing fiber with the matrix resin while continuously feeding the reinforcing fiber by a process such as a general film impregnation method or a melt impregnation method. By cutting this fiber reinforced resin sheet into a desired size, a fiber reinforced resin sheet as a molding material is obtained. You may form the fiber reinforced resin sheet of a desired width and length by mutually joining the edge part of the width direction of the several fiber reinforced resin sheet cut | disconnected to the desired size with an adhesive agent. The thickness of a fiber reinforced resin sheet can be made into the value within the range of 0.03-0.50 mm, for example.

（１−２．凸状部）
本実施形態において、繊維強化樹脂シートを用いて成形される繊維強化樹脂構造体２０は、図１に示すように、凸状部２２を有している。かかる凸状部２２は、例えば、繊維強化樹脂構造体２０の剛性を高めるためのリブとして形成される。ただし、繊維強化樹脂構造体２０に凸状部２２を形成する目的は、これに限られない。例えば、凸状部２２が、自動車構造部材における反り防止のためのものであってもよい。 (1-2. Convex part)
In this embodiment, the fiber reinforced resin structure 20 shape | molded using a fiber reinforced resin sheet has the convex-shaped part 22, as shown in FIG. For example, the convex portion 22 is formed as a rib for increasing the rigidity of the fiber reinforced resin structure 20. However, the purpose of forming the convex portion 22 in the fiber reinforced resin structure 20 is not limited to this. For example, the convex portion 22 may be for preventing warpage in an automobile structural member.

図２は、繊維強化樹脂構造体２０のうち凸状部２２が形成された部分の断面を示す断面図である。かかる図２は、凸状部２２の延在方向に対して直交する方向の断面を示している。繊維強化樹脂構造体２０は、第１の表層２４ａ及び第２の表層２４ｂと、内部層２６とを備える。   FIG. 2 is a cross-sectional view showing a cross section of a portion of the fiber reinforced resin structure 20 where the convex portion 22 is formed. FIG. 2 shows a cross section in a direction orthogonal to the extending direction of the convex portion 22. The fiber reinforced resin structure 20 includes a first surface layer 24a and a second surface layer 24b, and an inner layer 26.

本実施形態では、第１の表層２４ａ及び第２の表層２４ｂは、それぞれ１枚の一方向繊維強化樹脂シートが溶融及び硬化して形成されたものである。かかる第１の表層２４ａ及び第２の表層２４ｂに含まれる連続繊維Ｆ１ａ，Ｆ１ｂは、凸状部２２の延在方向に対して交差する方向に沿って配向している。また、内部層２６は、３枚の一方向繊維強化樹脂シートが溶融及び硬化して形成されたものである。かかる内部層２６に含まれる連続繊維Ｆ２は、凸状部２２の延在方向に沿って配向している。   In the present embodiment, each of the first surface layer 24a and the second surface layer 24b is formed by melting and curing one unidirectional fiber-reinforced resin sheet. The continuous fibers F1a and F1b included in the first surface layer 24a and the second surface layer 24b are oriented along a direction intersecting the extending direction of the convex portion 22. The inner layer 26 is formed by melting and curing three unidirectional fiber reinforced resin sheets. The continuous fibers F2 included in the inner layer 26 are oriented along the extending direction of the convex portions 22.

凸状部２２は、第１の表層２４ａ側の表面に形成されている。凸状部２２は、第１の表層２４ａに設けられたスリットＳＬから、内部層２６が外部に膨出して形成されている。また、凸状部２２の根元部分では、第１の表層２４ａの一部が凸状部２２に沿って立ち上げられている。すなわち、凸状部２２の根元部分の表面が第１の表層２４ａにより構成され、凸状部２２のそれ以外の多くの部分が内部層２６により構成される。   The convex portion 22 is formed on the surface on the first surface layer 24a side. The convex portion 22 is formed by the inner layer 26 bulging out from the slit SL provided in the first surface layer 24a. In addition, at the root portion of the convex portion 22, a part of the first surface layer 24 a is raised along the convex portion 22. That is, the surface of the root portion of the convex portion 22 is constituted by the first surface layer 24 a, and many other portions of the convex portion 22 are constituted by the inner layer 26.

したがって、凸状部２２には、主として凸状部２２の延在方向に沿って配向した連続繊維Ｆ２が含まれる。この連続繊維Ｆ２の配向方向は、第１の表層２４ａに設けられるスリットＳＬの方向に沿っており、繊維強化樹脂構造体２０の成形時において、内部層２６がスリットＳＬを介して外部に膨出しやすくなっている。また、膨出する連続繊維Ｆ２が、凸状部２２の延在方向に沿って配向していることにより、内部層２６が膨出した場合であっても凸状部２２の延在方向に対して交差する方向に張力が生じにくくなっており、繊維強化樹脂構造体２０の反りが抑制されている。   Therefore, the convex portion 22 includes continuous fibers F2 oriented mainly along the extending direction of the convex portion 22. The orientation direction of the continuous fiber F2 is along the direction of the slit SL provided in the first surface layer 24a, and the inner layer 26 bulges outside through the slit SL when the fiber reinforced resin structure 20 is molded. It has become easier. Moreover, even if it is a case where the inner layer 26 bulges because the continuous fiber F2 which bulges is orientating along the extension direction of the convex part 22, it is with respect to the extension direction of the convex part 22. Thus, tension is unlikely to occur in the intersecting direction, and warping of the fiber reinforced resin structure 20 is suppressed.

