Preform, preform manufacturing apparatus, and preform manufacturing method

Abstract

The present invention provides a base material in which fibers are uniformly impregnated with resin, a base material manufacturing apparatus, and a base material manufacturing method. [Solution] The base body 1 is a molded article including fibers 23 and a resin 22 impregnated in the fibers 23. The base body 1 has a first end face 11. A plurality of first ridges T1 are provided on the first end face 11 so as to intersect with one another. The first ridges T1 have a rectangular cross section perpendicular to their extension direction. When the height of the rectangular shape of the first ridges T1 is H1 and the width of the rectangular shape of the first ridges T1 is B1, the relationship H1 / B1 ≥ 0.27 is satisfied.

Description

[Technical Field]

[0001] The present disclosure relates to a base body, a base body manufacturing apparatus, and a base body manufacturing method. [Background technology]

[0002] A preform, which is a molded article containing fibers and a resin impregnated in the fibers, is known. By processing such a preform, a resin gear, for example, as described in Patent Document 1, is produced as a final product. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2017-015100 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned preform, it is desirable that the fibers be uniformly impregnated with resin in order to improve the quality of the final product. Therefore, an object of the present disclosure is to provide a preform in which the fibers are uniformly impregnated with resin, a preform manufacturing apparatus, and a preform manufacturing method. [Means for solving the problem]

[0005] The present inventors have conducted extensive research and found that when a plurality of intersecting ridges are provided on the end face of a base body, the flow of resin during molding can be rectified by utilizing a plurality of grooves formed in a mold for molding the ridges. They also found that adjusting the cross-sectional shape of the ridges (i.e., the cross-sectional shape of the grooves) can effectively rectify the flow of resin and enable the resin to be uniformly impregnated into the fibers, which led to the present disclosure.

[0006] That is, the base body according to the present disclosure is [1] "a base body that is a molded article including fibers and a resin impregnated in the fibers, the base body having a first end face, a plurality of first ridges being provided on the first end face so as to intersect with one another, the first ridges having a rectangular cross section perpendicular to the direction of extension, the first ridges having a height of the rectangular shape of the first ridges being H1 and the width of the rectangular shape of the first ridges being B1, and satisfying H1 / B1 ≧ 0.27."

[0007] In the preform of the present disclosure, the first ridges are provided on the end surface of the preform, and therefore the flow of resin during molding can be regulated by utilizing the multiple grooves formed in the mold to form the first ridges. After further intensive research, the present inventors discovered that the flow of resin can be effectively regulated when H1 / B1 ≧ 0.27 is satisfied. Therefore, according to the present disclosure, by satisfying H1 / B1 ≧ 0.27, it is possible to provide a preform in which the fibers are uniformly impregnated with resin.

[0008] The preform according to the present disclosure may be [2] "the preform according to the above [1], in which the quadrangular shape of the first ridges is a trapezoidal shape." In this case, the first ridges can be smoothly released from the mold during molding of the preform.

[0009] The preform according to the present disclosure may be [3] "the preform according to [1] or [2] above, having a second end face opposite to the first end face, a plurality of second ridge ribs are provided on the second end face so as to intersect with one another, the second ridge ribs have a rectangular cross section perpendicular to the direction of extension, and when the area of ​​the rectangular shape of the first ridge ribs is a first cross-sectional area and the area of ​​the rectangular shape of the second ridge ribs is a second cross-sectional area, the cross-sectional area ratio, which is the ratio of the first cross-sectional area to the second cross-sectional area, is 0.035 to less than 1." If the cross-sectional area ratio, which is the ratio of the first cross-sectional area to the second cross-sectional area (hereinafter simply referred to as the "cross-sectional area ratio"), is less than 0.035, during molding of the preform, depending on the combination of the height and width of the first ridge ribs, there is a risk that the resin will not flow through the plurality of grooves formed in the mold for molding the first ridge ribs, making it difficult to uniformly impregnate the fibers with the resin. Furthermore, because the first ridges are removed by processing, there is a concern that the first ridges will become too large and the yield of the final product will decrease if the cross-sectional area ratio is greater than or equal to 1. In this regard, according to the present disclosure, by setting the cross-sectional area ratio to 0.035 to less than 1, it is possible to uniformly and reliably impregnate the fibers with resin in the base body while suppressing a decrease in the yield of the final product.

