Forming method

Abstract

To provide a hybrid molded body, a molding device, and a molding method that can suppress the occurrence of a leak path at a boundary between a prepreg and a resin.SOLUTION: A hybrid molded body 10 according to an embodiment is the hybrid molded body 10 in which a prepreg 11 made of reinforced fiber plastic and a resin 12 are integrally molded, and has a covering portion 13a at a boundary between the prepreg 11 and the resin 12, where the resin 12 covers at least a portion of the prepreg 11.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a hybrid molded article, a molding apparatus, and a molding method. [Background technology]

[0002] Patent Document 1 discloses a hybrid molding method in which, in order to combine a press material to be press-molded by a lower mold and an upper mold with an injection material to be injection-molded, the press material is placed on the gate of the lower mold, the upper mold is moved toward the lower mold, and the injection material is injected from the gate just before or at the same time as the upper mold reaches the bottom dead center. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2016-196115 Summary of the Invention [Problem to be solved by the invention]

[0004] The inventors have discovered the following problems with hybrid molded bodies, molding devices, and molding methods. Hybrid molded bodies molded using the molding method of Patent Document 1 have a butt-joint structure at the joint between a press material such as prepreg and an injection material such as resin. The edges of the continuous fiber-reinforced sheet-like fiber-reinforced plastic that makes up the prepreg can sometimes experience fraying of the fibers. In this state, the resin may not completely fill the joint, potentially making it impossible to achieve the desired joint strength at the joint, which is the boundary between the prepreg and the resin. This could lead to the risk of external forces or shear stresses occurring in the joint creating a leak path, such as a crack, originating from the joint.

[0005] The present invention has been made in consideration of the above problems, and provides a hybrid molded body, a molding apparatus, and a molding method that can suppress the occurrence of leak paths at the boundary between the prepreg and the resin. [Means for solving the problem]

[0006] A hybrid molded body according to one embodiment of the present invention is A hybrid molded body in which a prepreg made of reinforced fiber plastic and a resin are integrally molded, At the boundary between the prepreg and the resin, the resin has a covering portion that covers at least a part of the prepreg.

[0007] A hybrid molded article according to one aspect of the present invention includes a covering portion at the boundary between the prepreg and the resin, where the resin covers at least a portion of the prepreg. This configuration allows the butted portion between the prepreg and the resin to be covered, and also generates a shear force at the boundary between the prepreg and the resin, thereby suppressing the occurrence of a leak path at the boundary between the prepreg and the resin when an external force or shear stress is applied.

[0008] The width of the covering portion may be equal to or greater than the amount of misalignment of the prepreg, and the width and thickness of the covering portion may be set so that the shear strength at the boundary between the prepreg and the resin is equal to or greater than the shear stress. With this configuration, the covering portion can reliably cover the prepreg, and the occurrence of a leak path at the boundary between the prepreg and the resin can be suppressed.

[0009] A molding apparatus for molding a hybrid molded body according to one aspect of the present invention includes: A first mold and a second mold are provided for press-processing the prepreg, At least one of the opposing surfaces of the first mold and the second mold has a recess for molding the covering portion.

[0010] In a molding apparatus for molding a hybrid molded article according to one aspect of the present invention, at least one of the opposing surfaces of the first mold and the second mold has a recess for molding a covering portion. This configuration makes it possible to mold a hybrid molded article having a covering portion at the boundary between the prepreg and the resin. This makes it possible to suppress the occurrence of leak paths at the boundary between the prepreg and the resin.

[0011] At least one of the first mold and the second mold may include the resin injection means. With this configuration, the covering portion can be molded on either the surface on the first mold side or the surface on the second mold side, or on both the surface on the first mold side and the surface on the second mold side.

[0012] A molding apparatus for molding a hybrid molded body according to one aspect of the present invention includes: a first mold provided with a resin injection means; A second mold on which the prepreg is placed, The injection means starts injecting the resin onto the prepreg when the distance between the first mold and the second mold reaches a predetermined distance.

[0013] In a molding apparatus for molding a hybrid molded product according to one aspect of the present invention, the injection means starts injecting resin onto the prepreg when the distance between the first mold and the second mold reaches a predetermined distance. Because the entire prepreg is covered with resin, the boundary between the prepreg and the resin can be covered. This prevents leaks from occurring at the boundary between the prepreg and the resin.

