Process for the production of composite molded article

A process for the production of a composite molded article in which a core portion of a porous resin layer is present between surface portions of a fiber-reinforced resin and the whole of the composite molded article is integrated, the process comprising the following steps,

• (a) the mixture preparation step of preparing a particles-containing resinous mixture of a curable liquid molding resin with light-weight filler particles having an average particle size of 0.01 to 2 mm, the light-weight filler particles being a mixture of rigid particles and compressible particles,
• (b) the laminate preparation step of preparing a laminate of a reinforcing fibrous sheet/separation sheet/layer of the resinous mixture in the above step (a)/separation sheet/reinforcing fibrous sheet,
• (c) the impregnation step of centripetally pressing and centrifugally relaxing the laminate at least once each, thereby removing gas bubbles other than gas bubbles contained in the particles with infiltrating the liquid molding resin contained in the layer of the resinous mixture into the reinforcing fibrous sheets through the separation sheets,
• (d) the curing step of curing the liquid molding resin and molding the laminate by heating the laminate in a mold heated at a predetermined temperature to form the cured composite molded article, and
• (e) the step of opening the mold and taking out the obtained composite molded article.

A process for the production of a composite molded article in which a core portion of a porous resin layer is present between two surface portions of a fiber-reinforced resin and the whole of the composite molded article is integrated, the process including the following steps,

• (a) the mixture preparation step of preparing a particles-containing resinous mixture of a curable liquid molding resin with light-weight filler particles having an average particle size of 0.01 to 2 mm, the light-weight filler particles being a mixture of rigid particles and compressible particles,
• (b) the laminate preparation step of continuously feeding two separation sheets and two reinforcing fibrous sheets such that the two separation sheet are positioned between the two reinforcing fibrous sheets and continuously feeding the mixture prepared in the above step (a) into a portion between the two separation sheets, to continuously prepare a laminate of a reinforcing fibrous sheet/separation sheet/layer of the resinous mixture in the above step (a)/separation sheet/reinforcing fibrous sheet,
• (c) the impregnation step of centripetally pressing and centrifugally relaxing the laminate at least once each, thereby removing gas bubbles other than gas bubbles contained in the particles with infiltrating the liquid molding resin contained in the layer of the resinous mixture into the reinforcing fibrous sheets through the separation sheets, and
• (d) the curing step of heating the laminate under pressure or under no pressure to cure the resin to form the composite molded article.

A process for the production of a partially cured composite material in which a core portion of a porous resin layer is present between surface portions of a fiber-reinforced resin and the whole of the composite molded article is integrated, the process including the following steps,

• (a) the mixture preparation step of preparing a particles-containing mixture of a curable liquid molding resin with light-weight filler particles having an average particle size of 0.01 to 2 mm, the light-weight filler particles being a mixture of rigid particles and compressible particles,
• (b) the laminate preparation step of continuously feeding two separation sheets and two reinforcing fibrous sheets such that the two separation sheet are positioned between the two reinforcing fibrous sheets and continuously feeding the mixture prepared in the above step (a) into a portion between the two separation sheets, to continuously prepare a laminate of a reinforcing fibrous sheet/separation sheet/layer of the mixture in the above step (a)/separation sheet/reinforcing fibrous sheet,
• (c) the impregnation step of centripetally pressing and centrifugally relaxing the laminate at least once each, thereby removing gas bubbles other than gas bubbles contained in the particles with infiltrating the liquid molding resin contained in the layer of the mixture into the reinforcing fibrous sheets through the separation sheets, and
• (d) the partially curing step of heating the laminate under pressure or under no pressure to partially cure the resin to form the partially cured composite material having form retainability.

A process for the production of a composite molded article in which a core portion of a porous resin layer is present between surface portions of a fiber-reinforced resin and the whole of the composite molded article is integrated, the process comprising the following steps,

• (a) the mixture preparation step of preparing a particles-containing resinous mixture of a curable liquid molding resin with light-weight rigid particles having an average particle size of 0.01 to 2 mm,
• (b) the laminate preparation step of continuously feeding two separation sheets and two reinforcing fibrous sheets such that the two separation sheet are positioned between the two reinforcing fibrous sheets and continuously feeding the resinous mixture prepared in the above step (a) into a portion between the two separation sheets, to continuously prepare a laminate of a reinforcing fibrous sheet/separation sheet/layer of the resinous mixture in the above step (a)/separation sheet/reinforcing fibrous sheet,
• (c) the impregnation step of centripetally pressing and centrifugally relaxing the laminate at least once each, thereby removing gas bubbles other than gas bubbles contained in the particles with infiltrating the liquid molding resin contained in the layer of the resinous mixture into the reinforcing fibrous sheets through the separation sheets, and
• (d) the curing step of heating the laminate under pressure or under no pressure to cure the resin to form the composite molded article.

A process for the production of a partially cured composite material in which a core portion of a porous resin layer is present between surface layers of a fiber-reinforced resin and the whole of the composite material is integrated, the process including the following steps,

• (a) the mixture preparation step of preparing a particles-containing resinous mixture of a curable liquid molding resin with light-weight rigid particles having an average particle size of 0.01 to 2 mm,
• (b) the laminate preparation step of continuously feeding two separation sheets and two reinforcing fibrous sheets such that the two separation sheet are positioned between the two reinforcing fibrous sheets and continuously feeding the resinous mixture prepared in the above step (a) into a portion between the two separation sheets, to continuously prepare a laminate of a reinforcing fibrous sheet/separation sheet/layer of the resinous mixture in the above step (a)/separation sheet/reinforcing fibrous sheet,
• (c) the impregnation step of centripetally pressing and centrifugally relaxing the laminate at least once each, thereby removing gas bubbles other than gas bubbles contained in the particles with infiltrating the liquid molding resin contained in the layer of the mixture into the reinforcing fibrous sheets through the separation sheets, and
• (d) the preliminary curing step of heating the laminate under pressure or under no pressure to partially cure the resin to form the partially cured composite material having shape retainability.