[0010] The preform according to the present disclosure may be [4] "the preform according to any one of [1] to [3] above, wherein the first ridges extend in a lattice pattern when viewed from a direction perpendicular to the first end face." In this case, the flow of resin can be rectified more effectively during molding of the preform, allowing the resin to be more uniformly impregnated into the fibers.

[0011] The elementary body manufacturing apparatus according to the present disclosure is [5] "an apparatus for manufacturing an elementary body, which is a molded product containing fibers and a resin impregnated in the fibers, comprising: a first mold having a protruding portion; and a second mold arranged opposite the first mold and having a storage space for accommodating the protruding portion; a plurality of rectifying grooves are formed on the tip surface of the protruding portion so as to intersect with one another; a filling region for arranging fibers is formed between the tip surface of the protruding portion and the inner surface of the storage space; a flow path for circulating resin in the filling region is formed between the side surface of the protruding portion and the inner surface of the storage space; the rectifying grooves have a rectangular cross section perpendicular to their extension direction, and satisfy the relationship MH1 / MB1 ≧ 0.27, where MH1 is the height of the rectangular shape of the rectifying groove and MB1 is the width of the rectangular shape of the rectifying groove." The present disclosure makes it possible to manufacture the above-described elementary body, i.e., to provide an elementary body in which fibers are uniformly impregnated with resin.

[0012] The method for producing a primary body according to the present disclosure is [6] "a method for producing the primary body using the primary body production apparatus described in [5] above, comprising the steps of arranging fibers in the filling region, injecting resin so that the resin flows into the filling region via the flow path, and curing the resin, wherein in the step of injecting resin, at least a portion of the resin that has traveled through the flow path passes through a plurality of straightening grooves formed in the tip surface of the protrusion." The method for producing a primary body according to the present disclosure also uses the above production apparatus, making it possible to provide a primary body in which the fibers are uniformly impregnated with resin. [Effects of the Invention]

[0013] According to the present invention, it is possible to provide a raw material having fibers uniformly impregnated with resin, an apparatus for manufacturing the raw material, and a method for manufacturing the raw material. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a perspective view showing an elemental body according to one embodiment. [Figure 2]FIG. 2 is an enlarged view of a part of the cross section taken along line II-II in FIG. [Figure 3] FIG. 3 is another perspective view showing the base body of FIG. [Figure 4] FIG. 4 is an enlarged view of a part of the cross section taken along line IV-IV in FIG. [Figure 5] FIG. 5 is a cross-sectional view showing an apparatus for manufacturing the base body of FIG. [Figure 6] Fig. 6(a) is a cross-sectional view showing the upper mold of Fig. 5. Fig. 6(b) is a bottom view showing the upper mold of Fig. 5. Fig. 6(c) is an enlarged view showing the flow rectifying groove of Fig. 6(a). [Figure 7] Fig. 7(a) is a plan view showing the lower mold of Fig. 5. Fig. 7(b) is a cross-sectional view showing the lower mold of Fig. 5. [Figure 8] Fig. 8(a) is a plan view showing the void reservoir of Fig. 5. Fig. 8(b) is an enlarged view showing a part of the cross section taken along line VIII-VIII of Fig. 8(a). [Figure 9] FIG. 9 is a flowchart showing a method for manufacturing the base body of FIG. [Figure 10] FIG. 10 is a cross-sectional view showing a state in the middle of filling the resin in the manufacturing apparatus of FIG. [Figure 11] FIG. 11 is a perspective view schematically showing the first ridges of the base body of FIG. [Figure 12] FIG. 12 is an enlarged view of the flow rectifying grooves of FIG. [Figure 13] FIG. 13 is a graph for explaining the flow analysis results. [Figure 14] Figure 14(a) is a diagram showing the flow analysis results for a good elementary body, and Figure 14(b) is a diagram showing the flow analysis results for a bad elementary body. [Figure 15] FIG. 15 is a table showing the flow analysis results. [Figure 16] Fig. 16(a) is a perspective view showing a base body according to a first modified example, and Fig. 16(b) is another perspective view showing the base body of Fig. 16(a). [Figure 17]Fig. 17(a) is a perspective view showing a base body according to a second modified example, and Fig. 17(b) is another perspective view showing the base body of Fig. 17(a). DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, the embodiments will be described in detail with reference to the accompanying drawings. In the description of the drawings, the same or corresponding elements are designated by the same reference numerals, and duplicate explanations will be omitted. The terms "upper" and "lower" are used for convenience based on the state shown in the drawings.