[0014] A method for molding a hybrid molded body according to one aspect of the present invention includes the steps of: A molding method for integrally molding a prepreg and a resin to form the hybrid molded article according to claim 1 or 2, The hybrid molded body is molded by injecting the resin so that the resin covers at least a portion of the prepreg at the boundary between the prepreg and the resin after press molding.

[0015] In a method for molding a hybrid molded body according to one aspect of the present invention, a resin is injected to mold a hybrid molded body so that the resin covers at least a portion of the prepreg at the boundary between the prepreg and the resin after press molding, thereby suppressing the occurrence of a leak path at the boundary between the prepreg and the resin.

[0016] A method for molding a hybrid molded body according to one aspect of the present invention includes the steps of: The method includes a step of bringing a first mold relatively close to a second mold in which a prepreg is placed, and when the distance between the first mold and the second mold reaches a predetermined distance, injecting the resin to form the hybrid molded body.

[0017] In a method for molding a hybrid molded body according to one aspect of the present invention, a first mold is brought relatively close to a second mold in which a prepreg is placed, and when the distance between the first mold and the second mold reaches a predetermined distance, resin is injected to mold the hybrid molded body. Since the entire prepreg is covered with resin, the boundary between the prepreg and the resin can be covered. This prevents the occurrence of leak paths at the boundary between the prepreg and the resin.

[0018] A method for molding a hybrid molded body according to one aspect of the present invention includes the steps of: a step of bringing the first mold relatively close to the second mold in which the prepreg is arranged, and press-forming the prepreg; After the press working, the first mold is moved in a direction away from the second mold, and when the distance between the first mold and the second mold reaches a predetermined distance, the resin is injected to form the hybrid molded body.

[0019] In a method for molding a hybrid molded body according to one aspect of the present invention, after press working, the first mold is moved in a direction away from the second mold, and when the distance between the first mold and the second mold reaches a predetermined distance, resin is injected to mold the hybrid molded body. Since the entire prepreg is covered with resin, the boundary between the prepreg and the resin can be covered. This prevents the occurrence of leak paths at the boundary between the prepreg and the resin. [Effects of the Invention]

[0020] The present invention can provide a hybrid molded article, a molding apparatus, and a molding method that can suppress the occurrence of leak paths at the boundary between the prepreg and the resin. [Brief explanation of the drawings]

[0021] [Figure 1] 1 is a plan view showing a hybrid molded body according to a first embodiment. [Figure 2] FIG. 2 is a cross-sectional view taken along line II-II in FIG. [Figure 3] 1 is a front cross-sectional view showing a hybrid molding device according to a first embodiment. [Figure 4] 5 is a diagram showing the operation of the hybrid molding device according to the first embodiment. FIG. [Figure 5] 5 is a diagram showing the operation of the hybrid molding device according to the first embodiment. FIG. [Figure 6] FIG. 10 is a plan view showing a hybrid molded body according to a second embodiment. [Figure 7] FIG. 7 is a cross-sectional view taken along line VII-VII in FIG. [Figure 8] FIG. 10 is a front cross-sectional view showing a hybrid molding device according to a second embodiment. [Figure 9] FIG. 10 is a diagram illustrating the operation of the hybrid molding device according to the second embodiment. [Figure 10] FIG. 10 is a diagram showing the operation of the hybrid molding device according to the third embodiment. [Figure 11] FIG. 10 is a diagram showing the operation of the hybrid molding device according to the third embodiment. [Figure 12] FIG. 10 is a front cross-sectional view showing a hybrid molded body according to a fourth embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0022] Specific embodiments of the present invention will be described in detail below with reference to the drawings. The right-handed xyz coordinate system shown in the figure is for convenience in explaining the positional relationship of the components. Unless otherwise specified, the positive z-axis direction is vertically upward. The xy plane is a horizontal plane. The hybrid molded body described in this specification can be used, for example, as a battery case part.

[0023] <First Embodiment> First, a hybrid molded body according to this embodiment will be described with reference to Figures 1 and 2. Next, a hybrid molding apparatus according to this embodiment will be described with reference to Figure 3. Furthermore, a molding method for a hybrid molded body according to this embodiment will be described with reference to Figures 4 and 5.

