Manufacturing method for fiber-reinforced resin articles

Abstract

This disclosure provides a useful improvement to a method for manufacturing FRP articles having insert members. [Solution] A method for manufacturing an FRP article having an insert member includes: (i) a molding step in which a prepreg premolded body 5 having a prepreg 3 and an insert member 4 is placed in a mold together with a core 6 having a fusible portion 7 containing wax, and then the prepreg premolded body 5 is heated in the mold to obtain a cured product; and (ii) a core removal step in which the core is removed from the cured product.

Claims

1. A molding process in which a prepreg premolded body having a prepreg and insert members is placed in a mold together with a core having a fusible portion containing wax, and then the prepreg premolded body is heated in the mold to obtain a cured product, A core removal step of removing the core from the cured product, A method for manufacturing fiber-reinforced resin articles, including the method described above.

2. The manufacturing method according to claim 1, wherein in the molding step, the wax is softened in at least a portion of the fusible portion.

3. The manufacturing method according to claim 1, wherein in the molding step, the wax melts in at least a portion of the fusible portion.

4. The manufacturing method according to claim 1, wherein in the molding step, the cured product is obtained by applying pressure to a portion of the prepreg arranged on the side surface of the insert member.

5. The manufacturing method according to claim 1, wherein in the molding step, the core is placed in the mold without the fusible portion being covered by an outer shell.

6. The manufacturing method according to claim 1, wherein the core further comprises an outer shell covering the fusible portion.

7. The manufacturing method according to claim 1, wherein the fiber-reinforced resin article has a hollow structure.

8. The manufacturing method according to claim 1, wherein the shape of the fiber-reinforced resin article is flat or has an open cross-section.

9. The manufacturing method according to claim 1, wherein the fusible portion further contains particles of a material having the property of generating heat under a high-frequency electromagnetic field, and the core is preheated by induction heating before the molding step.

10. The manufacturing method according to claim 1, wherein the fusible portion further contains particles of a material having the property of absorbing microwaves and generating heat, and the core is preheated by microwave heating before the molding step.

11. The manufacturing method according to any one of claims 1 to 10, wherein the prepreg premolded body further has an adhesive layer between the prepreg and the insert member.

12. The manufacturing method according to any one of claims 1 to 10, wherein the fiber-reinforced resin article has an undercut portion.

13. The manufacturing method according to any one of claims 1 to 10, wherein the boundary between the prepreg and the insert member has an uneven shape in cross-sectional view.

14. The manufacturing method according to any one of claims 1 to 10, wherein the insert member penetrates a portion of the prepreg.

15. The manufacturing method according to any one of claims 1 to 10, wherein the length of the insert member is longer than the thickness of the prepreg, the prepreg is arranged on the entire surface of the side surface of the insert member, and the prepreg is also arranged on the bottom surface of the insert member.

16. The manufacturing method according to any one of claims 1 to 10, wherein the material of the insert member is at least one selected from the group consisting of iron, aluminum, copper, steel, and aluminum alloy.

17. The manufacturing method according to any one of claims 1 to 10, wherein the material of the insert member is at least one selected from the group consisting of engineering plastics, polyester resins, and polyamide resins.

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