また、凸状部２２の根元部分の表面には、凸状部２２の延在方向に対して交差する方向に沿って配向した連続繊維Ｆ１ａ，Ｆ１ｂが凸状部２２の立上り方向に沿って積層される。繊維強化樹脂材料では、繊維の配向方向における剛性や強度が高いことから、凸状部２２の根元部分の連続繊維Ｆ１ａ，Ｆ１ｂが凸状部２２を補強する状態になり、凸状部２２が倒れにくくなっている。   Further, continuous fibers F1a and F1b oriented along the direction intersecting the extending direction of the convex portion 22 are laminated on the surface of the root portion of the convex portion 22 along the rising direction of the convex portion 22. Is done. In the fiber reinforced resin material, since the rigidity and strength in the fiber orientation direction are high, the continuous fibers F1a and F1b at the base portion of the convex portion 22 are in a state of reinforcing the convex portion 22, and the convex portion 22 falls. It has become difficult.

かかる凸状部２２の高さは、例えば、０．１〜８．０ｍｍの範囲内の値とすることができる。凸状部２２の高さが高すぎると、冷間プレス加工によって凸状部２２を形成することが困難になる場合がある。また、凸状部２２の高さが低すぎると、凸状部２２に要求される所望の効果を得ることができない場合がある。したがって、凸状部２２の高さが、０．５〜５．０ｍｍの範囲内の値であることがより好ましく、１．０〜３．０ｍｍの範囲内の値であることがさらに好ましい。   The height of the convex portion 22 can be set to a value in the range of 0.1 to 8.0 mm, for example. If the height of the convex portion 22 is too high, it may be difficult to form the convex portion 22 by cold pressing. If the height of the convex portion 22 is too low, the desired effect required for the convex portion 22 may not be obtained. Therefore, the height of the convex portion 22 is more preferably a value within the range of 0.5 to 5.0 mm, and still more preferably a value within the range of 1.0 to 3.0 mm.

第１の表層２４ａ及び第２の表層２４ｂは、凸状部２２の延在方向に直交する方向に配向した連続繊維Ｆ１ａ，Ｆ１ｂを含んでいるが、連続繊維Ｆ１，Ｆ１ｂのうちの少なくとも一方の配向方向が凸状部２２の延在方向に直交していなくてもよく、少なくとも交差していればよい。また、内部層２６の全部が、同一方向に配向した連続繊維Ｆ２を含んでいなくてもよい。例えば、内部層２６のうち、第１の表層２４ａに近い層領域に、凸状部２２の延在方向に沿って配向した連続繊維Ｆ２が含まれ、それ以外の層領域に、異なる方向に配向した連続繊維が含まれていてもよい。   The first surface layer 24a and the second surface layer 24b include continuous fibers F1a and F1b oriented in a direction orthogonal to the extending direction of the convex portion 22, but at least one of the continuous fibers F1 and F1b. The orientation direction does not have to be orthogonal to the extending direction of the convex portion 22, and it is sufficient that it is at least crossed. Further, the entire inner layer 26 may not include the continuous fibers F2 oriented in the same direction. For example, in the inner layer 26, the layer region close to the first surface layer 24a includes the continuous fibers F2 oriented along the extending direction of the convex portion 22, and the other layer regions are oriented in different directions. Continuous fibers may be included.

以上のように、本実施形態にかかる繊維強化樹脂構造体２０は、内部層２６の連続繊維Ｆ２を、その配向方向に沿って形成されたスリットＳＬを介して膨出させることにより形成された凸状部２２を有することから、反りが抑制されている。また、凸状部２２の根元部分の表面が、棒出した連続繊維の配向方向とは異なる方向に配向した第１の表層２４ａの連続繊維Ｆ１ａによって補強され、倒れにくくなっている。したがって、凸状部２２の剛性や強度が向上している。   As described above, the fiber reinforced resin structure 20 according to the present embodiment is formed by projecting the continuous fibers F2 of the inner layer 26 through the slits SL formed along the orientation direction. Since it has the shape part 22, curvature is suppressed. Further, the surface of the root portion of the convex portion 22 is reinforced by the continuous fibers F1a of the first surface layer 24a oriented in a direction different from the orientation direction of the continuous fibers that stick out, and is not easily collapsed. Therefore, the rigidity and strength of the convex portion 22 are improved.