[0024] Fig. 1 is a plan view showing a hybrid molded body according to embodiment 1. Note that the hatching shown in Fig. 1 is added to make each part easier to see, and does not represent a cross-sectional view.

[0025] As shown in Fig. 1, the hybrid molded body 10 is a molded body in which a prepreg 11 made of fiber-reinforced plastic and a resin 12 are integrally molded. At the boundary between the prepreg 11 and the resin 12, the resin 12 has a covering portion 13a that covers at least a portion of the prepreg 11. The covering portion 13a is a part of the covering body 13. Details of the covering body 13 and the covering portion 13a will be described later using Fig. 2. In Fig. 1, the prepreg 11 is shown with grid-like hatching, and the covering body 13 and the covering portion 13a are shown with diagonal lines slanting upward to the right.

[0026] Here, the prepreg 11 is a continuous fiber-reinforced sheet obtained by impregnating a type of fiber-reinforced plastic, such as carbon fiber reinforced plastic (CFRP) or glass fiber reinforced plastic (GFRP), with a thermoplastic resin or a thermosetting resin. The resin 12 is a thermoplastic resin such as acrylic resin, polyethylene, polypropylene, polyvinyl chloride, or polystyrene. The prepreg 11 is processed into any desired shape and molded by press working. The resin 12 is molded by injection molding. In other words, the hybrid molded product 10 is hybrid molded by press working and injection molding.

[0027] 2 is a cross-sectional view taken along line II-II in FIG. 1. As shown in FIG. 2, the joint surface B between prepreg 11 and resin 12 has a butt-joint structure. Covering body 13 is a part of resin 12. Covering body 13 is provided so as to protrude in the positive direction of the z-axis from the xy plane on the positive side of the z-axis of prepreg 11 and resin 12. Covering portion 13a of covering body 13 covers at least a part of the xy plane on the positive side of the z-axis of prepreg 11. In other words, covering body 13 covers the butt-joint portion of joint surface B between prepreg 11 and resin 12.

[0028] As shown in Fig. 2, the width W of the covering portion 13a is set to be equal to or greater than the amount of misalignment of the prepreg 11. Here, the amount of misalignment refers to the amount of misalignment in the xy plane when the prepreg 11 is placed in a molding device when molding the hybrid molded body 10 according to this embodiment. More specifically, this will be described later with reference to Fig. 3. In the hybrid molded body 10 according to this embodiment, as an example, when the amount of misalignment is ±10 mm, the width W of the covering portion 13a can be 11 mm and the thickness T can be 3 mm, but this is not limited to this.

[0029] Here, the definitions of the width W and thickness T of the covering portion 13a shown in FIG. 2 will be explained. The width W and thickness T of the covering portion 13a shown in FIG. 2 are set so that the shear strength at the boundary between the prepreg 11 and the resin 12 is equal to or greater than the shear stress. Here, the shear strength at the boundary between the prepreg 11 and the resin 12 varies depending on the strength of the materials of the prepreg 11 and the resin 12 themselves and the width W and thickness T of the covering portion 13a. The shear stress is calculated by dividing the shear force generated by applying tensile forces in the positive and negative x-axis directions to the hybrid molded body 10 by the area of ​​the boundary between the prepreg 11 and the covering portion 13a. The width W and thickness T of the covering portion 13a are set so that the shear stress is equal to or less than the shear strength.

[0030] Furthermore, the thickness T can be defined as follows. When the resin 12 is injected during molding of the hybrid molded body 10 according to this embodiment, the force of the injection may cause the resin 12 to infiltrate into the xy plane on the negative side of the z axis of the prepreg 11. The thickness T of the covering portion 13a can be set to a thickness that prevents the prepreg 11 from protruding from the xy plane on the positive side of the z axis of the covering portion 13a, even when the resin 12 infiltrates into the xy plane on the negative side of the z axis of the prepreg 11 and the prepreg 11 is lifted in the positive direction of the z axis by the resin 12.

[0031] The location where the covering portion 13a is to be provided may be determined in advance using computer simulation such as CAE (Computer Aided Engineering). For example, the locations where shear stress may occur in the hybrid molded body 10 may be identified in advance using CAE, and the covering portion 13a may be provided only at those locations.

