JP2019155850A - Composite material - Google Patents

Abstract

To provide a composite material excellent in light weight and mechanical strength.SOLUTION: A composite material of the present invention is a composite material including: a core member having a layer structure; and a support plate member laminated on a lower surface side of the core member and constituted of a fiber reinforcement resin material obtained by impregnating a reinforcement fiber with a resin, in which the core member has a wall part and a light weight part having a specific gravity smaller than that of the wall part, and the wall part has a nonwoven fabric having a plurality of fiber fillers aligned in substantially parallel, relative to an in-plane direction of the lower surface of the core member.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite material.

  Various studies have been made in the technical development related to fiber resin composite materials. As this type of technology, for example, the technology described in Patent Document 1 is known. Patent Document 1 describes that an aramid honeycomb (aramid sheet 1) containing para-aramid fibers 3 and a binder 4 is used as a fiber resin composite material. In this aramid honeycomb, it is described that the orientation of the fibers (para-aramid fibers 3) on the wall surface of the cell wall 18 is random (FIG. 2 (1), FIG. 3, 4, etc. of Patent Document 1).

JP 2001-277387A

  As a result of investigation by the present inventor, it was found that the composite material described in Patent Document 1 has room for improvement in terms of weight reduction and mechanical strength.

As a result of further examination by the present inventors, by using a core member having a wall part and a lightweight part having a specific gravity smaller than that of the wall part, a support plate member made of a fiber reinforced resin material, and a laminated composite material, It has been found that it is possible to realize a structure in which the mechanical strength of the core member reduced in weight can be increased by the support plate member.
Furthermore, in consideration of the trade-off relationship between weight reduction and mechanical strength in the technical field of composite materials, as a result of various investigations, the orientation of the fiber filler of the nonwoven fabric constituting the wall is appropriately controlled. Thus, it was found that the mechanical strength of the composite material can be improved while maintaining the weight reduction.
As a result of further earnest research based on such knowledge, a wall portion having a nonwoven fabric in which a plurality of fiber fillers are oriented substantially parallel to one surface perpendicular to the stacking direction in which the core member and the support plate member are stacked. By adopting it, it was found that the mechanical strength was improved while maintaining the weight reduction in the composite material, and the present invention was completed.

According to the present invention,
A core member having a layer structure;
A laminated material on one surface of the core member, and a support plate member made of a fiber reinforced resin material formed by impregnating a resin with a reinforced fiber, and a composite material comprising:
The core member has a wall portion and a lightweight portion having a specific gravity smaller than that of the wall portion,
A composite material is provided in which the wall portion includes a nonwoven fabric in which a plurality of fiber fillers are oriented substantially parallel to the one surface of the core member.

  ADVANTAGE OF THE INVENTION According to this invention, the composite material excellent in weight reduction and mechanical strength is provided.

(A) It is a top view which illustrates the structure of the composite material of this embodiment. (B) It is aa sectional drawing of (a). It is a perspective schematic diagram which illustrates the structure of a foamable papermaking body. It is sectional process drawing which illustrates the manufacturing method of a foamable papermaking body. It is sectional process drawing which illustrates the manufacturing method of a foam (molded body of a foamable papermaking body).

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
In all the drawings, the same reference numerals are given to the same components, and the description will be omitted as appropriate. Moreover, the figure is a schematic diagram and does not match the actual dimensional ratio. In the present embodiment, description will be made by defining the front-rear, left-right, up-down directions as shown. However, this is provided for the sake of convenience in order to briefly explain the relative relationship between the components. Therefore, the direction at the time of manufacture and use of the product which implements the present invention is not limited.

  The composite material of the present embodiment includes a core member having a layer structure, and a support plate member made of a fiber reinforced resin material that is laminated on one surface of the core member and impregnated with resin in a reinforced fiber. Is. The core member has a wall portion and a lightweight portion having a specific gravity smaller than that of the wall portion. The wall portion in the core member has a plurality of fiber fillers substantially parallel to one surface of the core member. It is possible to have a non-woven fabric that is oriented.

  In the composite material of the present embodiment, by adopting a core member having a wall portion and a lightweight portion having a specific gravity smaller than that of the wall portion, a structure excellent in weight reduction can be realized, and a fiber is added to the core member having the wall portion. By laminating support plate members made of a reinforced resin material, a structure with excellent mechanical strength can be realized.

  According to this embodiment, a wall having a nonwoven fabric in which a plurality of fiber fillers are oriented substantially parallel to one surface perpendicular to the stacking direction in which the core member and the support plate member are stacked, that is, one surface of the core member. By using the part, in the composite material, it is possible to further improve mechanical strength such as impact strength from the stacking direction while maintaining weight reduction.

  As the composite material 100 of this embodiment, it can be used for an aircraft, a motor vehicle part, an electronic device housing, a building (container) wall material, etc., for example.

  Each element of the composite material of this embodiment will be described.

  The composite material 100 of this embodiment is provided with the core member 110 which has a layer structure, and the support plate member 120 laminated | stacked on the lower surface 116 of the core member 110, as shown to Fig.1 (a) (b). . As shown in FIG. 1B, the composite material 100 has a sandwich structure in which support plate members 120 and 122 are laminated on a lower surface 116 (one surface) and an upper surface 118 (a surface facing the one surface) of the composite material 100, respectively. Can have.

  The composite material 100 only needs to have a two-layer structure of the core member 110 and the support plate member 120. As shown in FIG. 1B, the composite material 100 includes the support plate member 122, the core member 110, and the support plate member 120. You may be comprised by the sandwich structure of 3 layers. With this two-layer structure or three-layer sandwich structure as a basic structure, the composite material 100 may have a repeating structure of a plurality of basic structural units. In this case, the basic structural units may be the same or different. In the laminated structure of the composite material 100, the plurality of basic structural units may be formed continuously, or may be formed through other functional layers such as a cushion layer and an adhesive layer.

The composite material 100 may have a sheet-like structure as shown in FIG. 1B, but may have various three-dimensional structures depending on the purpose.
The shape of the composite material 100 in a top view when viewed in a direction perpendicular to one surface of the support plate member 120 is, for example, various shapes such as a rectangular shape, a polygonal shape, a circular shape, a curved shape, or a combination thereof. Can have. On the other hand, the shape of the composite material 100 in a cross-sectional view when viewed in the stacking direction of the support plate member 120 and the core member 110 is, for example, a rectangular shape, a polygonal shape, a circular shape, a curved shape in FIG. It can have various shapes such as a combination thereof. In the case of the composite material 100 having a three-dimensional structure, for example, the lower surface 116 of the core member 110 may be configured to face each other along one surface of the support plate member 120 having a three-dimensional shape.

