Method for manufacturing a joined part including fiber-reinforced resin

Abstract

To enable suppressing a transfer of a crease generated on a covering member such as a vacuum bag to a fiber reinforced resin.SOLUTION: A method for manufacturing a joint component 120 containing a fiber reinforced resin 125 includes the steps of: placing a plate 70 being a rigid plate on a prepreg 40, and further covering a laminate 150 containing an adhesive film 30 (adhesive agent), the prepreg 40, and the plate 70, with a bag film 80 (covering member); evacuating an inside covered with the bag film 80; and heat-treating a vehicle component 20 (base material), the evacuated bag film 80, and the laminate 150.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] Disclosed herein is a method for producing a bonded component in which a fiber reinforced resin is bonded to a substrate. [Background technology]

[0002] Conventionally, there have been known joined parts in which fiber reinforced plastic (FRP) is joined to a base material. For example, heterogeneous joined parts in which CFRP (Carbon Fiber Reinforced Plastics) is joined to a dissimilar base material such as a metal part are known.

[0003] In manufacturing the joining parts, for example, prepreg (Pre-Impregnated) is used as a fiber-reinforced resin material. Prepreg is an intermediate material (in other words, a semi-finished product) made by impregnating a bundle of reinforcing fibers with uncured thermosetting resin and forming it into a sheet shape.

[0004] For example, in Patent Documents 1 and 2, the above-mentioned joined parts are manufactured using a vacuum bag method. Specifically, an adhesive layer such as a thermal adhesive film is laminated on the surface of a reinforcing member such as a bumper reinforcement of a vehicle. A prepreg is laminated on the adhesive layer. Furthermore, a release film is laminated on the prepreg, and a breather cloth is laminated on the release film. The breather cloth is a member that becomes an air flow path during evacuation, and is made of, for example, a nonwoven fabric having a predetermined thickness.

[0005] The laminate consisting of the adhesive layer, the prepreg, the release film, and the breather cloth is covered with a vacuum bag, and the peripheral portion of the vacuum bag surrounding the portion covering the laminate is attached (fixed) in a frame shape to the laminate surface of the base material with an adhesive tape or the like.

[0006] In this state, an operator operates a vacuum pump to remove the air from inside the vacuum bag through the degassing port of the vacuum bag, creating a vacuum. While maintaining this vacuum state, the substrate and laminate are placed in a molding furnace such as an autoclave and heated. During this process, the thermosetting resin contained in the prepreg hardens. During this heating process, the adhesive layer also melts, bonding (adhering) the prepreg and substrate together. [Prior art documents] [Patent documents]

[0007] [Patent Document 1] JP 2020-19307 A [Patent Document 2] JP 2001-47507 A Summary of the Invention [Problem to be solved by the invention]

[0008] By the way, the vacuum bag may shrink during the heat treatment. During the shrinkage process, wrinkles may occur in the vacuum bag, and these wrinkles may be transferred to the fiber reinforced resin. For example, the wrinkles of the vacuum bag may be transferred to the resin during heat curing, that is, while the resin is still soft, and as a result, grooves (streaks) may appear on the surface of the fiber reinforced resin after heat curing, which may impair the appearance quality.

[0009] Therefore, this specification discloses a method for manufacturing a joined part including fiber reinforced resin, which can suppress the transfer of wrinkles generated in a covering member such as a vacuum bag to the fiber reinforced resin. [Means for solving the problem]

[0010] The method for producing a bonded component containing fiber-reinforced resin disclosed in this specification includes the steps of placing an adhesive on the surface of a substrate, laminating a prepreg, in which reinforcing fibers are impregnated with an uncured thermosetting resin, on the adhesive, placing a rigid plate on the prepreg, and covering the laminate containing the adhesive, the prepreg, and the rigid plate with a covering member, drawing a vacuum from the inside covered with the covering member, and heat-treating the substrate, the evacuated covering member, and the laminate covered with the covering member.

[0011] According to the above-described configuration, since the rigid plate is inserted between the prepreg and the covering member, even if wrinkles occur in the covering member, the transfer of the wrinkles to the prepreg is suppressed.

[0012] In the above-described configuration, the rigid plate may have the same coefficient of thermal expansion as the fiber reinforced resin from which the prepreg is cured.