[0016] As shown in FIG. 1, the base material 1 according to this embodiment is a molded article containing fibers and a resin impregnated in the fibers. The base material 1 is an intermediate for obtaining a final product. The final product is produced by processing the base material 1. The final product is, for example, a resin gear (so-called high-strength resin gear) used as a gear for bicycles, vehicles, or industrial use.

[0017] As the fibers for the base material 1, it is preferable to use at least one type of staple fiber selected from para-aramid fibers, meta-aramid fibers, carbon fibers, glass fibers, boron fibers, ceramic fibers, ultra-high strength polyethylene fibers, polyketone fibers, polyparaphenylene benzobisoxazole fibers, wholly aromatic polyester fibers, polyimide fibers, and polyvinyl alcohol fibers. In particular, when a blend of para-aramid fibers and meta-aramid fibers is used as the staple fibers, an excellent balance of heat resistance, strength, and processability after resin molding is achieved. The melting point or decomposition temperature of the fibers is preferably 250°C or higher. By using such fibers, the base material 1 can be produced with excellent heat resistance without thermal degradation at the molding or processing temperatures during molding and the ambient temperature during actual use.

[0018] The slurry may be an organic solvent, a mixture of an organic solvent and water, or water. It is preferable to use water as the slurry, as it is particularly economical and has a low environmental impact. When using an organic solvent, it is also possible to use organic solvents such as methanol, ethanol, acetone, toluene, and diethyl ether, with due attention to safety.

[0019] The resin may be either a thermosetting resin or a thermoplastic resin, but a thermosetting resin is preferred from the viewpoint of improving the strength of the resin gear to be manufactured. More specifically, a combination of one or more resins selected from epoxy resin, polyaminoamide resin, phenolic resin, unsaturated polyester resin, polyimide resin, polyethersulfone resin, polyetheretherketone resin, polyamideimide resin, polyamide resin, polyester resin, polyphenylene sulfide resin, polyethylene resin, polypropylene resin, etc., and a curing agent appropriate for the selected resin can be used. Among these, polyaminoamide resin is preferred from the viewpoint of the strength and heat resistance of the cured resin. It is also preferred to use a resin containing 5 parts by mass or less of n-octyl bromide as a curing accelerator for the catalyst, for example, per 100 parts by mass of a mixture of 2,2'-(1,3-phenylene)bis-2-oxazoline, which has excellent heat resistance and strength, and an amine curing agent.

[0020] The base body 1 is a three-dimensional member having an axis. In this embodiment, the base body 1 has a columnar (approximately cylindrical) outer shape. As shown in FIGS. 2 and 3 , the base body 1 has a first end face 11, which is an end face on one side in the axial direction, and a second end face 12, which is an end face on the other side in the axial direction. The second end face 12 is an end face opposite to the first end face 11. A plurality of first ridges T1 are provided on the first end face 11 so as to intersect with one another. A plurality of second ridges T2 are provided on the second end face 12 so as to intersect with one another. The first ridges T1 and the second ridges T2 will be described in detail below.

[0021] As shown in FIG. 5, the manufacturing apparatus 100 for the base body 1 according to this embodiment is an apparatus for manufacturing the base body 1 described above, and includes an upper mold 110, a lower mold 120, and a void reservoir 130. As shown in FIGS. 5, 6(a), 6(b), and 6(c), the upper mold 110 constitutes a first mold. The upper mold 110 has a flat plate portion 111 extending horizontally and a three-dimensional protrusion portion 112 extending downward from one end of the flat plate portion 111. The flat plate portion 111 is a plate-like portion that is rectangular in plan view. The flat plate portion 111 is provided so as to face the lower mold in the up-down direction, and is provided above the lower mold 120. The protrusion portion 112 is provided on one end of the flat plate portion 111 in the longitudinal direction. A through-hole 111x is formed at the other end in the longitudinal direction (and at the center in the lateral direction) of the flat plate portion 111, penetrating the flat plate portion 111 in the thickness direction. The through-hole 111x is a flow path for the resin 22 to be injected.