  In addition, when the composite material 100 is provided with the several core member 110, you may be comprised by the same or different thing, respectively. Moreover, when the composite material 100 is provided with the some support plate member 120,122, you may be comprised by the same or different thing, respectively.

  The thicknesses of the composite material 100, the core member 110, and the support plate members 120 and 122 can be set as appropriate according to the application.

[Support plate member]
Next, the configuration of the support plate member will be described.
The support plate members 120 and 122 can be made of a fiber reinforced resin material obtained by impregnating a reinforced fiber with a resin. As the support plate members 120 and 122, as shown in FIG. 1B, a sheet-like fiber reinforced resin material having two main surfaces of an upper surface and a lower surface can be used. The support plate members 120 and 122 may be composed of one layer of fiber reinforced resin material, but may be composed of a laminate of two or more fiber reinforced resin materials.

Examples of the resin used for the fiber reinforced resin material include a thermosetting resin and a thermoplastic resin.
Examples of the thermosetting resin used for the fiber reinforced resin material include phenol resin, epoxy resin, bismaleimide resin, melamine resin, and urethane resin.
Examples of the thermoplastic resin used for the fiber reinforced resin material include polycarbonate, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyamide, polyether ketone, polyether ether ketone, polysulfone, and polyphenylene sulfide.
These may be used alone or in combination of two or more. Among these, thermosetting resins are preferable from the viewpoint of mechanical strength or chemical resistance, and phenol resins, epoxy resins, and bismaleimide resins can be used. Moreover, a phenol resin can be used from the point which can be used for a wide use.

The reinforcing fiber used for the fiber-reinforced resin material can be composed of a woven fabric (fiber cloth) or a non-woven fabric. Examples of the reinforcing fibers include organic fibers, inorganic fibers, and metal fibers. Specifically, polyamide fibers, aramid fibers, polyimide fibers, polyparaphenylene benzoxazole fibers, polyarylate fibers, ultra high molecular weight polyethylene fibers, high strength polypropylene fibers and other synthetic fibers, acrylic fibers, phenol fibers, carbon fibers, etc. Organic fibers; inorganic fibers such as glass fibers, ceramic fibers, rock wool, potassium titanate fibers, and basalt fibers; and metal fibers such as stainless fibers, steel fibers, aluminum fibers, copper fibers, brass fibers, and bronze fibers. These may be used alone or in combination of two or more.
Among these, an aramid fiber, a carbon fiber, etc. can be used from a viewpoint of mechanical strength and weight reduction. In addition, glass fibers can be used from the viewpoints of moldability, uniformity of molded products, and wear resistance.

  In addition, as the reinforcing fiber used for the fiber reinforced resin material, one that has been subjected to a surface treatment in advance for the purpose of increasing the adhesion with the resin may be used. Examples of the surface treatment method include coupling agent treatment, oxidation treatment, ozone treatment, plasma treatment, corona treatment, and blast treatment. Among these, a coupling agent treatment can be used.

  Moreover, the said fiber reinforced resin material can contain another component other than said resin and a reinforced fiber according to the objective. Examples of other components include curing agents, curing aids, fillers, mold release agents, coupling agents, flame retardants, and colorants such as carbon black.

Next, a method for manufacturing the support plate members 120 and 122 will be described.
An example of a method for producing the support plate members 120 and 122 is a step of impregnating a reinforcing fiber with a resin composition containing the above-described resin or other components as necessary to form a fiber-reinforced resin material. Can be included. This fiber-reinforced resin material is used as the support plate members 120 and 122, and can be formed into a sheet shape such as a roll shape capable of being wound or a sheet shape having a rectangular shape.
Further, when the resin composition in the fiber reinforced resin material contains a thermosetting resin, after impregnation, the resin composition (thermosetting resin composition) is heated until it becomes a semi-cured state (B stage state). And a drying step of drying.

  In this embodiment, as a known impregnation means, for example, a resin varnish is prepared by dissolving a resin composition in a solvent, and the resin varnish is applied to the reinforced fiber by various coaters. And a method of spraying the resin varnish on the reinforcing fibers by spraying, a method of laminating a resin film (resin film) made of a resin composition on one side or both sides of the reinforcing fibers, and the like. The resin film may be a papermaking body (papermaking prepreg) obtained by drying a papermaking layer constituted by a papermaking method.

[Core material]
Next, the configuration of the core member will be described.
As shown in FIG. 1B, the core member 110 can have a layer structure having a wall portion 112 and a lightweight portion 114 that is lighter than the wall portion 112.

  When the core member 110 is viewed from the upper surface 118, the lightweight portion 114 is configured by a space partitioned by the wall portion 112 as shown in FIG. Thereby, the mechanical strength of the core member 110 can be increased. Moreover, since the core member 110 can be provided with a plurality of lightweight portions 114, the weight can be reduced.

  The wall 112 is formed from the lower surface 116 (one surface) of the core member 110 to the entire upper surface 118 (the other surface facing the one surface). That is, in the cross-sectional view of the core member 110, the entire periphery on the side wall surface side of the lightweight portion 114 can be covered with the wall portion 112. Thereby, the mechanical strength of the core member 110 can be improved. On the other hand, since the adjacent two lightweight parts 114 can form a side wall with the common wall part 112, the core member 110 can be reduced in weight.

  A part or the whole of the lightweight portion 114 may be formed of a gap portion or a foamed portion. The foam part is made of a foam member, and when the wall part 112 has a foam structure, the foam part has a foam rate higher than that of the wall part 112. By making the lightweight part 114 have a smaller specific gravity than the wall part 112, the weight of the core member 110 can be improved.

  The wall 112 can have a honeycomb structure as shown in FIG. 1A when viewed from a direction perpendicular to the upper surface 118 of the core member 110. Thereby, it is possible to improve weight reduction and mechanical strength. Further, the shape of the wall portion 112 when viewed from the upper surface 118 of the core member 110 can be various shapes other than the honeycomb structure, for example, a rectangular shape, a polygonal shape, a circular shape, a curved shape, It can have various shapes such as a combination thereof. These may be used alone or in combination of two or more.

The said wall part 112 can have the nonwoven fabric comprised with the some fiber filler.
The nonwoven fabric in the wall 112 can have a structure in which a plurality of fiber fillers are oriented substantially parallel to the lower surface 116 of the core member 110 as shown in FIG. In the present specification, the term “substantially” means that a range in consideration of manufacturing tolerances and variations is included unless otherwise specified. Thereby, since the resistance force with respect to the impact from the lamination direction of the core member 110 and the support plate member 120 can be increased, it is possible to realize a structure that improves the mechanical strength while reducing the weight.

  Further, the nonwoven fabric in the wall portion 112 may have a structure in which a plurality of fiber fillers are randomly oriented as shown in FIG. 1A in a cross-sectional view parallel to the lower surface 116 of the core member 110. it can. Thereby, variation in the mechanical strength of the wall portion 112 in the in-plane direction of the lower surface 116 can be suppressed.