[0013] When the heat treatment is performed under conditions where the laminate is vacuumed and each component is restrained, each component may be deformed due to thermal expansion. By using a material with the same thermal expansion coefficient as the fiber reinforced resin from which the prepreg is cured for the rigid plate, the fiber reinforced resin and the rigid plate are substantially deformed in the same manner, particularly after the prepreg is cured. By making the deformation modes substantially equal, the imbalance of the surface pressure distribution between the rigid plate and the fiber reinforced resin due to the difference in deformation is suppressed.

[0014] In the above-described configuration, the rigid plate may be made of fiber-reinforced resin obtained by curing prepreg.

[0015] According to the above-mentioned configuration, the fiber reinforced resin obtained by curing the prepreg, i.e., the finished product, is used as the rigid plate. According to this configuration, since the rigid plate can be used as an upper mold during molding of the fiber reinforced resin, the prepreg and the fiber reinforced resin after the curing can be molded following the shape of the upper mold.

[0016] In the above-mentioned configuration, the step of placing the adhesive may include a step of placing the substrate in a mold having a chamber with an opening at the top. In this case, the mold is provided with a degassing port for drawing a vacuum in the chamber during the step of drawing a vacuum.

[0017] When a degassing port is provided in a covering member such as a vacuum bag, the covering member may thermally shrink during heat treatment, which may result in the degassing port coming off the covering member. In contrast, in the above configuration, the degassing port is provided in the mold, which prevents the port from coming off during heat treatment.

[0018] In the above configuration, the covering member and the rigid plate may be integrated together.

[0019] According to the above-mentioned configuration, the work of placing the rigid plate on the prepreg and the work of covering the laminate with the covering member can be performed at the same time, thereby shortening the work time. Effect of the Invention

[0020] According to the method for manufacturing a joined component including fiber-reinforced resin disclosed in this specification, it is possible to suppress the transfer of wrinkles generated in a covering member such as a vacuum bag to the fiber-reinforced resin. [Brief description of the drawings]

[0021] [Figure 1] 1A to 1C are diagrams illustrating a joined component manufactured by the method according to the present embodiment. [Diagram 2] FIG. 2 is an exploded perspective view illustrating materials, processing tools, and the like used in manufacturing the joining component according to the present embodiment. [Diagram 3] 3 is a cross-sectional view taken along line AA in FIG. 2. [Figure 4] 1A to 1C are diagrams illustrating a manufacturing process (1 / 8) of a joint component according to the present embodiment. [Diagram 5] 10A to 10C are diagrams illustrating a manufacturing process (2 / 8) of the joined component according to the present embodiment. [Figure 6]11A to 11C are diagrams illustrating a manufacturing process (3 / 8) of the joined component according to the present embodiment. [Figure 7] 11A to 11C are diagrams illustrating a manufacturing process (4 / 8) of the joined component according to the present embodiment. [Figure 8] 11A to 11C are diagrams illustrating a manufacturing process (5 / 8) of the joined component according to the present embodiment. [Figure 9] FIG. 9 is a diagram showing another example of FIG. 8. [Figure 10] 6A to 6C are diagrams illustrating a manufacturing process (6 / 8) of the joined component according to the present embodiment. [Figure 11] 7A to 7C are diagrams illustrating a manufacturing process (7 / 8) of the joined component according to the present embodiment. [Figure 12] 8A to 8C are diagrams illustrating a manufacturing process (8 / 8) of the joined component according to the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0022] Hereinafter, a method for manufacturing a joint component including a fiber-reinforced resin according to an embodiment will be described with reference to the drawings. The shapes, materials, quantities, and values ​​described below are examples for the purpose of explanation and can be changed as appropriate according to the specifications of the joint component to be manufactured. In addition, the same reference numerals are used for equivalent elements in all drawings below.

[0023] <Materials and processing supplies for joining parts> 1 illustrates a joint component 120 manufactured by the manufacturing method according to this embodiment. The joint component 120 is formed by joining a fiber reinforced resin 125 to a vehicle component 20, which is a base material.

