US 12,466,143 B2
Method for manufacturing fiber-reinforced resin structure
Nami Nakayama, Nomi (JP); and Yuichi Kondo, Nomi (JP)
Assigned to HOKURIKU COLOR FOAM CO., LTD., Nomi (JP)
Appl. No. 17/781,532
Filed by HOKURIKU COLOR FOAM CO., LTD., Nomi (JP)
PCT Filed Jun. 17, 2020, PCT No. PCT/JP2020/023871
§ 371(c)(1), (2) Date Jun. 1, 2022,
PCT Pub. No. WO2021/111661, PCT Pub. Date Jun. 10, 2021.
Claims priority of application No. 2019-218410 (JP), filed on Dec. 2, 2019; application No. 2019-218411 (JP), filed on Dec. 2, 2019; application No. 2019-218412 (JP), filed on Dec. 2, 2019; application No. 2019-218413 (JP), filed on Dec. 2, 2019; application No. 2020-104766 (JP), filed on Jun. 17, 2020; application No. 2020-104767 (JP), filed on Jun. 17, 2020; application No. 2020-104768 (JP), filed on Jun. 17, 2020; and application No. 2020-104769 (JP), filed on Jun. 17, 2020.
Prior Publication US 2023/0102696 A1, Mar. 30, 2023
Int. Cl. B29C 70/68 (2006.01); B29C 70/34 (2006.01); B29K 23/00 (2006.01); B29K 105/04 (2006.01)
CPC B29C 70/68 (2013.01) [B29C 70/34 (2013.01); B29K 2023/00 (2013.01); B29K 2105/04 (2013.01); B29K 2995/0063 (2013.01)] 15 Claims
OG exemplary drawing
 
1. A method of manufacturing a fiber-reinforced resin structure, comprising the steps of:
preparing an assembly having a first foam body in a columnar shape, which is a flexible body, a first fiber body which is wound one or more turns around a side surface portion of the first foam body, a second foam body in a columnar shape, which is a flexible body, and a second fiber body which is wound one or more turns around the second foam body, wherein a column axis of the first foam body and a column axis of the second foam body are arranged parallel such that the column axis of the first foam body and the column axis of the second foam body are directed to the same direction and the first fiber body and the second fiber body are contact with each other, and wherein both the first foam body and the second foam body do not have a hollow portion having a diameter that is 1/20 or more of each outer diameter of the first foam body and the second foam body, and wherein an uncured thermosetting resin is impregnated in the first fiber body and the second fiber body,
curving the assembly so that the column axis of the first foam body and the column axis of the second foam body are curved together in parallel to the same degrees as the first fiber body and the second fiber body are curved,
thermally curing the thermosetting resin included in the assembly in order for the first foam body and the second foam body to remain in a posture in which the first foam body and the second foam body are curved,
cooling the assembly to shrink the first foam body and the second foam body after the thermally curing step, and
removing the first foam body and the second foam body from the assembly;
wherein
the uncured thermosetting resin is one or more selected from the group consisting of an epoxy resin, an unsaturated polyester resin, a polyvinyl ester resin, a phenol resin, a polyurethane resin, an acrylic resin, a melamine resin, a urea resin, a benzoguanamine resin, a rosin-modified maleic acid resin and a rosin-modified fumaric acid resin,
a resin constituting the first foam body and the second foam body is polyethylene and/or polypropylene, and
each of the first foam body and the second foam body is a closed cell foam or a foam containing both closed cells and open cells, wherein, in the case where the first foam body and/or the second foam body contain closed cells and open cells, the closed cell ratio is 50.0 to 99.9%.