  The wall portion 112 can be formed of a formed body of a papermaking body containing the fiber filler and binder resin. In the nonwoven fabric in the papermaking body, the fiber fillers are bound with a binder resin. Thereby, the mechanical strength of the wall part 112 can be improved. Moreover, by using the papermaking method, which is a method for producing a papermaking body, the core member 110 having various shapes and three-dimensional shapes in plan view and the wall portion 112 constituting the same can be realized.

  The wall 112 may have a foam structure. That is, the wall part 112 may be comprised with the foam which has a foaming structure. Thereby, the weight reduction in the core member 110 can further be improved.

The foam structure of the foam may have a closed cell structure or an open cell structure. In the foam of this embodiment, the whole may have a closed cell structure from the viewpoint of the balance between strength and rigidity, and partly together with the closed cell structure from the viewpoint of the balance of strength, rigidity and weight reduction. It may have an open cell structure.
In this embodiment, the closed cell structure means a structure having a plurality of spaces (bubbles) isolated from the outside by a cured body of a thermosetting resin. In such a closed cell structure, since gas is suppressed from passing between adjacent spaces, a structure having excellent airtightness can be realized.

  The foam may be entirely or partly formed of a foamed paper product (paper product containing thermally expandable microcapsules). In the present embodiment, from the viewpoint of production stability, it is preferable that the entire foam is composed of a foamed paper product (foamed product).

Hereinafter, the foamable papermaking product and the foamed molded product of this embodiment will be described.
<Foaming papermaking>
FIG. 2 is a schematic perspective view showing an example of the foamable papermaking product 10 of the present embodiment.
The foamable papermaking body 10 of the present embodiment is a papermaking body in which the thermally expandable microcapsules C are dispersed.

  Here, in the present specification, the term “papermaking” is generally used as a technical term indicating the state of an object obtained by using a method of spreading a fiber material. Regarding the state of this thing, it describes in the patent gazette 1 (patent 4675276) and the patent gazette 2 (patent 5426399), for example. According to the document, the papermaking product is described as a wet solid content remaining on a filter after a liquid component is dehydrated from a raw material slurry in which raw materials such as fibers and resins are dispersed in a dispersion medium. ing. The said wet state here means the uncured state before performing heat processing, ie, the uncured state before post-cure.

  In the present embodiment, the foamable paper-making body 10 may be a sheet shape or a three-dimensional shape processed into a shape imitating a desired molded product shape (that is, a shape of an element). And the molded object (foaming molded object 50) can be obtained by performing foam molding, such as heat processing, with respect to this foamable papermaking body 10. FIG. The foamed molded body 50 is a cured product of the foamable papermaking body 10.

The foamable papermaking body 10 according to the present embodiment is obtained by a papermaking method.
As shown in FIG. 2, the foamable papermaking product 10 obtained by the papermaking method has structural features 1 to 3 in the following points.
(Feature 1) The fiber filler B and the thermally expandable microcapsule C are randomly oriented in a plan view of the surface of the foamable papermaking body 10.
(Characteristic 2) In the cross-sectional view in the thickness direction of the foamable papermaking product 10, the orientation state of the fiber filler B is highly controlled, and the fiber filler B is oriented in a specific direction. In other words, the fiber filler B is in a laminated state in the thickness direction of the foamable papermaking product 10.
(Feature 3) The fiber fillers B are bound by the binder resin A.
As described above, in the foamable papermaking product 10 shown in FIG. 2, the binder resin A, the fiber filler B, and the thermally expandable microcapsule C are randomly entangled in the surface direction, and such a surface structure overlaps in the thickness direction. It has such a papermaking structure.

Further, the foamable papermaking product 10 can be used as a material for obtaining a foamed molded product 50 shown in FIG. 4 by molding it into a desired shape by foaming treatment.
The resin in the foamable papermaking product 10 is not completely cured, for example, in a B stage state. Therefore, the foamable papermaking product 10 can be deformed into another shape. And the foaming paper-making body 10 can obtain the foaming molding 50 by foaming and complete-hardening resin by heating at the curing temperature of binder resin A which is a thermosetting resin.

Subsequently, the component which comprises the foamable papermaking body 10 is demonstrated.
(Binder resin A)
The binder resin A is not particularly limited as long as it functions as a binder that connects the fiber fillers B, but for example, a thermosetting resin can be used.
Examples of the thermosetting resin include phenol resin, epoxy resin, unsaturated polyester resin, melamine resin, polyurethane, and the like. These resins can be appropriately selected and used as necessary, and one kind may be used alone, or two or more kinds may be used in combination.
From the viewpoint of mechanical properties and heat resistance, it is preferable to use at least one of a phenol resin and an epoxy resin. Moreover, it is preferable to use a phenol resin from a viewpoint of coexistence in the weight reduction and the dimension with high intensity | strength.

  The thermosetting resin may have a granular or powdery shape. Thereby, the intensity | strength of the foaming molding 50 obtained by foaming and hardening the foamable papermaking body 10 can be improved more effectively. The reason for this is not clear, but when the foamable paper product 10 is heated and pressurized to be foamed, the thermosetting resin has a granular or powdery shape, so that the impregnation property at the time of melting is improved, and the fiber filler B It is estimated that the interface with the thermosetting resin is well formed.

As the thermosetting resin, for example, one having an average particle size of 500 μm or less and a solid state at room temperature can be used. Thereby, in the manufacturing process of the foamable papermaking body 10, it can make it easy to form the aggregation state of a thermosetting resin. Moreover, in the manufacturing process of the foamable papermaking body 10, from the viewpoint of obtaining a varnish-like material composition, the average particle size of the thermosetting resin is more preferably 1 nm or more and 300 μm or less.
The thermosetting resin having such an average particle diameter can be obtained by performing a pulverization process using, for example, an atomizer pulverizer.
The average particle size of the thermosetting resin is determined, for example, by using a laser diffraction particle size distribution measuring device such as SALD-7000 manufactured by Shimadzu Corporation as the average particle size based on a 50% particle size. Can do.

  The thermosetting resin contained in the foamable papermaking product 10 is preferably in a semi-cured state. The semi-cured thermosetting resin is completely cured in the process of producing the foamable paper product 10 and then foaming it into a desired shape by heating and pressurizing. Thereby, the foaming molding 50 excellent in the balance of high intensity | strength and weight reduction is obtained.

(Fiber filler B)
The fiber filler B is obtained by cutting a fiber yarn or a long fiber bundle into a predetermined length.
From the viewpoint of obtaining a special structure by papermaking, the average fiber length of the fiber filler B is, for example, 0.1 mm or more, preferably 1 mm or more, and from the viewpoint of obtaining mechanical strength, for example, 2 mm or more, preferably 2.5 mm. More preferably, it is 3 mm or more. On the other hand, from the viewpoint of obtaining good dispersibility, it is preferably 20 mm or less, more preferably 15 mm or less, and further preferably 12 mm or less.