＜２．繊維強化樹脂構造体の製造方法＞
本実施形態にかかる繊維強化樹脂構造体２０の製造方法について具体的に説明する。本実施形態にかかる繊維強化樹脂構造体の製造方法は、強化繊維にマトリックス樹脂を含浸させた繊維強化樹脂シートを積層した繊維強化樹脂積層体を冷間プレス加工することによって繊維強化樹脂構造体を成形する繊維強化樹脂構造体の製造方法である。本実施形態においては、繊維強化樹脂積層体の内部層の繊維強化樹脂シートが一方向繊維強化樹脂シートを含み、内部層の一方向繊維強化樹脂シート中の強化繊維の配向方向に沿う一方、表層の繊維強化樹脂シート中の強化繊維に交差する方向に沿ってスリットを設けてプレス加工が行われる。これにより、内部層の一方向繊維強化樹脂シートの強化繊維及びマトリックス樹脂を、スリットを介して表層から膨出させて、繊維強化樹脂構造体の表面に凸状部が形成される。 <2. Manufacturing method of fiber reinforced resin structure>
The manufacturing method of the fiber reinforced resin structure 20 according to the present embodiment will be specifically described. The manufacturing method of the fiber reinforced resin structure concerning this embodiment is a fiber reinforced resin structure by cold-pressing the fiber reinforced resin laminated body which laminated the fiber reinforced resin sheet which impregnated the matrix resin in the reinforced fiber. It is a manufacturing method of the fiber reinforced resin structure to shape | mold. In the present embodiment, the fiber reinforced resin sheet of the inner layer of the fiber reinforced resin laminate includes a unidirectional fiber reinforced resin sheet, and the surface layer is along the orientation direction of the reinforced fibers in the unidirectional fiber reinforced resin sheet of the inner layer. A slit is provided along the direction intersecting the reinforcing fibers in the fiber reinforced resin sheet, and press working is performed. Thereby, the reinforced fiber and matrix resin of the unidirectional fiber reinforced resin sheet of the inner layer are swelled from the surface layer through the slits, and a convex portion is formed on the surface of the fiber reinforced resin structure.

図３は、成形素材としての繊維強化樹脂シート１０ａ，１０ｂ，１０ｃ，１０ｄ，１０ｅから繊維強化樹脂構造体２０が得られるまでの工程を模式的に示した説明図である。かかる製造方法は、積層工程と、加熱工程と、冷間プレス工程とを備える。以下、各工程について詳細に説明する。   FIG. 3 is an explanatory view schematically showing a process until the fiber reinforced resin structure 20 is obtained from the fiber reinforced resin sheets 10a, 10b, 10c, 10d, and 10e as the molding material. Such a manufacturing method includes a laminating step, a heating step, and a cold pressing step. Hereinafter, each step will be described in detail.

（２−１．積層工程）
積層工程は、複数枚の繊維強化樹脂シート１０を積層して繊維強化樹脂積層体１２を形成する工程である。本実施形態では、それぞれ連続繊維が一方向に配向した５枚の一方向繊維強化樹脂シート１０ａ，１０ｂ，１０ｃ，１０ｄ，１０ｅが用いられる。このとき、繊維強化樹脂積層体１２の最上層及び最下層に位置する一方向繊維強化樹脂シート１０ａ，１０ｅの連続繊維の配向方向Ｄ１と、内部に位置する一方向繊維強化樹脂シート１０ｂ，１０ｃ，１０ｄの連続繊維の配向方向Ｄ２とが交差するように積層する。本実施形態では、一方向繊維強化樹脂シート１０ａ，１０ｅの連続繊維の配向方向Ｄ１と、一方向繊維強化樹脂シート１０ｂ，１０ｃ，１０ｄの連続繊維の配向方向Ｄ２とが直交する。 (2-1. Lamination process)
The lamination step is a step of forming a fiber reinforced resin laminate 12 by laminating a plurality of fiber reinforced resin sheets 10. In the present embodiment, five unidirectional fiber reinforced resin sheets 10a, 10b, 10c, 10d, and 10e each having continuous fibers oriented in one direction are used. At this time, the orientation direction D1 of the continuous fibers of the unidirectional fiber reinforced resin sheets 10a, 10e located in the uppermost layer and the lowermost layer of the fiber reinforced resin laminate 12, and the unidirectional fiber reinforced resin sheets 10b, 10c, located therein, Lamination is performed so that the orientation direction D2 of 10d continuous fibers intersects. In the present embodiment, the continuous fiber orientation direction D1 of the unidirectional fiber reinforced resin sheets 10a and 10e and the continuous fiber orientation direction D2 of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d are orthogonal to each other.