[0022] The protruding portion 112 is a three-dimensional portion extending downward from one end side in the longitudinal direction (and the center part in the lateral direction) of the flat plate portion 111. A plurality of flow rectification grooves 112y are formed so as to intersect with each other on the lower surface 112a, which is the tip surface of the protruding portion 112. The flow rectification grooves 112y rectify the flow of the resin 22. Each flow rectification groove 112y is a groove extending in a straight line. When viewed from below, the plurality of flow rectification grooves 112y are formed in a lattice pattern on the lower surface 112a. The resin 22 flows along the plurality of flow rectification grooves 112y, so that the resin 22 flows over substantially the entire area of ​​the lower surface 112a.

[0023] As shown in Figures 5, 7(a) and 7(b), the lower mold 120 constitutes a second mold. The lower mold 120 is provided so as to face the upper mold 110 in the vertical direction, and is provided below the upper mold 110. The lower mold 120 has a base 121 that is approximately rectangular parallelepiped in shape. A hollow cylindrical storage space 121x is formed on one end side in the longitudinal direction of the lower mold 120 (and at the center in the lateral direction).

[0024] The accommodation space 121x has a shape corresponding to the protrusion 112 of the upper mold 110 and accommodates the protrusion 112. Specifically, the accommodation space 121x is formed to be slightly larger than the protrusion 112 in the radial direction and is formed to be spaced apart from the side surface 112b of the protrusion 112 to an extent that the resin 22 running down the side surface 112b of the protrusion 112 can flow downward. The depth of the accommodation space 121x is formed to be deeper than the length of the protrusion 112 in the up-down direction. Therefore, a filling region 121y into which the resin 22 is filled is formed between the lower surface 112a of the protrusion 112 and the lower surface 121a of the accommodation space 121x. Such a filling region 121y is a region (space) in which the fibers 23 are arranged (set) before the resin 22 is injected.

[0025] A hollow cylindrical ejector pin space 121z is formed below the accommodation space 121x. The ejector pin space 121z is concentric with the accommodation space 121x and has a smaller diameter than the accommodation space 121x. An ejector pin 140 (described later) is inserted into the ejector pin space 121z.

[0026] A flow path 121b, which is a flow path for resin 22 and continues to through-hole 111x of flat plate portion 111, is formed on upper surface 121u of base portion 121. Flow path 121b is a recess formed on upper surface 121u. Flow path 121b has a first portion 121c that continues to through-hole 111x and is formed so as to extend linearly in the direction of storage space 121x, and a second portion 121d that continues to first portion 121c and is formed in a circular shape along the outer edge of storage space 121x.

[0027] As shown in Figures 5, 8(a), and 8(b), the ejector pin 140 is housed in the ejector pin space 121z (see Figure 7(b)), and is a component for extracting the base form 1 from the filling region 121y. The void reservoir 130 is provided on the tip surface (i.e., the upper surface) of the ejector pin 140. The void reservoir 130 has a plurality of grooves 132. The plurality of grooves 132 are formed so as to intersect with each other on the tip surface of the ejector pin 140. Each groove 132 extends in a straight line. The plurality of grooves 132 are formed in a lattice pattern on the tip surface of the ejector pin 140. With this configuration, voids are collected in the plurality of grooves 132, and the voids can be collected.

[0028] The method for manufacturing the base body 1 is carried out using the manufacturing apparatus 100 described above. Vacuum injection molding is used in the method for manufacturing the base body 1 because the resin has low viscosity when molten. In the method for manufacturing the base body 1, first, as shown in FIG. 5, fibers 23 are placed in the filling region 121y (step S1 in FIG. 9). Resin 22 is injected into the upper mold 110 so that the resin 22 flows into the filling region 121y through a flow path between the side surface 112b of the protrusion 112 and the inner surface 121w of the accommodation space 121x (step S2 in FIG. 9).

[0029] 5 and 10, in step S2, resin 22 is injected from the upper end of the through-hole 111x of the upper mold 110. The injected resin 22 reaches the side surface 112b of the protruding portion 112 through the through-hole 111x, the first portion 121c, and the second portion 121d. The resin 22 flows downward through the flow path 161 between the side surface 112b and the inner surface 121w of the accommodation space 121x and reaches the filling region 121y. Then, at least a portion of the resin 22 flows through the plurality of flow straightening grooves 112y formed in the lower surface 112a of the protruding portion 112, and over substantially the entire area of ​​the lower surface 112a.