  Examples of the fiber filler B include carbon fiber, glass fiber, metal fiber, ceramic fiber, wholly aromatic polyamide (aramid), wholly aromatic polyester, wholly aromatic polyester amide, wholly aromatic polyether, wholly aromatic polycarbonate, Totally aromatic polyazomethine, polyphenylene sulfide (PPS), poly (para-phenylenebenzobisthiazole) (PBZT), polybenzimidazole (PBI), polyetheretherketone (PEEK), polyamideimide (PAI), polyimide, polytetra Examples include fluoroethylene (PTFE), poly (para-phenylene-2,6-benzobisoxazole) (PBO), and the like. These fiber fillers B can be appropriately selected and used as necessary, and one kind may be used alone, or two or more kinds may be used in combination.

  Furthermore, from the viewpoint of achieving a balance between weight reduction and strength, inorganic fibers may be used, and glass fibers and carbon fibers may be preferably used. From the viewpoint of strength and rigidity, it is preferable to use carbon fiber. Moreover, when using glass fiber, you may use what gave the aminosilane process. The aminosilane treatment is performed by impregnating glass fibers with an amino group-containing silane coupling agent solution, or by applying an amino group-containing silane coupling agent solution to glass fibers.

  Examples of amino group-containing silane coupling agents include N- (β-aminoethyl) -γ-aminopropyltrimethoxysilane, N- (β-aminoethyl) -γ-aminopropylmethyldimethoxysilane, and γ-aminopropyl. Methyldimethoxysilane, γ-aminopropylmethyldiethoxysilane, γ-aminopropyltrimethoxysilane, γ-aminopropyltriethoxysilane, N- (β-aminoethyl) -γ-aminopropylmethyldimethoxysilane, N- (β An amino group-containing alkoxysilane such as (aminoethyl) -γ-aminopropylmethyldiethoxysilane, and hydrolysates thereof. These amino group-containing silane coupling agents may be used alone or in combination of two or more.

  From the viewpoint of increasing strength, the content of the fiber filler B may be, for example, 10% by weight or more, or 20% by weight or more with respect to the binder resin A (thermosetting resin). From the viewpoint of balancing strength and weight reduction, for example, the binder resin A (thermosetting resin) may be 80% by weight or less, 75% by weight or less, or 70% by weight or less. It may be 50% by weight or less.

(Thermal expansion microcapsule C)
The thermally expandable microcapsule C is a particle obtained by microencapsulating a volatile liquid foam material with a thermoplastic shell polymer having a gas barrier property. The thermally expandable microcapsule C functions as a foam material by the following mechanism. That is, while the outer shell of the capsule is softened by heating, the liquid foam material enclosed in the capsule is vaporized and the pressure is increased. As a result, the particles expand and hollow spherical particles (foamed particles of the thermally expandable microcapsule C) are formed.

Examples of the liquid foam material include low boiling point hydrocarbons such as isopentane, isobutane, and isopropane.
Examples of the thermoplastic shell polymer include polyacrylonitrile, vinylidene chloride-acrylonitrile copolymer, vinylidene chloride-methyl methacrylate copolymer, vinylidene chloride-ethyl methacrylate, acrylonitrile-methyl methacrylate copolymer, acrylonitrile-ethyl methacrylate, and the like. Can be mentioned. These may be used alone or in combination of two or more.

  Examples of the thermally expandable microcapsule C include commercially available products such as EXPANSEL (manufactured by Nippon Philite), Microsphere F50, Microsphere F60 (manufactured by Matsumoto Yushi Seiyaku Co., Ltd.), Advancel EM (manufactured by Sekisui Chemical Co., Ltd.). Product can be used.

  The content of the heat-expandable microcapsule C may be 0.05% by weight or more with respect to the binder resin A (thermosetting resin) from the viewpoint of reducing the density of the foamed molded body 50, and 0.1% by weight. % Or more. Further, from the viewpoint of expressing an appropriate strength of the foamed molded product 50, it may be 10% by weight or less or 5% by weight or less with respect to the binder resin A (thermosetting resin).

  In addition, the foamable papermaking body 10 in this embodiment can contain components, such as a pulp, a flocculant, and various additives other than the said component.

(pulp)
The foamable papermaking body 10 of the present embodiment may include pulp. Pulp is a fiber material having a fibril structure and is different from the fiber filler B. Pulp can be obtained, for example, by mechanically or chemically fibrillating the fiber material.
Since the pulp can be made together with the binder resin A, the fiber filler B, and the heat-expandable microcapsule C at the time of manufacturing the foamable papermaking product 10, these can be more effectively aggregated, and thus more stable foaming. It becomes possible to realize manufacture of the papermaking body 10.

  Examples of the pulp include cellulose fibers such as linter pulp and wood pulp, natural fibers such as kenaf, jute and bamboo, para-type wholly aromatic polyamide fibers (aramid fibers) and copolymers thereof, aromatic polyester fibers, poly Examples include fibrillated organic fibers such as benzazole fibers, meta-type aramid fibers and copolymers thereof, acrylic fibers, acrylonitrile fibers, polyimide fibers, and polyamide fibers. Pulp may be used individually by 1 type and may use 2 or more types together.

  The content of the pulp may be 0.5% by weight or more, 1% by weight or more, or 2% by weight or more with respect to the binder resin A (thermosetting resin). Thereby, aggregation of the thermosetting resin at the time of papermaking can be generated more effectively, and further stable production of the foamable papermaking body 10 can be realized. On the other hand, the pulp content may be 10% by weight or less, 8% by weight or less, or 5% by weight or less with respect to the binder resin A (thermosetting resin). Thereby, it becomes possible to improve the mechanical characteristic and thermal characteristic of the foaming molding 50 more effectively.

(Flocculant)
The foamable papermaking body 10 of the present embodiment may include a flocculant. The aggregating agent has a function of aggregating the binder resin A, the fiber filler B, and the thermally expandable microcapsule C in the form of a flock when the foamable papermaking product 10 is manufactured. For this reason, manufacture of the more stable foamable papermaking body 10 is realizable.

  Examples of the flocculant include cationic polymer flocculants, anionic polymer flocculants, nonionic polymer flocculants, and amphoteric polymer flocculants. More specifically, for example, cationic polyacrylamide, anionic polyacrylamide, Hoffman polyacrylamide, mannic polyacrylamide, amphoteric copolymerized polyacrylamide, cationized starch, amphoteric starch, polyethylene oxide and the like can be mentioned. These flocculants may be used individually by 1 type, and may use 2 or more types together. In the flocculant, the polymer structure and molecular weight, the amount of functional groups such as hydroxyl groups and ionic groups, and the like can be adjusted according to the required characteristics.