[0024] The vehicle component 20 is, for example, a vehicle frame member or a reinforcing member thereof, and is required to have a certain degree of rigidity to withstand a collision load. Examples of the frame member include a pillar, a side member, a rocker, etc. Also, an example of the reinforcing member is a bumper reinforcement. The vehicle component 20 is made of, for example, a metal material such as high tensile steel or a light metal.

[0025] By using the joined parts 120, which are made of dissimilar joined parts of metal parts and fiber-reinforced parts such as CFRP, as the skeletal members and reinforcing members of a vehicle, it is possible to reduce the weight while maintaining the load-bearing capacity, compared to the case of metal parts alone.

[0026] For example, when the vehicle component 20 is a front bumper reinforcement, the front surface to which a load is first input during a frontal collision (head-on collision) becomes the joining surface 22 to which the fiber reinforced resin 125 is joined.

[0027] As described later, in the manufacturing method of the joining component 120 according to this embodiment, a heat treatment is performed. The fiber reinforced resin 125 is a mixed material of reinforcing fibers and resin, and the thermal expansion coefficient differs depending on the material. For example, when carbon fibers are used as the reinforcing fibers, the thermal expansion coefficient is −1×10 ―6 / ℃ ~ -3×10 ―6 / ℃ (i.e., it shrinks when heated). On the other hand, when epoxy resin is used as the resin, its thermal expansion coefficient is 15×10 -6 / ℃ ~ 45×10 -6 / °C. These thermal expansion coefficients are reflected in the thermal expansion coefficient of the entire fiber reinforced resin 125. For example, if the fiber reinforced resin 125 is carbon fiber reinforced plastic (CFRP), its thermal expansion coefficient is -1.5×10 -6 ~ 0.5×10 -6 It will be about that amount.

[0028] 2 shows examples of processing tools and materials used in the manufacturing method of the joint part according to the present embodiment. The materials of the joint part 120 include a vehicle part 20 as a base material, an adhesive film 30, and a prepreg 40.

[0029] The processing tools used in the manufacturing method according to this embodiment include a mold 10, a release film 50, a breather cloth 60, a plate 70 (rigid plate), and a bag film 80 (covering member). The manufacturing equipment used in the manufacturing method according to this embodiment includes a vacuum pump 100 and an autoclave 110 (see FIG. 12), which is a molding furnace.

[0030] For convenience of explanation, hereinafter, the adhesive film 30, the prepreg 40, the release film 50, the breather cloth 60, and the plate 70 are collectively referred to as a laminate 150. The laminate 150 and the bag film 80 have, for example, a rectangular shape in the developed state.

[0031] The molding die 10 is a metal mold made of a metal material such as stainless steel. The molding die 10 is, for example, box-shaped, and has a chamber 11 that is open at the top. The chamber 11 contains a vehicle part 20, which is a base material.

[0032] For example, the chamber 11 is divided by a plurality of partition walls, and can accommodate a plurality of vehicle components 20. For example, in the example of Fig. 2, four vehicle components 20 are accommodated in the chamber 11. Furthermore, an adhesive film 30 and a prepreg 40 are laminated and joined onto the joining surface 22 of each vehicle component 20.

[0033] 3 illustrates an AA cross section of FIG. 2. A plurality of support protrusions 14 are formed on the inner side surface 12 and the inner bottom surface 13 of the chamber 11. The vehicle component 20 is supported by the support protrusions 14. Furthermore, by providing the support protrusions 14, a clearance 17 (gap) is formed between the vehicle component 20 and the inner side surface 12 and the inner bottom surface 13. Furthermore, a deaeration path 15 is provided in the inner bottom surface 13. As described later, by providing the clearance 17, the chamber 11 and the internal space of the bag film 80 are connected to each other, and as a result, the inside of the bag film 80 can be evacuated via the deaeration path 15.

[0034] A degassing port 16 is formed at the lower end of the degassing path 15, and is connected to a vacuum pipe 102. Since the connection mechanism between the degassing port 16 and the vacuum pipe 102 is known, the detailed structure is not shown in FIG. 3 etc.

[0035] The vacuum pipe 102 is connected to a vacuum pump 100 (see FIG. 2). As described later, a part of the vacuum pipe 102 (the part on the molding die side) is housed in an autoclave 110 (see FIG. 12), which is a molding furnace. Since the inside of the autoclave 110 is subject to high temperature and pressure as described later, the vacuum pipe 102 is made of, for example, a heat-resistant and load-bearing material. For example, the vacuum pipe 102 is made of a flexible pipe made of SUS material or the like.