[0030] Next, the resin 22 is hardened (step S3 in FIG. 9). This results in the base body 1. The base body 1 thus obtained is then milled on the side of the first end face 11 to remove the first ridges T1, and on the side of the second end face 12 to remove the second ridges T2. The base body 1 is then subjected to a cutting process and a gear cutting process to manufacture a resin gear. In the cutting process, the outer diameter portion and the side surface of the inner diameter portion of the base body 1 are milled to machine the base body 1 to predetermined dimensions. In the gear cutting process, the base body 1 is gear cut. In the gear cutting process, a tooth profile is formed in the base body 1, and a resin gear is manufactured.

[0031] In this embodiment, as shown in FIGS. 1, 2, and 11, a plurality of first ridges T1 are provided on the first end surface 11 of the base body 1 so as to intersect with one another. The first ridges T1 are convex portions that are provided so as to extend. When viewed from a direction perpendicular to the first end surface 11, the first ridges T1 extend in a lattice pattern. The cross section of the first ridges T1 perpendicular to the direction of extension (hereinafter also referred to as the "transverse cross section") is rectangular. In the example shown in the figures, the rectangular cross section of the first ridges T1 is trapezoidal. Specifically, the rectangular cross section of the first ridges T1 is a trapezoid whose width narrows toward the tip.

[0032] If the height of the rectangular cross section of the first ridges T1 is H1 [mm] and the width of the rectangular cross section of the first ridges T1 is B1 [mm], then H1 / B1 ≧ 0.27 is satisfied. The height H1 corresponds to the dimension in the protruding direction of the first ridges T1. The width B1 corresponds to the dimension in the width direction perpendicular to both the protruding direction and the extending direction of the first ridges T1. For example, the height H1 may be 0.5 mm to 2.5 mm and the width B1 may be 0.5 mm to 3.0 mm.

[0033] The width B1 may be the maximum width, minimum width, or average width of the first ridges T1. Here, the width B1 refers to the maximum width of the first ridges T1. The height H1 may be the maximum height, minimum height, or average height of the first ridges T1. Here, the height H1 is a constant value that does not vary in the width direction because the tip end surfaces of the first ridges T1 are flat surfaces parallel to the first end face 11. The definitions of the width B1 and the height H1 also apply to the widths B2, MB1, MB2 and heights H2, MH1, MH2 described below.

[0034] As shown in FIGS. 5 and 6(c), the first ridges T1 correspond to the rectifying grooves 112y of the upper mold 110. That is, the rectifying grooves 112y extend in a lattice pattern when viewed from a direction perpendicular to the lower surface 112a. The rectifying grooves 112y have a rectangular cross section, and in the illustrated example, the rectangular cross section of the rectifying grooves 112y is trapezoidal. Specifically, the rectangular cross section of the rectifying grooves 112y is a trapezoid whose width narrows toward the tip. When the height (depth) of the rectangular cross section of the rectifying grooves 112y is MH1 and the width of the rectangular cross section of the rectifying grooves 112y is MB1, the relationship MH1 / MB1≧0.27 is satisfied. The height MH1 corresponds to the dimension of the rectifying grooves 112y in the depth direction. The width MB1 corresponds to the dimension in the width direction perpendicular to both the depth direction and the extension direction of the flow rectifying groove 112y. The height MH1 is equal to the height H1, and the width MB1 is equal to the width B1.

[0035] As shown in Figure 12, the first ridges T1 are formed when the fibers 23 penetrate into the rectifying grooves 112y and the resin 22 flows during molding of the base body 1. Experiments have confirmed that there is a correlation between the penetration height Y1 [mm] of the fibers 23 and the width B1 of the first ridges T1. For example, it has been confirmed that there is a relationship of Y1 = 0.16B1. The penetration height Y1 is the length of the fibers 23 that penetrate from the lower surface 112a of the upper mold 110 into the rectifying grooves 112y in the depth direction of the rectifying grooves 112y.