  The content of the flocculant may be 0.01% by weight or more, 0.05% by weight or more, or 0.1% by weight or more with respect to the binder resin A (thermosetting resin). Thereby, in manufacture of the foamable papermaking body 10, the improvement of a yield can be aimed at. On the other hand, the content of the flocculant may be 1.5% by weight or less, 1% by weight or less, or 0.5% by weight or less with respect to the binder resin A (thermosetting resin). Thereby, in manufacture of the foamable papermaking body 10 using a papermaking method, it becomes possible to perform a dehydration process etc. more easily and stably.

  The foamable paper product of the present embodiment can further use various additives for the purpose of adjusting production conditions and expressing required physical properties. For example, thermoplastic resins, inorganic powders for improving properties, metal powders, stabilizers such as antioxidants and UV absorbers, flame retardants, mold release agents, plasticizers, resin curing catalysts and accelerators, pigments , Dry paper strength improver, wet strength strength improver, yield improver, drainage improver, size fixer, rosin sizing agent for acidic papermaking, rosin sizing agent for neutral papermaking, alkyl Examples thereof include sizing agents such as ketene dimer sizing agents, alkenyl succinic anhydride sizing agents and specially modified rosin sizing agents, and coagulants such as sulfuric acid bands, aluminum chloride and polyaluminum chloride.

  The foamable papermaking body 10 of this embodiment may have aramid microfibers as an additive. Thereby, the handleability of the papermaking body which dried the foaming papermaking body 10 can be made favorable.

<Method for producing foamed paper>
FIG. 3 is a process cross-sectional view illustrating the manufacturing process of the foamable papermaking product 10.
The method for producing the foamable paper product 10 of the present embodiment is to mix the binder resin A, the fiber filler B, and the thermally expandable microcapsule C, and then paper the mixture by a papermaking method to produce the foamable paper product 10. A process of obtaining. Here, the papermaking method uses a papermaking technique which is one of papermaking techniques as shown in FIG.

  Hereinafter, with reference to FIG. 3, the manufacturing method of the foamable papermaking body 10 by a wet papermaking method is explained in full detail.

  First, as shown to Fig.3 (a), the binder resin A, the fiber filler B, and the thermally expansible microcapsule C are added to a solvent, and it stirs, mixes, and disperses. At this time, you may add other components except a flocculant among the components mentioned above in a solvent. Thereby, the varnish-like material composition (slurry) for forming the foamable papermaking body 10 can be obtained.

  A method of dispersing each component in a solvent is not particularly limited, and examples thereof include a method of stirring using a disperser.

The solvent is not particularly limited, but it is difficult to volatilize in the process of dispersing the constituent materials of the material composition, and it is easy to remove the solvent in order to suppress remaining in the foamed papermaking product. From the standpoint of suppressing the increase in energy due to, the one having a boiling point of 50 ° C. or higher and 200 ° C. or lower is preferable.
Examples of the solvent include alcohols such as water, ethanol, 1-propanol, 1-butanol and ethylene glycol, ketones such as acetone, methyl ethyl ketone, 2-heptanone and cyclohexanone, ethyl acetate, butyl acetate, methyl acetoacetate, Examples thereof include esters such as methyl acetoacetate and ethers such as tetrahydrofuran, isopropyl ether, dioxane and furfural. These solvents may be used alone or in combination of two or more. Among these, it is more preferable to use water because the supply amount is abundant, the cost is low, the environmental load is low, the safety is high, and the handling is easy.

  Subsequently, a flocculant may be further added to the obtained slurry. Thereby, it becomes easier to obtain the aggregate F formed by aggregating the binder resin A, the fiber filler B, and the thermally expandable microcapsule C in the solvent in a flock shape (FIG. 3B).

  Then, the foamable papermaking body 10 can be obtained by papermaking the slurry which mixed the binder resin A, the fiber filler B, the thermally expansible microcapsule C, etc. with a filter.

Specifically, as shown in FIG. 3B, the above slurry is introduced into a container provided with a mesh 30 (filter) having a sheet-like bottom surface. Then, the solvent in the slurry is passed through the mesh 30 and discharged out of the container, and the aggregate F in the slurry is left on the mesh 30 (filter). Thereby, the aggregate F and the solvent can be separated from each other.
Here, by appropriately selecting the shape of the mesh 30, it is possible to adjust the shape of the foamable paper product to be obtained.
Thereafter, the agglomerate F obtained on the filter (mesh 30) may be subjected to a drying treatment, for example, in a drying furnace to further remove the solvent remaining in the agglomerate F.
Thus, the foamable papermaking product 10 shown in FIG.

In this embodiment, by the paper making method as shown in FIG. 3 (b), the fiber filler B whose shape is maintained in the surface direction of the foamable paper product 10 (formed along the surface direction of the filter), It is considered that a structure in which the structures entangled at random and appropriately are stacked in the thickness direction of the foamable sheet 10 can be formed. Thereby, a lot of fiber filler B can be mixed now and the foamable paper-making body 10 excellent in the balance of weight reduction and intensity | strength can be obtained.
Further, by using the papermaking method, the dispersion of the thermally expandable microcapsules C in the foamable papermaking product 10 can be increased.

  Further, the filter used in the papermaking method may have a flat plate shape as shown in FIG. A three-dimensional foamable papermaking product 10 can be formed by a papermaking method using a three-dimensional filter (hereinafter referred to as a three-dimensional papermaking method). Thereby, the core member 110 having a three-dimensional shape can be easily realized by using the three-dimensional papermaking method.

Further, in the papermaking method, the foamable papermaking body 10 is formed in a part of the region A on the filter surface and the foamable papermaking body 10 is not formed in the other region B (hereinafter referred to as a multicolor papermaking method). .) May be employed. By using the multicolor papermaking method, it is possible to adjust a region (a shape in a top view) in which the foamable papermaking body 10 is formed. In the multi-color papermaking method, for example, means for making a slurry with a filter in a state in which a coated area covering the filter surface with a mask or the like and an uncovered area not covered are provided, and a suction area for sucking slurry on the back side of the filter and a suction area A means for making a slurry through a filter in a state where a non-suction region is provided can be used.
According to this embodiment, it is possible to appropriately control the shape of the wall 112 in a top view by adjusting the formation region of the foamable papermaking body 10 in the multicolor papermaking method.

