Formed article of fiber-reinforced resin material, and method and die apparatus for producing the same
AssigneeHonda Motor Co., Ltd.
InventorYoshihide Yuza
Life of this patent
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Abstract
A formed article of a fiber-reinforced resin material is provided. The fiber-reinforced resin material is obtained by impregnating a plurality of stacked fiber layers with a resin. The formed article contains a first portion and a second portion formed to have a deep-drawn shape with respect to the first portion. The second portion contains a gradually changing portion with its thickness gradually changing, and the thickness of the gradually changing portion decreases with distance from the first portion.
Claims7
A formed article of a fiber-reinforced resin material comprising a plurality of stacked fiber layers and a resin, the stacked fiber layers being impregnated with the resin, the formed article comprising a first portion and a second portion formed to have a deep-drawn shape with respect to the first portion,
- wherein the first portion is flat and contiguous with the second portion;
- wherein the second portion includes a gradually changing portion that extends from a bend in the formed article between the first portion and the second portion, the gradually changing portion extending to a thickened portion of the second portion, the gradually changing portion having a thickness that gradually decreases with distance from the first portion,
- wherein the thickness of the gradually changing portion is defined by opposing side walls of the gradually changing portion, a first side wall of the opposing side walls being slanted with respect to a second side wall of the opposing side walls,
- wherein the thickened portion is thicker than a thinnest portion in the gradually changing portion of the second portion, and
- wherein the gradually changing portion and the thickened portion are distinct sections of the second portion.
A method for producing a formed article of a fiber-reinforced resin material, the method comprising a step of forming the article in a cavity formed between a first shaping die and a second shaping die of a die apparatus, the fiber-reinforced resin material containing a plurality of stacked fiber layers and a resin, the stacked fiber layers being impregnated with the resin, the formed article containing a bend between a first portion and a second portion, the first portion being flat and contiguous with the second portion,
- wherein the first shaping die or the second shaping die includes a gradually changing portion-forming region configured to form a gradually changing portion on at least part of a design surface or a back surface of the second portion, the gradually changing portion having a thickness that gradually decreases with distance from the first portion,
- wherein the thickness of the gradually changing portion is defined by opposing side walls of the gradually changing portion, a first side wall of the opposing side walls being slanted with respect to a second side wall of the opposing side walls,
- wherein the second portion contains a thickened portion, the gradually changing portion extends from the bend to the thickened portion, and the thickened portion is thicker than a thinnest portion in the gradually changing portion of the second portion, and
- wherein the gradually changing portion and the thickened portion are distinct sections of the second portion.
A die apparatus for producing a formed article of a fiber-reinforced resin material, the apparatus comprising a first shaping die and a second shaping die, the fiber-reinforced resin material containing a plurality of stacked fiber layers and a resin, the stacked fiber layers being impregnated with the resin, the formed article containing a first portion and a second portion formed to have a deep-drawn shape with respect to the first portion, the formed article being press-formed in a cavity formed between the first shaping die and the second shaping die,
- wherein the formed article has a bend between a first portion and a second portion, the first portion being flat and contiguous with the second portion,
- wherein the first shaping die or the second shaping die includes a gradually changing portion-forming region configured to form a gradually changing portion on at least part of a design surface or a back surface of the second portion, the gradually changing portion having a thickness that gradually decreases with distance from the first portion,
- wherein the thickness of the gradually changing portion is defined by opposing side walls of the gradually changing portion, a first side wall of the opposing side walls being slanted with respect to a second side wall of the opposing side walls,
- wherein the second portion contains a thickened portion, the gradually changing portion extends from the bend to the thickened portion, and the thickened portion is thicker than a thinnest portion in the gradually changing portion of the second portion, and
- wherein the gradually changing portion and the thickened portion are distinct sections of the second portion.
Dependencies are inferred from the claim text.