[0036] Returning to Figure 1, an outer edge ridge E1 is provided at the edge of the first end face 11 of the base body 1, extending along the edge of the first end face 11. The outer edge ridge E1 is continuous with both ends of the multiple first ridges T1. The tip end faces of the outer edge ridge E1 and the first ridges T1 are arranged to be flush with each other.

[0037] As shown in Figures 3 and 4, a plurality of second ridges T2 are provided on the second end surface 12 of the base body 1 so as to intersect with one another. The second ridges T2 are convex portions that are provided so as to extend. When viewed from a direction perpendicular to the second end surface 12, the second ridges T2 extend in a lattice pattern. The second ridges T2 have a rectangular cross section. In the example shown, the rectangular cross section of the second ridges T2 is trapezoidal. Specifically, the rectangular cross section of the second ridges T2 is a trapezoid whose width narrows toward the tip.

[0038] For example, the height H2 of the rectangular cross section of the second ridges T2 is 2.5 mm. The width B1 of the rectangular cross section of the second ridges T2 is 3.0 mm. When the area of ​​the rectangular shape of the first ridges T1 is the first cross-sectional area and the area of ​​the rectangular shape of the second ridges T2 is the second cross-sectional area, the cross-sectional area ratio, which is the ratio of the first cross-sectional area to the second cross-sectional area, is 0.035 to less than 1.

[0039] As shown in FIGS. 5 and 8(b), the second ridges T2 correspond to the grooves 132 of the ejector pin 140. That is, the grooves 132 extend in a lattice pattern when viewed from a direction perpendicular to the tip surface of the ejector pin 140. The grooves 132 have a rectangular cross section, and in the example shown, the rectangular cross section of the groove 132 is trapezoidal. Specifically, the rectangular cross section of the groove 132 is a trapezoid whose width narrows toward the tip. The height (depth) MH2 of the rectangular cross section of the groove 132 corresponds to the dimension in the depth direction of the groove 132. The width MB2 of the rectangular cross section of the groove 132 corresponds to the dimension in the width direction perpendicular to both the depth direction and the extension direction of the groove 132. The height MH2 is equal to the height H2, and the width MB2 is equal to the width B2.

[0040] Returning to Figure 3, the second end surface 12 of the base body 1 is provided with an outer edge ridge E2 extending along the edge of the second end surface 12. The outer edge ridge E2 is continuous with both ends of the multiple second ridges T2. The tip end surfaces of the outer edge ridge E2 and the second ridges T2 are arranged to be flush with each other.

[0041] [Action and effect] As described above, in the preform 1, the first ridges T1 are provided on the first end face 11, and the flow of the resin 22 during molding can be rectified by utilizing the plurality of rectifying grooves 112y formed in the upper mold 110 in order to form the first ridges T1. Here, the present inventors conducted further intensive studies and found that the flow of the resin 22 can be effectively rectified when H1 / B1 ≧ 0.27 is satisfied. Therefore, in the present embodiment, H1 / B1 ≧ 0.27 is satisfied, and it is thereby possible to provide a preform 1 in which the fibers 23 are uniformly impregnated with the resin 22.

[0042] In the preform 1, the rectangular cross section of the first ridges T1 is trapezoidal. In this case, the first ridges T1 can be smoothly released from the upper die 110 when the preform 1 is molded.

[0043] If the cross-sectional area ratio, which is the ratio of the first cross-sectional area (the cross-section of the first ridges T1) to the second cross-sectional area (the cross-section of the second ridges T2), is less than 0.035, depending on the combination of the height H1 and width B1 of the first ridges T1, the resin 22 may not flow through the multiple flow straightening grooves 112y formed in the upper mold 110 during molding of the base body 1, making it difficult to uniformly impregnate the fibers 23 with the resin 22. For example, if the height H1 of the first ridges T1 is too low relative to the width B1, the fibers 23 may get caught in the flow straightening grooves 112y during molding, hindering the impregnation of the resin 22. On the other hand, because the first ridges T1 are removed during processing, if the cross-sectional area ratio is 1 or greater, the first ridges T1 may become too large, which may reduce the yield of the final product. For example, if the height H1 of the first ridges T1 is too high relative to the width B1, the resin 22 may flow more easily, but the yield of the final product may decrease. In this regard, in this embodiment, by setting the cross-sectional area ratio to 0.035 to less than 1, it is possible to uniformly and reliably impregnate the fibers 23 in the base body 1 with the resin 22, while suppressing a decrease in the yield of the final product.