In the multicolor papermaking method, the foamable papermaking product 10 can be configured so as to have a void in a portion corresponding to the region B. That is, the foamable papermaking body 10 having a perforated structure can be formed. In this case, the foamable papermaking body 10 corresponding to the region A can be used as the wall portion 112, and the gap corresponding to the region B can be used as the lightweight portion 114. The lightweight part 114 in the core member 110 can be configured by a gap. Thereby, weight reduction can be improved.
In addition, the foamable papermaking body 10 which has the lightweight part 114 of desired shapes, such as a perforated structure, is realizable by removing the predetermined area | region of the foamable papermaking body 10 with a cutting means.

The multicolor papermaking method can be repeated a plurality of times. Each time the multicolor papermaking process is performed, the region on the filter forming the foamable papermaking body 10 can be appropriately changed. Thereby, the foamable papermaking body 10 provided with at least the foamable papermaking body A and the foamable papermaking body B having different thicknesses and composition conditions in the plane or in the stacking direction can be realized.
In this case, an entangled region in which the respective fiber fillers are entangled with each other can be formed between the foamable papermaking product A and the foamable papermaking product B. When the foamable papermaking A is used for the wall portion 112 and the foamable papermaking B is used for the light weight portion 114, in the core member 110, the fiber filler in the wall portion 112 and the other in the foamed member constituting the light weight portion 114 are used. An entangled region in which the fiber fillers are entangled with each other is formed. Thereby, the mechanical strength of the core member 110 can be improved.

  For example, the sheet member (hole) of the foamable papermaking product 10 having different compositions and structures in the plane is obtained by repeatedly performing the multicolor papermaking method using slurries having different composition conditions such as the content of the thermally expandable microcapsule C. A sheet-like foamable paper-making body 10) having no perforated structure can be formed. Moreover, the sheet | seat member of the foamable papermaking body 10 from which thickness differs in a plane can be formed by changing the papermaking conditions in a multicolor papermaking method. The foaming ratio of the foamed molded product 50 can be adjusted according to the content of the thermally expandable microcapsule C and the thickness. In the foamable papermaking product 10, a portion having a small content of the heat-expandable microcapsule C or a portion having a small thickness can be used as the lightweight portion 114. In the lightweight part 114 in the core member 110, a part or all of the lightweight part 114 can be formed of a foamed member having a foaming rate higher than that of the wall part 112. Thereby, mechanical strength and weight reduction can be improved.

In addition, you may use the above papermaking method combining suitably.
Moreover, the papermaking body which does not have a foam structure, and its manufacturing method can be made into the same as said foamable papermaking body and its manufacturing method except the point which does not contain the thermally expansible microcapsule C.

<Foamed molded product>
The foamed molded product 50 of the present embodiment is a molded product of the foamable papermaking product 10 and has a cell structure in which bubbles D formed by foaming the thermally expandable microcapsules C are dispersed in the molded product.

<Method for producing foam molded article>
The manufacturing method of the foaming molding 50 of this embodiment prepares the slurry which mixed the binder resin A (thermosetting resin), the filler (fiber filler B), and the thermally expansible microcapsule C, and forms this slurry. A step of obtaining the foamable papermaking product 10 by,
The foamable papermaking body 10 is disposed in a part of the inside of the molds 40 and 41, the thermally expandable microcapsule C is expanded, and the foamable papermaking body 10 is expanded to the whole inside of the molds 40 and 41. The process of obtaining the foam (foaming molding 50) which consists of a molding of the foamable papermaking body 10 by this can be included.

FIG. 4 is a schematic cross-sectional view showing an example of a method for producing a foam according to this embodiment.
Hereinafter, with reference to FIG. 4, the manufacturing method of the foaming molding 50 is explained in full detail.

  First, as shown to Fig.4 (a), the foamable papermaking body 10 is arrange | positioned inside the metal mold | dies 40 and 41 (metal mold cavity). At this time, the volume of the mold cavity including the mold 40 and the mold 41 is assumed to be larger than the volume of the foamable papermaking product 10. Thereby, the foamable papermaking body 10 which is a raw material can be arrange | positioned in the state which the inside of metal mold | die 40,41 is not completely filled, ie, what is called a short shot. This mold cavity can be appropriately set according to the shape of the foamable papermaking product 10.

Next, foam molding is performed on the foamable papermaking product 10. For example, as shown in FIG. 4B, the heat-expandable microcapsule C is expanded by the heat treatment, and the foamable papermaking product 10 is expanded. The expanded foamed paper product 10 is filled in the entire mold cavity. At this time, the foamable papermaking product 10 is formed by the internal pressure (stress from the molds 40 and 41) due to the foaming of the thermally expandable microcapsule C, and the foamed molded product 50 is obtained. Thereby, it can shape | mold to the foaming molding 50 which has a predetermined shape.
In the above-described foam molding step, the curing reaction of the binder resin A proceeds, and a matrix resin having a three-dimensional structure (cured resin body having a three-dimensional network structure) is formed in the foam molded body 50. Further, the thermally expandable microcapsule C expands by the above heat treatment, and bubbles D (hollow spherical particles) are formed.
Thus, the foaming molding 50 of this embodiment can be manufactured by the short shot method. By using the short shot method, the foamable papermaking product 10 can be formed using the foaming pressure generated by the expansion of the bubbles of the thermally expandable microcapsule C.

  Although the said heat processing is not specifically limited, For example, it is good also as about 160-250 degreeC and about 10 to 30 minutes. In the manufacturing method of the foam molded body 50 of the present embodiment, the molding pressure is not applied from the outside, but the internal pressure in the molds 40 and 41 is, for example, about 1.5 to 5 MPa.

Here, an injection molding method etc. are mentioned as a method of applying a molding pressure from the outside. In this method, the thermally expandable microcapsule cannot be foamed due to the filling pressure or holding pressure, and the bubbles are destroyed.
On the other hand, in the manufacturing method of the foamed molded product 50 of this embodiment, since no molding pressure is applied from the outside, unexpanded of the thermally expandable microcapsule C and destruction of the bubbles D can be sufficiently suppressed. .

(Manufacturing method of composite material 100)
The composite material 100 of this embodiment can include a step of laminating the core member 110 and the support plate member 120. As a lamination method, the core member 110 and the support plate member 120 may be joined by heating or pressurizing, or these may be joined via an adhesive layer.
Further, when the support plate members 120 and 122 are laminated on both surfaces of the core member 110, they may be joined together.

  When the wall portion 112 of the core member 110 is formed of the foam molded body 50, a support plate member is disposed on the lower surface of the foamable papermaking body 10 in the molding space in the molds 40 and 41 of FIG. Foam molding can be performed in a state where support plate members are disposed on the upper surface and the lower surface of the foamable papermaking body 10, respectively. Thereby, while being able to form a foam structure in the wall part 112, it is possible to couple | bond the core member 110 and the support plate members 120 and 122. FIG.

  As mentioned above, although embodiment of this invention was described, these are illustrations of this invention and various structures other than the above are also employable.

  EXAMPLES Hereinafter, although this invention is demonstrated in detail with reference to an Example, this invention is not limited to description of these Examples at all.