[0036] 2 and 3, the adhesive film 30 is a film-like adhesive, and is composed of, for example, a thermoplastic adhesive film (hot melt adhesive film). The dimensions of the adhesive film 30 are set so as to be smaller than the joining surface 22 and equal to or smaller than those of the prepreg 40. For example, the length and width of the adhesive film 30 and the prepreg 40 are set so as to be equal to each other.

[0037] In the following, when describing the dimensions of each processing tool or material, "length" refers to the dimension in the X-axis direction (longitudinal dimension) in Fig. 2. Also, "width" refers to the dimension in the Y-axis direction (shortitudinal dimension) in Fig. 2.

[0038] The prepreg 40 is a soft intermediate material (semi-finished product) in which a bundle of reinforcing fibers is impregnated with an uncured thermosetting resin such as an epoxy resin and formed into a sheet shape. The reinforcing fibers include carbon fibers and glass fibers.

[0039] By subjecting the prepreg 40 to a heat treatment, the thermosetting resin is cured, and a fiber reinforced resin 125 (finished product) as exemplified in Fig. 1 is obtained. Note that a plurality of prepregs 40 may be laminated in manufacturing the joining component 120. For example, 3 to 10 layers of prepregs 40 may be laminated on the adhesive film 30.

[0040] The dimensions of the prepreg 40 are formed to be smaller than the joining surface 22 of the vehicle component 20. For example, the prepreg 40 is formed so that the length and width of the prepreg 40 are 80% or more and 95% or less of the length of the joining surface 22.

[0041] The release film 50 is a film for preventing adhesion between the prepreg 40 and the upper layer, and is made of, for example, a resin film with a silicone coating on the surface, a fluororesin film, or the like.

[0042] The dimensions of the release film 50 are determined, for example, so as to cover all the prepregs 40 in the chamber 11. For example, as illustrated in Fig. 11, the dimensions of the release film 50 are determined so that when all the prepregs 40 are covered with the release film 50, the release film 50 slightly protrudes outward from the prepregs 40 and the adhesive film 30 and terminates inside the clearance 17 of the chamber 11.

[0043] The breather cloth 60 is a member that serves as an air passage during evacuation, and is made of, for example, a nonwoven fabric having a predetermined thickness. The dimensions of the breather cloth 60 are set to be slightly larger than the release film 50, and the periphery thereof is connected to the clearance 17 of the chamber 11 (see FIG. 11).

[0044] The plate 70, which is a rigid plate, is placed on the prepreg 40 with the release film 50 and the breather cloth 60 sandwiched therebetween. The plate 70 functions as a sacrificial layer or a protective layer for suppressing the transfer of wrinkles in the bag film 80 to the prepreg 40 during heat treatment.

[0045] For example, the plate 70 is made of a metal plate such as an aluminum plate having a thickness of 1 mm or more and 5 mm or less. For example, the dimensions of the plate 70 are determined so that it is slightly larger than the prepreg 40. For example, the plate 70 is determined to have a length and width that are longer than the prepreg 40 by a range of 5 mm or more and 15 mm or less. Alternatively, as exemplified in FIG. 9, the plate 70 may be configured with dimensions that cover all the prepregs 40 contained in the chamber 11.

[0046] Furthermore, the plate 70 may be made of a rigid plate material having the same coefficient of thermal expansion as the fiber reinforced resin 125 (see FIG. 1) after the prepreg 40 is heat-treated and hardened. As described later, the prepreg 40 and the plate 70 are pressed against the bag film 80 (or, more theoretically, against atmospheric pressure) by vacuum drawing, and their positions are fixed. Then, during the heat treatment, when the fiber reinforced resin 125 formed by hardening the prepreg 40 and the plate 70 thermally expand within the bag film 80, each member is deformed.