[0044] In the preform 1, the first protrusions T1 extend in a lattice pattern when viewed from a direction perpendicular to the first end face 11. In this case, when the preform 1 is molded, the lattice-shaped flow-straightening grooves 112y can be used to straighten the resin 22, more effectively straightening the flow of the resin 22. As a result, in the preform 1, the resin 22 can be more uniformly impregnated into the fibers 23.

[0045] The manufacturing apparatus 100 for the base material 1 can manufacture the base material 1 described above, that is, it is possible to provide a base material 1 in which the fibers 23 are uniformly impregnated with the resin 22. The manufacturing method for the base material 1, which uses the manufacturing apparatus 100 described above, makes it possible to provide a base material 1 in which the fibers 23 are uniformly impregnated with the resin 22.

[0046] Here, a flow analysis of the resin 22 was performed when the base body 1 was manufactured using the manufacturing apparatus 100. In the flow analysis, the flow of the resin 22 in the filling region 121y was visualized and evaluated when the width B1 and height H1 of the first ridges T1 of the base body 1 were changed. The results are shown in Fig. 13, Fig. 14(a), and Fig. 14(b).

[0047] FIG. 13 is a graph illustrating the flow analysis results. FIG. 14(a) is a diagram illustrating the flow analysis results for a good base body 1. FIG. 14(b) is a diagram illustrating the flow analysis results for a defective base body. FIGS. 14(a) and 14(b) show the degree of arrival of resin 22 in filling region 121y at a certain timing using shading. FIGS. 14(a) and 14(b) correspond to cross sections along the axial direction of base body 1.

[0048] As shown in FIG. 13, it can be confirmed that a uniform resin flow can be achieved in the filling region 121y by satisfying H1 / B1≧0.27. As shown in FIG. 14(a), by satisfying H1 / B1≧0.27, the resin 22 flows along the axial direction (the vertical direction in the figure) throughout the filling region 121y, and the flow of the resin 22 is not uneven in the direction perpendicular to the axial direction. Furthermore, by satisfying H1 / B1≧0.27, the flow of the resin 22 throughout the filling region 121y exhibits a horizontal stripe distribution, and the flow is uniform in the direction perpendicular to the axial direction. This confirms that the resin 22 is uniformly impregnated into the fibers 23.

[0049] On the other hand, as shown in Figure 14, when H1 / B1<0.27, it can be confirmed that the flow of resin becomes non-uniform in the filling region 121y. As shown in Figure 14(b), when H1 / B1<0.27, the resin 22 in the filling region 121y does not flow easily along the axial direction, and flows non-uniformly in the direction perpendicular to the axial direction. This confirms that it is difficult for the resin 22 to uniformly impregnate the fibers 23.

[0050] Whether the flow of the resin 22 in the filling region 121y is uniform or non-uniform can be evaluated as follows. Specifically, when the pressure value at the center of the first ridges T1 is measured from among the pressure values ​​obtained in the flow analysis, the evaluation can be performed by determining whether the pressure remains at or below 0 [Pa] from the time the resin 22 flows through the filling region 121y until it reaches the second ridges T2. This is because, if the flow of the resin 22 is non-uniform, the resin 22 does not flow into the center of the first ridges T1 from the time the resin 22 flows through the filling region 121y until it reaches the second ridges T2. Therefore, for example, if the pressure value at the center of the first ridges T1 remains at or below 0 [Pa], the flow of the resin 22 in the filling region 121y can be evaluated as non-uniform. Furthermore, for example, if the pressure value at the center of the first ridges T1 increases beyond 0 [Pa], the flow of the resin 22 in the filling region 121y can be evaluated as uniform.

[0051] FIG. 15 is a table showing the results of flow analysis performed by changing the height H1 and width B1 of the first ridges T1 of the base body 1. The values ​​in the table in the figure represent the cross-sectional area ratio, which is the ratio of the first cross-sectional area (the cross-section of the first ridges T1) to the second cross-sectional area (the cross-sectional area of ​​the second ridges T2). In the figure, values ​​with hatching behind them indicate results in which the resin 22 is uniformly impregnated into the fibers 23. Values ​​without hatching behind them indicate results in which the resin 22 is non-uniformly impregnated into the fibers 23. Results above the dashed line in the figure indicate results in which H1 / B1 is less than 0.27.