The materials used in the examples and comparative examples are as follows.
(Thermosetting resin)
Thermosetting resin 1: phenol resin (manufactured by Sumitomo Bakelite, PR-51723)
(Foam material)
Foam material 1: Thermally expandable microsphere (manufactured by Sekisui Chemical Co., Ltd., Advancel (registered trademark) EM-304)
(Additive)
Additive 1: Aramid microfiber (Daicel Finechem, Tiara)
(Fiber filler)
Fiber filler 1: Carbon fiber (Toho Tenax, HTC110, average fiber length: 6 mm)
Fiber filler 2: Aramid fiber (manufactured by Teijin Limited, T32PNW, average fiber length: 3 mm)
Fiber filler 3: Glass fiber (manufactured by Nitto Boseki Co., Ltd., CS3J-891, average fiber length: 3 mm)
Fiber filler 4: Carbon fiber (manufactured by Toho Tenax Co., Ltd., HTC110, average fiber length: 1 mm (fiber length cut short))
Fiber filler 5: aramid fiber (manufactured by Teijin Ltd., T32PNW, average fiber length: 1 mm (fiber length cut short))
Fiber filler 6: Glass fiber (manufactured by Nitto Boseki Co., Ltd., CS3J-891, average fiber length: 1 mm (fiber length cut short))

<Example 1>
(Preparation of foamed paper)
First, the raw material components shown in Table 1 (thermosetting resin, fiber filler, foaming material, and additive crushed to an average particle size of 50 μm (50% particle size based on mass) with an atomizer grinder) are shown in Table 1. The mixture was added to water at a blending ratio (raw material volume fraction after expansion molding [Vol%]) and stirred for 10 minutes with a disperser to obtain a mixture. Here, it added to 10000 weight part of water with respect to a total of 100 weight part of the constituent material which consists of a thermosetting resin, a fiber filler, a foaming material, and an additive.
Next, a solution in which 800 ppm of polyethylene oxide (PEO) is previously dissolved in water as a fixing agent (flocculating agent) is added in an amount of 0.2% by weight based on the total of the constituent materials described above, and the constituent materials are floc-like. Agglomerated.
(Paper making process)
Subsequently, the obtained agglomerates were separated from water with a 30 mesh metal net (papermaking). Thereafter, the papermaking layer remaining on the metal net was dehydrated and pressed under the conditions of 1 MPa and room temperature, and further dried in a drier at 70 ° C. for 5 hours to obtain a plate-like foamable papermaking product.
(Processing foamed paper)
The obtained plate-shaped foamable papermaking product was cut under the conditions of cutting out hexagonal cutout portions so as to have the “core member shape” shown in Table 1. As a result, a plate-like perforated foamable papermaking product was formed in which the shape of the remaining portion (wall portion) in the top view was a honeycomb shape.
(Production of composite materials)
FRP (B-stage prepreg made of glass cloth impregnated with phenol resin), the resulting foamable papermaking product, and the FRP are stacked in a predetermined thickness in the mold in this stacking order. Then, heat treatment is performed under the conditions of 180 ° C., 10 minutes, mold internal pressure: 10 MPa, and foamed molding by the short shot method is performed on both sides of the molded body (core member) of the foamable paper product (support plate). A “composite material” in which members were laminated was produced.

<Examples 2 and 3>
A “composite material” having a specific gravity higher than that of Example 1 was prepared in the same manner as in Example 1 using the raw material components and blending ratios shown in Table 1.

<Example 4>
In the same manner as in Example 1 except that the raw material components and blending ratios shown in Table 1 were used and the following (papermaking process) conditions were adopted and the above (processing of foamable papermaking product) was not performed. Material "was made.
The (paper making process) of Example 4 is as follows.
-A plurality of hexagonal masks were prepared, and a plurality of hexagonal masks were arranged on the surface of the metal net so that the area not covered with the hexagonal masks was in a honeycomb shape.
Subsequently, the obtained agglomerates were separated from water with a 30-mesh metal mesh in a state where the surface of the metal mesh was covered with a plurality of hexagonal masks (first paper making).
・ Subsequently, all hexagonal masks on the metal mesh were removed, and the obtained agglomerates were separated from the water again with the metal mesh in a state where the entire surface was not covered with the hexagonal mask (second papermaking). .
-In the region A where the hexagonal mask was not covered by the multicolor papermaking method in which the first papermaking and the second papermaking are continuously performed, a thick papermaking layer (remainder) is formed in the area A where the hexagonal mask was not covered. In the region B covered with the hexagonal mask, a relatively thin papermaking layer (uneven portion) was formed as compared with the first papermaking layer. That is, the uneven thickness process which makes a thin part in a part of papermaking layer was performed.
After this, the papermaking layer after the uneven thickness treatment remaining on the metal net is dehydrated and pressed under conditions of 1 MPa and room temperature, and further put into a 70 ° C. drier for 5 hours to be dried to form a plate-like foaming papermaking Got the body.
In the plate-like foamable papermaking product, the uneven thickness portion of the “core member shape” shown in Table 1 was configured to have a higher expansion ratio and a lower specific gravity than the remaining portion.

<Examples 5 and 6>
A “composite material” having a specific gravity higher than that of Example 4 was produced in the same manner as in Example 4 using the raw material components and blending ratios shown in Table 1.

<Example 7>
A “composite material” was produced in the same manner as in Example 1 except that the following ingredients (processing of foamable papermaking) were adopted using the raw material components and the blending ratio shown in Table 1.
Example 7 (Processing of foamable papermaking product) is as follows.
The obtained plate-shaped foamable papermaking product was cut under the conditions of cutting out a circular cutout portion so as to have the “shape of the core member” shown in Table 1. As a result, a plate-like perforated foamable papermaking product was formed in which the shape of the remaining part (wall part) in a top view was a round hole pattern.

<Examples 8 and 9>
A “composite material” having a specific gravity higher than that of Example 7 was produced in the same manner as in Example 7 using the raw material components and blending ratios shown in Table 1.

<Examples 10 to 13>
A “composite material” was prepared in the same manner as in Example 1 using the raw material components and the mixing ratio shown in Table 1.

<Reference Example 1>
The specific gravity is higher than Example 1 in the same manner as in Example 1 except that the raw material components and blending ratios shown in Table 1 are used (no foaming material is used) and the following conditions (preparation of composite material) are adopted. A “composite material” was produced.
Reference Example 1 (production of composite material) is as follows.
FRP, the obtained non-foaming paper-making body (paper-making body containing no foaming material), and the FRP are laminated in a predetermined thickness in this lamination order, and these are collectively put at 180 ° C. for 10 minutes. , “Internal pressure of the mold: Heat treatment was performed under the condition of 10 MPa, and“ composite material ”in which a cured product of FRP (support plate member) was laminated on both surfaces of the molded body (core member) of the non-foamed papermaking body by compression molding. Produced.