[0047] During this deformation, if the thermal expansion coefficients of both are equal, the deformation modes will be similar. For example, the amount of distortion of both will be equal. This suppresses unevenness in the distribution of contact pressure between the plate 70 and the fiber reinforced resin 125 (for example, the occurrence of one-sided contact). By suppressing unevenness in the distribution of contact pressure, it is possible to suppress unevenness in the thickness of the fiber reinforced resin 125 during cooling to room temperature after heat treatment.

[0048] Note that "equal thermal expansion coefficients" does not necessarily mean that the thermal expansion coefficients of the two are exactly the same. In addition to this, even if there is a difference in the thermal expansion coefficients of the two, as long as the difference falls within the tolerance range according to the required quality, the thermal expansion coefficients are considered to be equal.

[0049] For example, the plate 70 is made of the prepreg 40 after it has been heat-treated and cured, that is, the finished fiber reinforced resin 125. In this respect, the plate 70 can also function as an upper mold for the prepreg 40. For example, when the prepreg 40 is heated to obtain an uneven fiber reinforced resin 125, the plate 70 having the corresponding shape is placed on the breather cloth 60 as an upper mold.

[0050] When such a plate 70 is manufactured from the prepreg 40, for example, the prepreg 40 is cut out in a size suitable for the plate 70 from a roll on which the prepreg 40 is wound. The cut prepreg 40 is further heat-treated individually in an autoclave 110. This cures the thermosetting resin that serves as the binder, and the plate 70 is obtained.

[0051] 2, the bag film 80 is a covering member that covers a laminate 150 made up of the adhesive film 30, the prepreg 40, the release film 50, the breather cloth 60, and the plate 70. The bag film 80 is obtained by, for example, injection molding silicone rubber.

[0052] For example, the bag film 80 is thicker than the vacuum bags conventionally used in the manufacture of joining parts, and can be reused multiple times. As described later, the bag film 80 may heat shrink during the heating process and wrinkles may occur in some parts of the bag film 80, but by inserting the plate 70 between the prepreg 40 and the bag film 80, the wrinkles in the bag film 80 are prevented from being transferred to the prepreg 40 (and the fiber-reinforced resin).

[0053] The bag film 80 has a three-dimensional shape including a main body portion 82, a side wall portion 84, a step portion 86, and a seal portion 88. The main body portion 82 is disposed on the laminate. The main body portion 82 is formed, for example, to have the same dimensions as the length of the plate 70. For example, the main body portion 82 is thinner than the seal portion 88, and has higher elasticity than the seal portion 88. Furthermore, by making the main body portion 82 relatively thin, light transmittance is obtained in the main body portion 82, and an operator can visually check the laminate 150 inside the bag film 80 from the outside.

[0054] 3 and the bag film 80 covering it are evacuated by a vacuum pump 100 before being placed in an autoclave 110. At this time, an operator can check the position of the plate 70 from the main body 82 of the bag film 80 and, if necessary, interrupt the evacuation to correct the position of the plate 70.

[0055] Alternatively, the bag film 80 may be integrated with the plate 70. For example, the plate 70, which is a rigid plate, is joined to the back surface of the main body 82, that is, the surface facing the laminate 150. This allows the operation of placing the plate 70 on the prepreg 40 and the operation of covering the laminate 150 with the bag film 80 to be performed at the same time, thereby shortening the operation time.

[0056] 2 and 3, side walls 84 are erected from the four sides of a rectangular main body 82. The side walls 84 extend, for example, perpendicularly (in the Z-axis direction) to the surface of the main body 82. A step 86 is provided at the lower end of the side walls 84. The step 86 is formed to cover (absorb) the step structure formed by the breather cloth 60 and the release film 50, for example.

[0057] Furthermore, a seal portion 88 is connected to the outer end of the step portion 86. The seal portion 88 is a frame-like structure provided on the outer edge (four sides) of the rectangular bag film 80, and is formed with dimensions such that it does not cover the clearance 17 of the chamber 11, as illustrated in Fig. 11 for example. For example, the inner edge of the seal portion 88 is formed with dimensions that match the outer edge of the clearance 17 of the chamber 11 or exceed this outward.

[0058] Furthermore, the sealed portion 88 has a sufficient sealing margin with the sealing surface 19 of the forming mold 10 when a vacuum is drawn. For example, the sealed portion 88 is formed so that the lower surface of the sealed portion 88 (in other words, the surface that comes into contact with the sealing surface 19) has a dimension of 10 mm or more around the entire circumference of the bag film 80.