また、本実施形態では、最上層に位置する一方向繊維強化樹脂シート１０ａにあらかじめスリットＳＬが設けられている。かかるスリットＳＬは、内部に位置する一方向繊維強化樹脂シート１０ｂ，１０ｃ，１０ｄの連続繊維の配向方向に沿う一方、スリットＳＬが設けられる一方向繊維強化樹脂シート１０ａの連続繊維の配向方向に交差して配置されている。かかるスリットＳＬは、内部の一方向繊維強化樹脂シート１０ｂ，１０ｃ，１０ｄの連続繊維の配向方向に沿って形成されていればよく、表層の一方向繊維強化樹脂シート１０ａの連続繊維の配向方向に直交していなくてもよい。   In the present embodiment, the slits SL are provided in advance in the unidirectional fiber-reinforced resin sheet 10a located in the uppermost layer. The slit SL is along the orientation direction of the continuous fibers of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d located inside, and intersects the orientation direction of the continuous fibers of the unidirectional fiber reinforced resin sheet 10a provided with the slit SL. Are arranged. The slit SL only needs to be formed along the orientation direction of the continuous fibers of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d inside, and in the orientation direction of the continuous fibers of the surface unidirectional fiber reinforced resin sheet 10a. It does not need to be orthogonal.

スリットＳＬの幅は、例えば、５．０ｍｍ以下の値とすることができる。ただし、スリットＳＬの幅が大きすぎると、内部の連続繊維及びマトリックス樹脂を膨出させる際に、スリットＳＬの周囲の連続繊維を引きずり込むことができない場合がある。したがって、スリットＳＬの幅が、４．０ｍｍ以下の値であることがより好ましく、３．０ｍｍ以下の値であることがさらに好ましい。   The width of the slit SL can be set to a value of 5.0 mm or less, for example. However, if the width of the slit SL is too large, the continuous fibers around the slit SL may not be dragged in when the continuous fibers and the matrix resin inside are bulged. Therefore, the width of the slit SL is more preferably a value of 4.0 mm or less, and further preferably a value of 3.0 mm or less.

また、図３においては、カッター刃５を用いて一方向繊維強化樹脂シート１０ａにスリットＳＬを形成しているが、二枚の一方向繊維強化樹脂シートを所定の隙間を空けて並べて配置することによってスリットＳＬを形成してもよい。また、スリットＳＬは、繊維強化樹脂積層体１２の形成前に設けられなくてもよく、繊維強化樹脂積層体１２を形成した後に、カッター刃等によりスリットＳＬを設けてもよい。   In FIG. 3, the slit SL is formed in the unidirectional fiber reinforced resin sheet 10a using the cutter blade 5, but two unidirectional fiber reinforced resin sheets are arranged side by side with a predetermined gap therebetween. You may form slit SL by. In addition, the slit SL may not be provided before the formation of the fiber reinforced resin laminate 12, and the slit SL may be provided by a cutter blade or the like after the fiber reinforced resin laminate 12 is formed.

上述のとおり、成形素材としての繊維強化樹脂シート１０は、繊維強化樹脂シートを所望のサイズに切断したものであってもよく、所望のサイズに切断した繊維強化樹脂シートの幅方向の端部を互いに接合して所望の幅にしたものであってもよい。積層する繊維強化樹脂シート１０の枚数や平面視の大きさは、製造する繊維強化樹脂構造体２０の厚さや大きさに応じて、適宜選択し得る。   As described above, the fiber reinforced resin sheet 10 as a molding material may be obtained by cutting a fiber reinforced resin sheet into a desired size, and an end in the width direction of the fiber reinforced resin sheet cut into a desired size. They may be joined together to have a desired width. The number of fiber reinforced resin sheets 10 to be laminated and the size in plan view can be appropriately selected according to the thickness and size of the fiber reinforced resin structure 20 to be manufactured.

（２−２．加熱工程）
加熱工程は、繊維強化樹脂積層体１２を加熱する工程である。加熱工程では、例えば、繊維強化樹脂積層体１２が加熱装置４０に投入される。当該繊維強化樹脂積層体１２は、上面側及び下面側から、電熱線や遠赤外線ヒータ等の加熱手段４１，４３によって加熱される。加熱装置４０の温度は、マトリックス樹脂の融点以上に設定される。加熱工程では、マトリックス樹脂が分解しないように、繊維強化樹脂積層体１２が溶融状態にされる。用いられる加熱装置は、特に限定されない。 (2-2. Heating step)
The heating step is a step of heating the fiber reinforced resin laminate 12. In the heating step, for example, the fiber reinforced resin laminate 12 is put into the heating device 40. The fiber reinforced resin laminate 12 is heated from the upper surface side and the lower surface side by heating means 41 and 43 such as a heating wire and a far infrared heater. The temperature of the heating device 40 is set to be equal to or higher than the melting point of the matrix resin. In the heating step, the fiber reinforced resin laminate 12 is brought into a molten state so that the matrix resin is not decomposed. The heating device used is not particularly limited.