[0032] 2, the shape of the covering 13 other than the covering portion 13a is rectangular in the front cross section, but it may be any shape that protrudes in the positive direction of the z axis from the xy plane on the z axis positive side of the prepreg 11 and the resin 12. Specifically, for example, it may be triangular in the front cross section, protruding at an angle from the xy plane on the z axis positive side of the resin 12 toward the right end of the covering portion 13a. Furthermore, the corners of the rectangular shape of the covering portion 13a in the front cross section may be rounded.

[0033] In this way, the hybrid molded article according to the present embodiment can cover the butt joint between the prepreg and resin, and by generating a shear force at the boundary between the prepreg and resin, it is possible to suppress the occurrence of a leak path at the boundary between the prepreg and resin when an external force or shear stress is generated. Furthermore, because the hybrid molded article according to the present embodiment can cover the butt joint between the prepreg and resin, it can also improve airtightness.

[0034] Furthermore, the width of the covering portion of the hybrid molded article according to this embodiment may be equal to or greater than the amount of misalignment of the prepreg, and the width and thickness of the covering portion may be set so that the shear strength at the boundary between the prepreg and the resin is equal to or greater than the shear stress. This configuration allows the covering portion to reliably cover the prepreg, and suppresses the occurrence of leak paths at the boundary between the prepreg and the resin.

[0035] Next, the hybrid molding device according to the present embodiment will be described with reference to Fig. 3. Fig. 3 is a front cross-sectional view showing the hybrid molding device according to the first embodiment.

[0036] As shown in FIG. 3, the hybrid molding apparatus 20 according to this embodiment includes a first mold 21 and a second mold 22 for press-forming the prepreg 11. In FIG. 3, the xy plane on the negative side of the z axis of the first mold 21 includes the recess 21a for molding the covering portion 13a shown in FIG. 2, but this is not limited thereto. For example, the xy plane on the positive side of the z axis of the second mold 22 may include the recess for molding the covering portion 13a, or both the first mold 21 and the second mold 22 may include the recess. In other words, in the molding apparatus 20 according to this embodiment, at least one of the opposing surfaces of the first mold 21 and the second mold 22 includes the recess for molding the covering portion 13a.

[0037] Here, when placing the prepreg 11 at a desired position on the second mold 22, misalignment in the xy plane from the desired position may occur. The expected amount of misalignment can be determined by CAE. The width W1 is set so that the recess 21a can cover the prepreg 11 even when the expected amount of misalignment of the prepreg 11 is maximized. The width W1 is set to match the width W of the covering portion 13a shown in FIG. 2. The height T1 of the recess 21a is set to match the height T of the covering portion 13a shown in FIG. 2. Furthermore, in the hybrid molding apparatus 20 according to this embodiment, at least one of the first mold 21 and the second mold 22 may be provided with an injection means (not shown) for injecting the resin 12.

[0038] As described above, in the hybrid molding apparatus according to this embodiment, at least one of the opposing surfaces of the first mold and the second mold has a recess for molding the covering portion. This configuration makes it possible to mold a hybrid molded article having a covering portion at the boundary between the prepreg and the resin. This makes it possible to suppress the occurrence of leak paths at the boundary between the prepreg and the resin.

[0039] At least one of the first mold and the second mold may be provided with a resin injection means. With this configuration, the covering portion can be molded on either the surface on the first mold side or the surface on the second mold side, or on both the surface on the first mold side and the surface on the second mold side.

[0040] Next, a method for molding a hybrid molded body will be described with reference to Figures 4 and 5. Figures 4 and 5 are diagrams showing the operation of the hybrid molding apparatus according to embodiment 1. As shown in Figure 4, the first mold 21 is moved in a direction approaching the second mold 22 (negative direction of the z-axis, indicated by the hollow arrow), and the prepreg 11 is press-formed into a desired shape.

[0041] 5, resin 12 is injected from an injection means so that resin 12 covers at least a portion of prepreg 11 at the boundary between prepreg 11 and resin 12. Note that resin 12 is in a molten state when injected, and hardens after filling the space between first mold 21 and second mold 22. In this way, covering body 13 having covering portion 13a is formed in recess 21a, and hybrid molded body 10 according to this embodiment as shown in FIG.