[0059] 12, autoclave 110, which is a molding furnace, performs heat treatment under high temperature and high pressure conditions. Although not shown in FIG. 12, autoclave 110 may be provided with a compressor that introduces compressed air into autoclave 110.

[0060] The structure and function of autoclave 110 are known, so only a brief description will be given here. Autoclave 110 has a stage 112 on which mold 10 is placed within its furnace. Autoclave 110 also has a heater 116 for heating the air within the furnace, and a fan 114 for circulating the air. Furthermore, vacuum pipe 102 has one end connected to degassing port 16 of mold 10 and the other end connected to vacuum pump 100 outside the furnace.

[0061] <Manufacturing process for joining parts> 4 to 12 show an example of a manufacturing process of the joining component 120 according to this embodiment. Note that, in the following, this manufacturing process is described as a so-called manual operation by an operator or the like, but a part or the entire process may be performed by a robot or the like. Note that, in the following, a fiber reinforced resin 125, which is a finished product of the prepreg 40, is used as the plate 70.

[0062] 4, a vehicle part 20, which is a substrate, is accommodated in a chamber 11 of a mold 10. Furthermore, an adhesive film 30 is laminated on a joining surface 22 exposed from the chamber 11. For example, the center position of the joining surface 22 and the center position of the adhesive film 30 are aligned, and then the adhesive film 30 is laminated on the joining surface 22.

[0063] 5, the prepreg 40 is laminated on the adhesive film 30. In the same manner as above, the prepreg 40 is laminated on the adhesive film 30 with the centers of the adhesive film 30 and the prepreg 40 aligned.

[0064] 6, a release film 50 is hung so as to cover all of the prepregs 40 in the chamber 11. At this time, as illustrated in Fig. 11, the outer edge of the release film 50 is positioned so as to be located closer to the center than the clearance 17 of the chamber 11. For example, the outer edge of the release film 50 is attached to the joining surface 22 with a heat-resistant sealant tape or the like.

[0065] 7, the release film 50 is covered with the breather cloth 60. At this time, the outer edge of the breather cloth 60 is positioned so as to be connected to the upper end of the clearance 17 of the chamber 11, as shown in FIG.

[0066] 8, a plate 70 (here, fiber reinforced resin 125 which is a finished product of prepreg 40) is placed on breather cloth 60. The center position of plate 70 is aligned with the center position of the underlying prepreg 40. In this alignment, even if it is difficult to visually confirm plate 70, for example, if breather cloth 60 is made of opaque nonwoven fabric, a convex shape (bulge) is formed in breather cloth 60 at a position corresponding to prepreg 40. Based on this convex shape, a worker or the like can confirm the position of prepreg 40, and thus plate 70, which is a rigid plate, is placed on prepreg 40.

[0067] 10, a laminate 150 consisting of the adhesive film 30, the prepreg 40, the release film 50, the breather cloth 60, and the plate 70 is covered with a bag film 80, which is a covering member. As illustrated in FIG. 11, the bag film 80 is positioned so that the inner edge of the seal portion 88 coincides with the outer edge of the clearance 17 of the chamber 11 or is positioned outside of it.

[0068] In order to maintain the sealing performance between the sealing portion 88 of the bag film 80 and the sealing surface 19 of the mold 10, the sealing portion 88 may be attached in a frame shape onto the sealing surface 19 using a heat-resistant sealant tape or the like.

[0069] Thereafter, the vacuum pump 100 is driven by an operator or the like, and the inside covered with the bag film 80 is evacuated via the chamber 11 and the vacuum pipe 102. During this evacuation, the breather cloth 60 serves as an air flow path, so that the prepreg 40 covered with the breather cloth 60 is evenly pressurized over its surface.

[0070] The vacuum-drawn laminate 150 is placed in an autoclave 110 (see FIG. 12) which is a molding furnace together with the vehicle component 20 as the base material, the vacuum-drawn bag film 80, and the molding die 10, and is subjected to a heat treatment. The adhesive film 30 melts by the heat treatment, and the prepreg 40 and the vehicle component 20 are joined (bonded). Furthermore, the thermosetting resin of the prepreg 40 hardens, thereby obtaining a fiber-reinforced resin 125 (see FIG. 1) having the desired strength.