（２−３．冷間プレス工程）
冷間プレス工程は、溶融状態の繊維強化樹脂積層体１２を冷間プレス加工し、凸状部２２を有する所望の形状の繊維強化樹脂構造体２０を成形する工程である。冷間プレス工程では、冷間プレス装置５０の第１の金型５１及び第２の金型５３の温度がマトリックス樹脂の融点未満にされる。かかる冷間プレス工程において、第２の金型５３上に溶融状態の繊維強化樹脂積層体１２が設置された後に、対向する第１の金型５１及び第２の金型５３が互いに近接させられて繊維強化樹脂積層体１２がプレス加工される。これにより、繊維強化樹脂積層体１２が硬化して、所望の形状の繊維強化樹脂構造体２０が得られる。 (2-3. Cold pressing process)
The cold pressing step is a step of cold-pressing the molten fiber reinforced resin laminate 12 to form a fiber reinforced resin structure 20 having a desired shape having the convex portions 22. In the cold pressing process, the temperature of the first mold 51 and the second mold 53 of the cold pressing apparatus 50 is set to be lower than the melting point of the matrix resin. In the cold pressing step, after the molten fiber reinforced resin laminate 12 is placed on the second mold 53, the opposing first mold 51 and second mold 53 are brought close to each other. Thus, the fiber reinforced resin laminate 12 is pressed. Thereby, the fiber reinforced resin laminate 12 is cured, and the fiber reinforced resin structure 20 having a desired shape is obtained.

ここで、本実施形態にかかる繊維強化樹脂構造体２０の製造方法では、冷間プレス加工時に、繊維強化樹脂積層体１２の表層の一方向繊維強化樹脂シート１０ａに設けたスリットＳＬを介して、内部の一方向繊維強化樹脂シート１０ｂ，１０ｃ，１０ｄの一部を膨出させる。これにより、繊維強化樹脂構造体２０に凸状部２２が形成される。   Here, in the manufacturing method of the fiber reinforced resin structure 20 according to the present embodiment, through the slit SL provided in the unidirectional fiber reinforced resin sheet 10a of the surface layer of the fiber reinforced resin laminate 12 during the cold press processing, Part of the internal unidirectional fiber reinforced resin sheets 10b, 10c, and 10d is expanded. Thereby, the convex part 22 is formed in the fiber reinforced resin structure 20.

図４〜図６は、冷間プレス工程を実施している様子を示す説明図である。図４は、プレス開始時の様子を示し、図５は、プレス中の様子を示し、図６は、プレス終了時の様子を示す。図４、図５の上段、及び図６の上段は、それぞれ第１の金型５１、第２の金型５３及び繊維強化樹脂積層体１２の断面図を示す。図５の下段及び図６の下段は、それぞれ図５の上段の図及び図６の上段の図の部分拡大図である。   4-6 is explanatory drawing which shows a mode that the cold press process is implemented. FIG. 4 shows a state at the start of pressing, FIG. 5 shows a state during pressing, and FIG. 6 shows a state at the end of pressing. 4 and FIG. 5 and the upper part of FIG. 6 show cross-sectional views of the first mold 51, the second mold 53, and the fiber reinforced resin laminate 12, respectively. The lower part of FIG. 5 and the lower part of FIG. 6 are partially enlarged views of the upper part of FIG. 5 and the upper part of FIG.

図４に示すように、第１の金型５１のプレス面には、冷間プレス装置５０に繊維強化樹脂積層体１２が設置された状態において、一方向繊維強化樹脂シート１０ａに設けられたスリットＳＬに対向する位置に、凹部５１ａが設けられている。この凹部５１ａは、スリットＳＬを介して膨出してくる一方向繊維強化樹脂シート１０ｂ，１０ｃ，１０ｄの連続繊維及びマトリックス樹脂を受容して、凸状部２２を成形するためのものである。凹部５１ａの形状は、形成する凸状部２２の形状に応じて設計される。   As shown in FIG. 4, the slit provided in the unidirectional fiber reinforced resin sheet 10a in the state which the fiber reinforced resin laminated body 12 was installed in the cold press apparatus 50 in the press surface of the 1st metal mold | die 51. As shown in FIG. A recess 51a is provided at a position facing the SL. The concave portion 51a is for receiving the continuous fibers and the matrix resin of the unidirectional fiber reinforced resin sheets 10b, 10c, and 10d that bulge through the slit SL, and molding the convex portion 22. The shape of the concave portion 51a is designed according to the shape of the convex portion 22 to be formed.