[0042] In this way, in the method for molding a hybrid molded body according to the present embodiment, the resin is injected to mold the hybrid molded body so that the resin covers at least a portion of the prepreg at the boundary between the prepreg and the resin after press molding, thereby suppressing the occurrence of leak paths at the boundary between the prepreg and the resin.

[0043] <Embodiment 2> Next, a hybrid molded body according to this embodiment will be described with reference to Fig. 6 and Fig. 7. Subsequently, a hybrid molding apparatus according to this embodiment will be described with reference to Fig. 8. Furthermore, a molding method for a hybrid molded body according to this embodiment will be described with reference to Fig. 9.

[0044] Fig. 6 is a plan view showing a hybrid molded body according to embodiment 2. The hatching in Fig. 6 is added to make each part easier to see and does not represent a cross-sectional view. The hybrid molded body 30 according to this embodiment differs from the hybrid molded body 10 according to embodiment 1 shown in Fig. 1 in that the prepreg 31 is not press-processed and the shape of the covering portion 33 is different. The materials constituting the prepreg 31 and resin 32 of the hybrid molded body 30 are the same as those in embodiment 1, so a description thereof will be omitted here.

[0045] 6, the hybrid molded body 30 is a molded body in which a prepreg 31 made of fiber-reinforced plastic and a resin 32 are integrally molded. The prepreg 31 is not press-processed. The resin 32 has a covering portion 33 that covers the entire prepreg 31 (indicated by diagonal lines slanting upward to the right).

[0046] Fig. 7 is a cross-sectional view taken along line VII-VII in Fig. 6. As shown in Fig. 7, covering portion 33 is a part of resin 32, and covering portion 33 covers the entire xy plane on the positive side of the z axis of prepreg 31.

[0047] In this way, in the hybrid molded article according to the present embodiment, the prepreg is entirely covered with resin, so that the boundary between the prepreg and the resin can be covered, thereby suppressing the occurrence of a leak path at the boundary between the prepreg and the resin.

[0048] Next, a hybrid molding apparatus according to this embodiment will be described with reference to Fig. 8. Fig. 8 is a front cross-sectional view showing a hybrid molding apparatus 40 according to embodiment 2. The hybrid molding apparatus 40 according to this embodiment differs from embodiment 1 in that the injection means 43 is provided only in the first mold 41.

[0049] As shown in Fig. 8, the first mold 41 includes an injection means 43 that injects the resin 32. The prepreg 31 is placed on the second mold 42. The injection means 43 includes a sprue 44 and a gate 45. The sprue 44 is a path through which the resin 32 passes, and the gate 45 can adjust the speed at which the resin 32 flows into the mold. The injection means 43 may include a runner between the sprue 44 and the gate 45.

[0050] In the hybrid molding apparatus 40 according to this embodiment, the injection means 43 starts injecting the resin 32 onto the prepreg 31 when the distance between the first mold 41 and the second mold 42 reaches a predetermined distance. The resin 32 is in a molten state during injection, and hardens after filling the space between the first mold 41 and the second mold 42. Since the entire prepreg 31 is covered with the resin 32, the boundary between the prepreg 31 and the resin 32 can be covered. This prevents leaks from occurring at the boundary between the prepreg 31 and the resin 32.

[0051] 9 is a diagram showing the operation of a hybrid molding apparatus according to the second embodiment. In the molding method for a hybrid molded body according to this embodiment, the prepreg 31 is not press-processed. First, the first mold 41 is brought relatively close to the second mold 42 in which the prepreg 31 is placed. When the distance between the first mold 41 and the second mold 42 reaches a predetermined distance G, the injection means 43 begins injecting the resin 32 onto the prepreg 31. The resin 32 is in a molten state when injected, and hardens after filling the space between the first mold 41 and the second mold 42.

[0052] Here, the predetermined gap G can be any gap at which the prepreg 31 is not exposed, i.e., at which no leak path is formed. Furthermore, for example, the prepreg 31 is placed on the second mold 42, and the injection means is provided in the first mold 41, so that the prepreg 31 is pressed against the second mold 42 by the injection pressure of the resin 32. Therefore, it is possible to prevent the prepreg 31 from being lifted in the z-axis direction.

[0053] In this way, a covering portion 33 is formed that has a thickness at a predetermined interval G and covers the entire xy plane on the positive side of the z axis of the prepreg 31, and a hybrid molded body according to this embodiment as shown in Figures 6 and 7 is formed.