<Reference Example 2>
A “composite material” having a specific gravity lighter than that of Example 1 was produced in the same manner as in Example 1 using the raw material components and blending ratios shown in Table 1 (a large amount of foam material).

<Reference Examples 3-5>
A “composite material” was produced in the same manner as in Example 1 using the raw material components and the blending ratio shown in Table 1.

<Comparative Example 1>
A “composite material” having no cut-out portion or uneven thickness portion is obtained in the same manner as in Example 1 except that the above-mentioned “processing of foamable papermaking” is not performed on the obtained plate-like foamable papermaking. Produced.

<Comparative example 2>
“Composite material” in the same manner as in (Production of composite material) in Example 1 except that a commercially available plate-shaped aramid honeycomb core (manufactured by Showa Aircraft Industry Co., Ltd.) was used instead of the foamed paper product. Was made.

(Orientation of fiber filler)
Cut surfaces X of the obtained “composite material” cut in the stacking direction of the support plate member, core member and support plate member, and cut surfaces Y cut in the direction perpendicular to the stacking direction With respect to X and Y, the orientation of the fiber filler was observed with a microscope.
In Examples 1 to 13, Reference Examples 1 and 2, and Comparative Example 1, the orientation of the fiber filler was substantially parallel on the cut surface X in the stacking direction. On the other hand, in the cut surface Y in the orthogonal direction, the orientation of the fiber filler was random.

  On the other hand, in Reference Examples 3 to 5, at the cut surface X in the stacking direction, the fiber filler orientation was lowered as compared with each example, but was observed slightly, but the fiber filler oriented almost in parallel. Also occurred in part. On the other hand, in the cut surface Y in the orthogonal direction, the orientation of the fiber filler was random. Since the fiber length of the fiber filler is short, it is considered that sufficient orientation in the cut surface X was not obtained.

In Comparative Example 2, the fiber filler was arranged so as to pass through the cut surface X in the cut surface X in the stacking direction of the FRP and the aramid honeycomb core, and many fiber cross sections of the fiber filler were observed. On the other hand, in the cut surface Y in the orthogonal direction, the orientation of the fiber filler was random.

  The raw material volume fraction after foam molding of the foam material in Table 1 indicates the volume porosity of the foam. “-” In Table 1 means that measurement data based on the following evaluation items is not acquired.

  The obtained composite material was evaluated based on the following evaluation items. The evaluation results are shown in Table 1.

(Lightweight)
The specific gravity of the composite material of each example and each comparative example was determined. When the specific gravity of the composite material of Reference Example 1 was set to 1.00 (reference), the relative value of the specific gravity of the composite material of each Example and each Comparative Example was evaluated based on the following evaluation criteria. This Reference Example 1 was set as a lightness evaluation standard required for fiber resin composite materials. The evaluation results are shown in Table 1.
Evaluation criteria:
Less than 0.80: ◎ (shows good lightness)
0.80 or more and less than 0.90: ○ (shows relatively good lightness)
0.90 or more and less than 0.95: △ (indicates that improvement in lightness is necessary)
0.95 or more: x (indicates insufficient lightness)
In addition, although the comparative example 1 was excellent in intensity | strength, evaluation of the lightness was (triangle | delta).

(Strength)
A falling ball test in which an iron ball is freely dropped from a height of 150 cm was performed on the composite material of each example and each comparative example. The appearance of the dents and the degree of damage such as destruction were observed. Evaluation was performed based on the following evaluation criteria for the relative damage condition of the composite materials of each Example and each Comparative Example when the damage condition of Reference Example 2 was used as a reference. This Reference Example 2 was set as an evaluation standard for strength required for a fiber resin composite material. The evaluation results are shown in Table 1.
Evaluation criteria:
Remarkably reduced: ◎ (shows good strength)
Slightly reduced: ○ (shows relatively good strength)
Equivalent degree: △ (Indicates a strength that is practically acceptable)
Deteriorating: x (indicates insufficient strength)
In addition, although the comparative example 2 was excellent in the lightness, evaluation of intensity | strength was x.

  It turned out that the composite material of Examples 1-13 is excellent in the lightness compared with the reference example 1 and the comparative example 1. FIG. Moreover, it turned out that the composite material of Examples 1-13 is excellent in intensity | strength compared with the reference example 2, the reference examples 3-5, and the comparative example 2. FIG. Reference Examples 3 to 5 are more lightweight than Reference Example 1 and Comparative Example 1, and have the same strength as Reference Example 2, but are superior to Comparative Example 1 in strength. I understood.

DESCRIPTION OF SYMBOLS 10 Expandable paper-making body 30 Mesh 40 Mold 41 Mold 50 Foam molded body A Binder resin B Fiber filler C Thermal expansion microcapsule D Bubble F Aggregate 100 Composite material 110 Core member 112 Wall part 114 Light weight part 116 Lower surface 118 Upper surface 120 Support plate member 122 Support plate member

Claims (12)

A core member having a layer structure;
A laminated material on one surface of the core member, and a support plate member made of a fiber reinforced resin material formed by impregnating a resin with a reinforced fiber, and a composite material comprising:
The core member has a wall portion and a lightweight portion having a specific gravity smaller than that of the wall portion,
The said wall part is a composite material which has a nonwoven fabric in which several fiber fillers orientate substantially parallel with respect to the said one surface of the said core member. The composite material according to claim 1,
A composite material in which the plurality of fiber fillers in the wall are randomly oriented in a cross-sectional view parallel to the one surface of the core member. A composite material according to claim 1 or 2,
The composite material in which the wall portion is formed from the one surface of the core member to the other surface facing the one surface. The composite material according to any one of claims 1 to 3,
The composite material in which the lightweight part in the core member is configured by a space partitioned by the wall part. The composite material according to any one of claims 1 to 4,
A composite material in which the wall portion has a honeycomb structure. A composite material according to any one of claims 1 to 5,
A composite material in which the light-weight part is composed of a void part or a foamed part. The composite material according to any one of claims 1 to 6,
A composite material in which the wall has a foam structure. A composite material according to any one of claims 1 to 7,
A composite material in which the wall portion is composed of a formed body of a papermaking body containing the fiber filler and a binder resin. A composite material according to claim 8,
A composite material in which the binder resin contains a phenol resin. A composite material according to any one of claims 1 to 9,
A composite material in which the resin in the fiber-reinforced resin material contains an epoxy resin. A composite material according to any one of claims 1 to 10,
A composite material in which the support plate member is also laminated on the other surface of the core member facing the one surface. The composite material according to any one of claims 1 to 11,
A composite material having a sheet-like structure or a three-dimensional structure.

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