第１の金型５１と第２の金型５３とを互いに近接させて繊維強化樹脂積層体１２をプレスすると、図５に示すように、一方向繊維強化樹脂シート１０ａに設けられたスリットＳＬを介して、一方向繊維強化樹脂シート１０ｂの一部が凹部５１ａ内に膨出する。繊維強化樹脂積層体１２は、融点未満の温度にされた第１の金型５１及び第２の金型５３に接触した部分から速やかに硬化し始めるが、スリットＳＬの周囲は凹部５１ａに対向しており、硬化し始めるタイミングが遅れる。そのため、内部の一方向繊維強化樹脂シート１０ｂの一部がスリットＳＬを介して膨出可能であるとともに、一方向繊維強化樹脂シート１０ｂの膨出に伴って、スリットＳＬの周囲の一方向繊維強化樹脂シート１０ａの連続繊維が引きずられて立ち上げられる。   When the fiber reinforced resin laminate 12 is pressed by bringing the first mold 51 and the second mold 53 close to each other, the slit SL provided in the unidirectional fiber reinforced resin sheet 10a is formed as shown in FIG. Accordingly, a part of the unidirectional fiber reinforced resin sheet 10b bulges into the recess 51a. The fiber reinforced resin laminate 12 starts to harden quickly from the portion in contact with the first mold 51 and the second mold 53 that are set to a temperature lower than the melting point, but the periphery of the slit SL faces the recess 51a. The timing to start curing is delayed. Therefore, a part of the internal unidirectional fiber reinforced resin sheet 10b can bulge through the slit SL, and the unidirectional fiber reinforced around the slit SL as the unidirectional fiber reinforced resin sheet 10b bulges. The continuous fibers of the resin sheet 10a are pulled up and started up.

このとき、一方向繊維強化樹脂シート１０ｂの連続繊維がスリットＳＬの延在方向に沿って配向していることから、一方向繊維強化樹脂シート１０ｂの連続繊維及びマトリックス樹脂がスリットＳＬを介して流出しやすくなっている。また、連続繊維が流出する際に、内部で連続繊維が引っ張られることがない。一方で、内部の一方向繊維強化樹脂シート１０ｂの膨出に伴って引きずられる表層の連続繊維は、凸状部２２の立ち上げ方向に沿って積層される。そのため、凸状部２２の根元部分には、凸状部２２の延在方向とは異なる方向の繊維が積層される。   At this time, since the continuous fibers of the unidirectional fiber reinforced resin sheet 10b are oriented along the extending direction of the slit SL, the continuous fibers and the matrix resin of the unidirectional fiber reinforced resin sheet 10b flow out through the slit SL. It is easy to do. Further, when the continuous fiber flows out, the continuous fiber is not pulled inside. On the other hand, continuous fibers in the surface layer that are dragged as the internal unidirectional fiber-reinforced resin sheet 10 b bulges are laminated along the rising direction of the convex portion 22. Therefore, the fiber of the direction different from the extending direction of the convex part 22 is laminated | stacked on the root part of the convex part 22. FIG.

さらに繊維強化樹脂積層体１２のプレスが継続されると、図６に示すように、凹部５１ａ内が一方向繊維強化樹脂シート１０ｂの連続繊維及びマトリックス樹脂で充填される。そして、繊維強化樹脂積層体１２の内部も次第に冷却されて、繊維強化樹脂構造体２０が成形される。   Further, when the pressing of the fiber reinforced resin laminate 12 is continued, as shown in FIG. 6, the recess 51a is filled with the continuous fibers and the matrix resin of the unidirectional fiber reinforced resin sheet 10b. And the inside of the fiber reinforced resin laminated body 12 is also cooled gradually, and the fiber reinforced resin structure 20 is shape | molded.

繊維強化樹脂構造体２０は、繊維の配向方向に沿って剛性や強度等の物性が高くなる性質を有するため、凸状部２２の根元部分が一方向繊維強化樹脂シート１０ａの連続繊維によって補強された状態になる。したがって、凸状部２２は、強度が高められて、倒れにくくなる。また、内部の一方向繊維強化樹脂シート１０ｂの連続繊維が流出する際に、内部で連続繊維が引っ張られることがないために、繊維強化樹脂構造体２０の反りが抑制される。   Since the fiber reinforced resin structure 20 has a property of increasing physical properties such as rigidity and strength along the fiber orientation direction, the root portion of the convex portion 22 is reinforced by continuous fibers of the unidirectional fiber reinforced resin sheet 10a. It becomes a state. Therefore, the convex portion 22 is increased in strength and is difficult to fall down. Moreover, since the continuous fiber is not pulled inside when the continuous fiber of the internal unidirectional fiber reinforced resin sheet 10b flows out, the warp of the fiber reinforced resin structure 20 is suppressed.

以上説明したように、本実施形態にかかる繊維強化樹脂構造体２０の製造方法によれば、冷間プレス加工により繊維強化樹脂構造体２０を製造するにあたり、内部の一方向繊維強化樹脂シート１０ｂの連続繊維及びマトリックス樹脂をスリットＳＬを介して膨出させて凸状部２２が形成される。膨出する連続繊維は、スリットＳＬの方向に沿って配向していることから、繊維強化樹脂構造体２０において、連続繊維が引っ張られることによる反りの発生が抑制される。   As described above, according to the method for manufacturing the fiber reinforced resin structure 20 according to the present embodiment, when the fiber reinforced resin structure 20 is manufactured by cold pressing, the internal unidirectional fiber reinforced resin sheet 10b The convex portions 22 are formed by bulging the continuous fibers and the matrix resin through the slits SL. Since the continuous fibers that bulge are oriented along the direction of the slit SL, in the fiber reinforced resin structure 20, the occurrence of warpage due to the continuous fibers being pulled is suppressed.

