Fiber reinforced composite material molding and manufacturing method therefor

Patent metadata

Field	Value
Publication number	US-2016354983-A1
Application number	US-201515117761-A
Country	US
Kind code	A1
Filing date	Feb 19, 2015
Priority date	Feb 19, 2014
Publication date	Dec 8, 2016
Grant date	—

Abstract

The present invention relates to a method for manufacturing a fiber-reinforced composite material molding, having a step (A) for forming a plurality of partial preforms, each having a partial shape obtained by dividing the three-dimensional shape of a target fiber-reinforced composite material molding, by cutting a prepreg sheet containing reinforcing fibers and a matrix resin composition, and by preshaping the cut prepreg pieces; a step (B) for forming a preform having the three-dimensional shape of the target fiber-reinforced composite material molding by combining and integrating the plurality of partial preforms; and a step (C) for producing a fiber-reinforced composite material molding by compression-molding the preform, wherein the step (B) includes arranging a foamable material between the plurality of partial preforms when they are combined.

First claim

1 . A method for manufacturing a fiber-reinforced composite material molding, comprising:
a step (A) for forming a plurality of partial preforms, each having a partial shape obtained by dividing the three-dimensional shape of a target fiber-reinforced composite material molding, by cutting a prepreg sheet containing reinforcing fibers and a matrix resin composition, and by preshaping the cut prepreg pieces; a step (B) for forming a preform having the three-dimensional shape of the target fiber-reinforced composite material molding by combining and integrating the plurality of partial preforms; and a step (C) for producing a fiber-reinforced composite material molding by compression-molding the preform, wherein the step (B) includes arranging a foamable material between the plurality of partial preforms when they are combined.

2 . The method for manufacturing a fiber-reinforced composite material molding according to claim 1 , wherein a partial preform is obtained by layering a plurality of pieces of the cut prepreg to form a laminate and by preshaping the laminate.

3 . The method for manufacturing a fiber-reinforced composite material molding according to claim 1 , wherein the foamable material is a foamable resin film.

4 . The method for manufacturing a fiber-reinforced composite material molding according to claim 2 , wherein the foamable material is a foamable resin film.

5 . The method for manufacturing a fiber-reinforced composite material molding according to claim 1 , wherein the step (B) includes a step for combining the plurality of partial preforms by setting their end faces to abut each other.

6 . The method for manufacturing a fiber-reinforced composite material molding according to claim 1 , wherein the step (B) includes a step for combining the plurality of partial preforms by setting their edges to overlap.

7 . The method for manufacturing a fiber-reinforced composite material molding according to claim 6 , wherein the step (B) includes a step for combining the plurality of partial preforms by setting their edges to overlap each other with the foamable material placed in between.

8 . The method for manufacturing a fiber-reinforced composite material molding according to claim 3 , wherein the foamable resin film has properties to foam up when heated.

9 . The method for manufacturing a fiber-reinforced composite material molding according to claim 3 , wherein the foamable resin film has properties to foam up through chemical reactions.

10 . The method for manufacturing a fiber-reinforced composite material molding according to claim 3 , wherein the foamable resin contained in the foamable resin film includes an epoxy resin composition.

11 . The method for manufacturing a fiber-reinforced composite material molding according to claim 3 , wherein the thickness of the foamable resin film is 0.01 to 10.0 mm.

12 . The method for manufacturing a fiber-reinforced composite material molding according to claim 11 , wherein the thickness of the foamable resin film is 0.2 to 5.0 mm.

13 . The method for manufacturing a fiber-reinforced composite material molding according to claim 1 , wherein the plurality of partial preforms contain a plurality of groups of partial preforms, and the plurality of groups of partial preforms are those divided by different dividing-line patterns.

14 . A fiber-reinforced composite material molding produced by a method for manufacturing a fiber-reinforced composite material molding according to claim 1 ,
wherein a foamed body is arranged in at least a portion between the plurality of partial preforms.

Assignees

• Mitsubishi Rayon Co

Inventors

• Kakimoto Yoshihide
• Ikeda Kazuhisa
• Akiyama Kouichi
• KUTSUWADA Mitsuru

Classifications

• B29K2063/00

  Use of {EP, i.e.} epoxy resins {or derivatives thereof}, as moulding material · CPC title

• B29K2105/04

  cellular or porous · CPC title

• B29C70/84 Primary

  by moulding material on preformed parts to be joined {(joining plastic parts by moulding B29C65/70)} · CPC title

• B29K2105/0881

  unidirectional · CPC title

• B29C43/18

  incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles {(B29C43/206 takes precedence)} · CPC title