[0054] In the method for molding a hybrid molded body according to this embodiment, a first mold is brought relatively close to a second mold in which a prepreg is placed, and when the distance between the first mold and the second mold reaches a predetermined distance, resin is injected to mold the hybrid molded body. Because the entire prepreg is covered with resin, the boundary between the prepreg and the resin can be covered. This prevents the occurrence of leak paths at the boundary between the prepreg and the resin. Furthermore, by shaping the covering portion so that it covers the entire xy plane on the positive side of the z axis of the prepreg, a hybrid molded body having a covering portion can be more easily molded.

[0055] In this embodiment, the hybrid molding method according to this embodiment can also be performed using a molding apparatus in which the first mold 21 of the molding apparatus 20 of Embodiment 1 shown in FIG. 3 is provided with an injection means. This will be described with reference to FIG. 3. In this embodiment, the prepreg 11 is not press-formed. First, the first mold 21 is brought relatively close to the second mold 22 on which the prepreg 11 is placed. When the distance between the first mold 21 and the second mold 22 reaches a predetermined distance, the injection means begins injecting the resin 12 onto the prepreg 11. The resin 12 is in a molten state during injection, and hardens after filling the space between the first mold 21 and the second mold 22.

[0056] Here, the predetermined distance can be, for example, a distance at which at least a portion of the xy plane on the negative side of the z axis of the first mold 21 contacts at least a portion of the xy plane on the positive side of the z axis of the prepreg 11, as shown in Fig. 4. In this way, a hybrid molded article can be molded that includes a covering portion 13a that covers at least a portion of the prepreg 11, as shown in Fig. 5. This makes it possible to prevent leak paths from occurring at the boundary between the prepreg and the resin.

[0057] <Third Embodiment> Next, a molding method for a hybrid molded body according to the present embodiment will be described with reference to Figures 10 and 11. Figures 10 and 11 are diagrams showing the operation of a hybrid molding apparatus according to the third embodiment. A molding apparatus 60 used in the molding method according to the present embodiment differs from the molding apparatus 40 described above in the second embodiment in that the prepreg 51 is press-processed and in the position where an injection means for injecting resin is provided. In the present embodiment, the injection means (not shown) may be provided in at least one of the first mold 61 and the second mold 62, or may be provided in both. The materials constituting the prepreg 51 and resin 52 of the hybrid molded body are the same as those in the first embodiment, and therefore will not be described here.

[0058] As shown in FIG. 10, the first mold 61 is moved relatively close to the second mold 62 in which the prepreg 51 is placed (in the negative direction of the z-axis, indicated by the hollow arrow), and the prepreg 51 is press-formed. Next, refer to FIG. 11. After press-forming, the first mold 61 is moved relatively away from the second mold 62 (in the positive direction of the z-axis, indicated by the hollow arrow). When the gap G2 between the first mold 61 and the second mold 62 reaches a predetermined gap, the resin 52 is injected to form a hybrid molded body including the covering portion 53. The resin 52 is in a molten state when injected, and hardens after filling the gap between the first mold 61 and the second mold 62.

[0059] Here, the predetermined gap G2 can be any gap that does not expose the prepreg 51, i.e., does not form a leak path. Furthermore, for example, when the prepreg 51 is placed on the second mold 62 and the injection means is provided in the first mold 61, the prepreg 51 is pressed against the second mold 62 by the injection pressure of the resin 52. Therefore, it is possible to prevent the prepreg 51 from being lifted in the z-axis direction.

[0060] In the method for molding a hybrid molded body according to this embodiment, after press working, the first mold is moved in a direction away from the second mold, and when the distance between the first mold and the second mold reaches a predetermined distance, resin is injected to mold the hybrid molded body. Since the entire prepreg is covered with resin, the boundary between the prepreg and the resin can be covered. This prevents the occurrence of leak paths at the boundary between the prepreg and the resin.