[0071] At this time, the bag film 80, particularly the main body 82 (see FIG. 2), slightly shrinks due to heat. For example, the boundary between the main body 82 and the side wall 84, which is the transition area of ​​thickness, shrinks. However, the bag film 80 is thicker than the vacuum bags conventionally used in the manufacture of joining parts, and the scale of thermal shrinkage is suppressed compared to the vacuum bags. Therefore, the number and length of wrinkles generated in the bag film 80 are smaller than those of the conventional vacuum bags.

[0072] Furthermore, in the manufacturing method for the joining component according to the present embodiment, even if wrinkles occur in the bag film 80, the plate 70 is sandwiched between the prepreg 40 and the main body 82, so that the transfer of the wrinkles in the main body 82 to the prepreg 40 is suppressed. Therefore, even after wrinkles occur in the bag film 80, the bag film 80 can be repeatedly used to manufacture the joining component 120.

[0073] Heat treatment in the autoclave 110 causes the fiber reinforced resin 125 in which the prepreg 40 has hardened and the plate 70 to deform due to thermal expansion. At this time, since the thermal expansion coefficients of the fiber reinforced resin 125 and the plate 70 are equal, the manner in which the two undergo thermal deformation is the same. This suppresses bias in the distribution of surface pressure between the fiber reinforced resin 125 and the plate 70 (for example, suppresses one-sided contact). By suppressing bias in the in-plane distribution, it becomes possible to suppress bias in the thickness distribution of the fiber reinforced resin 125.

[0074] In this embodiment, an autoclave 110 that applies pressure and heat is used as the forming furnace. However, a forming furnace that has a heating function but does not have a pressure function may be used, in other words, the joining part 120 may be formed only by heating without applying pressure. [Explanation of symbols]

[0075] 10 molding die, 11 chamber, 15 degassing passage, 16 degassing port, 20 vehicle part (substrate), 22 joining surface of vehicle part, 30 adhesive film (adhesive), 40 prepreg, 50 release film, 60 breather cloth, 70 plate (rigid plate), 80 bag film (covering member), 82 main body portion of bag film, 84 side wall portion of bag film, 86 step portion of bag film, 88 seal portion of bag film, 100 vacuum pump, 110 autoclave, 120 joining part, 125 fiber reinforced resin, 150 laminate.

Claims

1. A method for manufacturing a mold comprising: placing a substrate in a mold having a chamber that is open at the top; disposing an adhesive on a surface of the substrate; A step of laminating a prepreg in which reinforcing fibers are impregnated with an uncured thermosetting resin on the adhesive; A step of disposing a rigid plate on the prepreg, and further covering a laminate including the adhesive, the prepreg, and the rigid plate with a covering member; A step of evacuating the inside covered with the covering member; a step of heat-treating the substrate, the covering member that has been evacuated, and the laminate covered with the covering member; Including, a degassing passage is provided on an inner bottom surface of the chamber of the mold, and a degassing port is provided in the degassing passage to evacuate the inside of the chamber during the evacuation step; Furthermore, support protrusions are formed on the inner side surface and the inner bottom surface of the chamber of the mold, and a clearance is formed between the substrate and the inner side surface and the inner bottom surface of the chamber by the support protrusions, In the step of covering the laminate with the covering member, an outer edge of the clearance is surrounded by an inner edge of the covering member. A method for producing a bonded component comprising fiber-reinforced resin.

2. A method for producing a joined component containing a fiber-reinforced resin according to claim 1, The rigid plate has the same thermal expansion coefficient as the fiber reinforced resin from which the prepreg is cured. A method for producing a bonded component comprising fiber-reinforced resin.

3. A method for producing a joined part containing a fiber-reinforced resin according to claim 2, The rigid plate is a fiber reinforced resin in which the prepreg is hardened. A method for producing a bonded component comprising fiber-reinforced resin.

4. A method for manufacturing a joined part containing a fiber-reinforced resin according to any one of claims 1 to 3, The covering member and the rigid plate are integrated together. A method for producing a bonded component comprising fiber-reinforced resin.

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