また、内部の一方向繊維強化樹脂シート１０ｂの連続繊維及びマトリックス樹脂がスリットＳＬから膨出する際に、スリットＳＬの周囲の連続繊維が引きずられて、凸状部２２の根元部分に積層される。かかる連続繊維は、内部から膨出した連続繊維の配向方向と異なる方向に配向しているため、凸状部２２が補強された状態になる。したがって、本実施形態にかかる繊維強化樹脂構造体２０の製造方法によれば、凸状部２２の剛性や強度等の物性を向上させることができる。   Further, when the continuous fibers and the matrix resin of the internal unidirectional fiber reinforced resin sheet 10 b bulge out from the slit SL, the continuous fibers around the slit SL are dragged and laminated on the root portion of the convex portion 22. . Since the continuous fibers are oriented in a direction different from the orientation direction of the continuous fibers bulged from the inside, the convex portion 22 is reinforced. Therefore, according to the manufacturing method of the fiber reinforced resin structure 20 according to the present embodiment, physical properties such as rigidity and strength of the convex portion 22 can be improved.

以上、添付図面を参照しながら本発明の好適な実施形態について詳細に説明したが、本発明はかかる例に限定されない。本発明の属する技術の分野における通常の知識を有する者であれば、特許請求の範囲に記載された技術的思想の範疇内において、各種の変更例または修正例に想到し得ることは明らかであり、これらについても、当然に本発明の技術的範囲に属するものと了解される。   The preferred embodiments of the present invention have been described in detail above with reference to the accompanying drawings, but the present invention is not limited to such examples. It is obvious that a person having ordinary knowledge in the technical field to which the present invention pertains can come up with various changes or modifications within the scope of the technical idea described in the claims. Of course, it is understood that these also belong to the technical scope of the present invention.

１０ 繊維強化樹脂シート
１０ａ，１０ｂ，１０ｃ，１０ｄ，１０ｅ 一方向繊維強化樹脂シート
１２ 繊維強化樹脂積層体
１６ スリット
１８ 層厚増加材料
２０ 繊維強化樹脂構造体
２２ 凸状部
２４ａ 第１の表層
２４ｂ 第２の表層
２６ 内部層
４０ 加熱装置
５０ 冷間プレス装置
５１ 第１の金型
５１ａ 凹部
５３ 第２の金型
ＳＬ スリット
DESCRIPTION OF SYMBOLS 10 Fiber reinforced resin sheet 10a, 10b, 10c, 10d, 10e Unidirectional fiber reinforced resin sheet 12 Fiber reinforced resin laminated body 16 Slit 18 Layer thickness increase material 20 Fiber reinforced resin structure 22 Convex part 24a 1st surface layer 24b 1st 2 surface layers 26 inner layer 40 heating device 50 cold press device 51 first mold 51a recess 53 second mold SL slit

Claims (10)