[0052] 15, it can be seen that the minimum cross-sectional area ratio among the results that satisfy H1 / B1≧0.27 (the cross-sectional area ratio above which the resin 22 is uniformly impregnated for any combination of width B1 and height H1) is 0.035. In other words, it can be seen that by setting the cross-sectional area ratio to 0.035 or more, the resin 22 can be uniformly and reliably impregnated into the fibers 23 in the base body 1.

[0053] [Variations] As described above, one aspect of the present disclosure is not limited to the above embodiment. The base body according to the present disclosure may be a circular base body 1A shown in Figures 16(a) and 16(b). Base body 1A differs from base body 1 (see Figure 1) in that a through-hole 500 is formed in the center. The base body according to the present disclosure may be a plate-shaped base body 1B shown in Figures 17(a) and 17(b). Base body 1B differs from base body 1 (see Figure 1) in that its outer shape is a rectangular plate.

[0054] In the above embodiment, the cross-sectional shapes of the first ridges T1 and the second ridges T2 are not particularly limited as long as they are rectangular. Various materials and shapes can be applied to each configuration in the above embodiment and the above modified examples. Each configuration in the above embodiment and the above modified examples can be applied as desired to each configuration in other embodiments or modified examples. [Explanation of symbols]

[0055] 1, 1A, 1B... base body, 11... first end surface, 12... second end surface, 22... resin, 23... fiber, 100... manufacturing apparatus, 110... upper mold (first mold), 112... protrusion, 112a... lower surface (tip surface), 112b... side surface, 112y... straightening groove, 120... lower mold (second mold), 121x... storage space, 121y... filling area, 121w... inner surface, 161... flow path, T1... first ridge, T2... second ridge.

Claims

1. A base body that is a molded article including fibers and a resin impregnated in the fibers, a first end surface; a plurality of first ridges are provided on the first end surface so as to intersect with each other, the first protrusion has a rectangular cross section perpendicular to its extending direction, A base body that satisfies H1 / B1≧0.27, where H1 is the height of the rectangular shape of the first ridge striations and B1 is the width of the rectangular shape of the first ridge striations.

2. The base body according to claim 1 , wherein the rectangular shape of the first ridge is a trapezoidal shape.

3. a second end surface opposite the first end surface, a plurality of second ridges are provided on the second end surface so as to intersect with each other, the second protrusion has a rectangular cross section perpendicular to its extending direction, 3. The base body according to claim 1 or 2, wherein a cross-sectional area ratio, which is the ratio of the first cross-sectional area to the second cross-sectional area, is 0.035 to less than 1, where the area of ​​the rectangular shape of the first protrusion ridges is a first cross-sectional area and the area of ​​the rectangular shape of the second protrusion ridges is a second cross-sectional area.

4. The base body according to claim 1 or 2, wherein the first ridges extend in a lattice pattern when viewed from a direction perpendicular to the first end face.

5. An apparatus for producing a preform, which is a molded article containing fibers and a resin impregnated in the fibers, comprising: a first mold having a protrusion; a second mold disposed opposite the first mold and having an accommodation space for accommodating the protrusion, a plurality of flow straightening grooves are formed on the tip end surface of the protrusion so as to intersect with each other, a filling region in which fibers are arranged is formed between the tip surface of the protrusion and the inner surface of the storage space, a flow path for circulating resin in the filling region is formed between a side surface of the protrusion and an inner surface of the accommodation space; The flow straightening groove has a rectangular cross section perpendicular to its extending direction, An apparatus for manufacturing a base body, wherein MH1 / MB1≧0.27 is satisfied, where MH1 is the height of the rectangular shape of the rectifying groove and MB1 is the width of the rectangular shape of the rectifying groove.

6. A method for manufacturing a preform using the preform manufacturing apparatus according to claim 5, comprising the steps of: disposing fibers in the packed region; injecting a resin so that the resin flows into the filling region through the flow path; and curing the resin. In the step of injecting resin, at least a portion of the resin that has traveled through the flow path passes through a plurality of straightening grooves formed on the tip surface of the protrusion.

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