[0061] <Fourth Embodiment> FIG. 12 is a front cross-sectional view showing a hybrid molded body according to the fourth embodiment. The materials constituting the prepreg 71 and resin 72 of the hybrid molded body are the same as those of the first embodiment, and therefore will not be described here. In the molded body 10 of the first embodiment, the covering portion 13a protrudes from the surface of the prepreg 11 on the positive side of the z-axis (see FIG. 2). In contrast, the hybrid molded body 70 according to the present embodiment is formed so that the covering portion 72a does not protrude from the surface 71S of the prepreg 71 on the positive side of the z-axis. In other words, the thickness of the prepreg 71 in the z-axis direction is thin at the boundary between the prepreg 71 and the resin 72.

[0062] As an example of forming the prepreg 71 with a thin thickness in the z-axis direction, for example, the prepreg 71 may be pre-processed to have a thickness 71a and a boundary portion having a thickness 71b that is thinner than the thickness 71a. Alternatively, for example, a process may be performed in which the prepreg 71 having the thickness 71a is press-processed to a thickness 71c, so that the boundary portion has a thickness 71b that is thinner than the thickness 71a. Furthermore, the number of layers of fiber-reinforced plastic that constitute the prepreg 71 may be different between the thicknesses 71a and 71b. Furthermore, a prepreg having a thickness 71b and a prepreg having a thickness 71c may be stacked and molded as a prepreg having a thickness 71a as a whole. Furthermore, a prepreg having a thickness 71b may be folded to form a prepreg having a portion with a thickness 71b and a portion with a thickness 71a.

[0063] The hybrid molded article according to this embodiment is configured so that the joint surfaces of the prepreg and the resin mesh with each other, and therefore it is possible to suppress the occurrence of leak paths at the boundary between the prepreg and the resin.

[0064] The present invention is not limited to the above-described embodiment, and can be modified as appropriate within the scope of the invention. [Explanation of symbols]

[0065] 10 Molded body 10 Hybrid molding 11 Prepreg 12 Resin 13 Covering 13a Covering part 20 Molding equipment 20 Hybrid molding equipment 21 First Type 21a Recess 22 Second Type 30 Hybrid molding 31 Prepreg 32 Resin 33 Covering section 40 Molding equipment 40 Hybrid molding equipment 41 First Type 42 Second Type 43 Injection means 44 sprues Gate 45 51 Prepreg 52 Resin 53 Covering part 60 Molding equipment 61 First Type 62 Second Type 70 Hybrid molding 71 Prepreg 71S side 72 Resin 72a Covering part B Joint surface G interval G2 interval W width W1 width

Claims

1. A molding method for integrally molding a prepreg made of reinforced fiber plastic and a resin to form a hybrid molded body, Injecting the resin so that the resin includes a covering portion that covers at least a part of the prepreg at the boundary portion with the prepreg after press molding, and forming the covering portion in a recess of a molding device to mold the hybrid molded body; a width of the covering portion is equal to or greater than a positional deviation of the prepreg in an xy plane when the prepreg is placed in the molding device during molding; The width and thickness of the covering portion are set so that the shear strength at the boundary between the prepreg and the resin is equal to or greater than the shear stress, The shear stress is a value obtained by dividing the shear force generated by applying a tensile force in the x-axis direction to the hybrid molded body by the area of ​​the boundary portion between the prepreg and the covering portion, the shear strength at the boundary between the prepreg and the resin depends on the strength of the materials of the prepreg and the resin and the width and thickness of the covering portion, the recess is provided on at least one of opposing surfaces of a first mold and a second mold used for press-molding the prepreg, In a state where the prepreg is pressed by the first mold and the second mold, the resin is injected into the recess to form the covering portion. Molding method.

2. A molding method for integrally molding a prepreg made of reinforced fiber plastic and a resin to form a hybrid molded body, a step of bringing a first mold relatively close to a second mold in which a prepreg is arranged, and injecting the resin when the distance between the first mold and the second mold reaches a predetermined distance to mold the hybrid molded body; the resin has a covering portion that covers the z-axis positive side of the entire xy plane of the prepreg, The thickness of the covering portion is set so that the shear strength at the boundary between the prepreg and the resin is equal to or greater than the shear stress, The shear stress is a value obtained by dividing the shear force generated by applying a tensile force in the x-axis direction to the hybrid molded body by the area of ​​the boundary portion between the prepreg and the covering portion, the shear strength at the boundary between the prepreg and the resin depends on the strength of the materials of the prepreg and the resin and the width and thickness of the covering portion, the first die and the second die have a fitting structure, and the predetermined interval is changeable; Molding method.

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