複数枚積層された繊維強化樹脂シートを冷間プレス加工して成形された繊維強化樹脂構造体であって、
強化繊維が一方向に沿って配向した一方向繊維強化樹脂シートを含む内部層と、
前記内部層の前記強化繊維の配向方向に交差する方向に沿って配向した強化繊維を含む表層と、
前記内部層の前記強化繊維の配向方向に沿って前記表層に設けられたスリットから前記内部層が外部に膨出して形成された凸状部と、
を備える、繊維強化樹脂構造体。 A fiber reinforced resin structure formed by cold pressing a plurality of laminated fiber reinforced resin sheets,
An inner layer including a unidirectional fiber reinforced resin sheet in which reinforcing fibers are oriented along one direction;
A surface layer containing reinforcing fibers oriented along a direction intersecting the orientation direction of the reinforcing fibers of the inner layer;
A convex portion formed by the inner layer bulging out from a slit provided in the surface layer along the orientation direction of the reinforcing fibers of the inner layer;
A fiber reinforced resin structure. 前記表層の一部が、前記凸状部に沿って立ち上げられている、請求項１に記載の繊維強化樹脂構造体。   The fiber-reinforced resin structure according to claim 1, wherein a part of the surface layer is raised along the convex portion. 前記表層の前記繊維強化樹脂シートは前記一方向繊維強化樹脂シートからなり、当該表層の前記一方向繊維強化樹脂シートの前記強化繊維の配向方向が、前記内部層の前記強化繊維の配向方向と交差する、請求項１又は２に記載の繊維強化樹脂構造体。   The fiber reinforced resin sheet of the surface layer is composed of the unidirectional fiber reinforced resin sheet, and the orientation direction of the reinforcing fibers of the unidirectional fiber reinforced resin sheet of the surface layer intersects with the orientation direction of the reinforcing fibers of the inner layer. The fiber-reinforced resin structure according to claim 1 or 2. 前記表層の前記繊維強化樹脂シートは前記強化繊維が少なくとも２つの方向に沿って配向した前記繊維強化樹脂シートであり、前記少なくとも２つの方向が、前記内部層の前記強化繊維の配向方向と交差する、請求項１又は２に記載の繊維強化樹脂構造体。   The fiber-reinforced resin sheet of the surface layer is the fiber-reinforced resin sheet in which the reinforcing fibers are oriented along at least two directions, and the at least two directions intersect with the orientation directions of the reinforcing fibers of the inner layer. The fiber-reinforced resin structure according to claim 1 or 2. 前記凸状部の高さが０．１〜５．０ｍｍの範囲内の値である、請求項１〜４のいずれか１項に記載の繊維強化樹脂構造体。   The fiber-reinforced resin structure according to any one of claims 1 to 4, wherein a height of the convex portion is a value within a range of 0.1 to 5.0 mm. 強化繊維にマトリックス樹脂を含浸させた繊維強化樹脂シートを複数枚積層して繊維強化樹脂積層体を形成する工程と、
前記繊維強化樹脂積層体を加熱する工程と、
加熱した前記繊維強化樹脂積層体を、冷間プレス装置を用いてプレス加工し、繊維強化樹脂構造体を成形する工程と、を備え、
前記繊維強化樹脂積層体の内部層の前記繊維強化樹脂シートは、前記強化繊維が一方向に沿って配向した一方向繊維強化樹脂シートを含み、
前記内部層の前記一方向繊維強化樹脂シート中の前記強化繊維の配向方向に沿う一方、表層の前記繊維強化樹脂シート中の前記強化繊維に交差する方向に沿ってスリットを設けて前記プレス加工することにより、前記内部層の前記一方向繊維強化樹脂シートの前記強化繊維及び前記マトリックス樹脂を、前記スリットを介して前記表層から膨出させて、前記繊維強化樹脂構造体の表面に凸状部を形成する、繊維強化樹脂構造体の製造方法。 A step of forming a fiber reinforced resin laminate by laminating a plurality of fiber reinforced resin sheets impregnated with a matrix resin into reinforced fibers;
Heating the fiber-reinforced resin laminate,
A step of pressing the heated fiber reinforced resin laminate using a cold press device to form a fiber reinforced resin structure, and
The fiber reinforced resin sheet of the inner layer of the fiber reinforced resin laminate includes a unidirectional fiber reinforced resin sheet in which the reinforced fibers are oriented along one direction,
While pressing along the orientation direction of the reinforcing fiber in the unidirectional fiber reinforced resin sheet of the inner layer, a slit is provided along the direction intersecting the reinforcing fiber in the fiber reinforced resin sheet of the surface layer, and the pressing is performed. Thus, the reinforcing fiber and the matrix resin of the unidirectional fiber reinforced resin sheet of the inner layer are swelled from the surface layer through the slit, and a convex portion is formed on the surface of the fiber reinforced resin structure. The manufacturing method of the fiber reinforced resin structure to form. 前記冷間プレス装置の金型のプレス面における、前記スリットに対向する位置に凹部が設けられ、
前記スリットから膨出させる前記一方向繊維強化樹脂シートの前記強化繊維及び前記マトリックス樹脂を前記凹部に進入させて前記凸状部を成形する、請求項６に記載の繊維強化樹脂構造体の製造方法。 In the press surface of the die of the cold press device, a recess is provided at a position facing the slit,
The manufacturing method of the fiber reinforced resin structure according to claim 6, wherein the reinforced fiber and the matrix resin of the unidirectional fiber reinforced resin sheet bulged from the slit are made to enter the concave portion to form the convex portion. . 前記スリットの幅が５．０ｍｍ以下の値である、請求項６又は７に記載の繊維強化樹脂構造体の製造方法。   The manufacturing method of the fiber reinforced resin structure of Claim 6 or 7 whose width | variety of the said slit is a value of 5.0 mm or less. あらかじめ前記スリットを設けた前記繊維強化樹脂シートを表層に配置して前記繊維強化樹脂積層体を形成する、請求項６〜８のいずれか１項に記載の繊維強化樹脂構造体の製造方法。   The manufacturing method of the fiber reinforced resin structure of any one of Claims 6-8 which arrange | positions the said fiber reinforced resin sheet which provided the said slit previously in a surface layer, and forms the said fiber reinforced resin laminated body. 前記繊維強化樹脂積層体を形成した後、前記表層側から前記スリットを形成し、前記繊維強化樹脂積層体を前記冷間プレス装置に設置する、請求項６〜８のいずれか１項に記載の繊維強化樹脂構造体の製造方法。
After forming the said fiber reinforced resin laminated body, the said slit is formed from the said surface layer side, and the said fiber reinforced resin laminated body is installed in the said cold press apparatus of any one of Claims 6-8. Manufacturing method of fiber reinforced resin structure.
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