Structure applying the glass fiber-reinforced resin foam having excellent fatigue resistance and insulating properties and manufacturing method thereof

Abstract

A vehicle sandwich structure composed of a foamed resin article in sheet form forming the core, a fiber-reinforced composite layer forming a surface material that is located on one or both sides of the foamed resin article in thickness direction; forming a binding layer of core and surface materials between the foamed resin article and the fiber-reinforced composite layer; a large number of glass fibers being inserted within said foamed resin article; more than 70% of total glass fibers being the glass fibers which form an angle between the longitudinal direction of each glass fiber and said foamed resin article, the angle of which satisfying a range from 45° to 90°.

1 . A vehicle sandwich structure, comprising:
 a foamed resin article in sheet form forming the core;   a fiber-reinforced composite layer forming a surface material that is located on one side or both sides in the thickness direction of said foamed resin article; and   a binding layer of core and surface materials between the foamed resin article and the fiber-reinforced composite layer,   wherein a large number of glass fibers being inserted within the foamed resin article;   more than 70% of total glass fibers being the glass fibers which form an angle between the longitudinal direction of each glass fiber and said foamed resin article, the angle of which satisfying a range from 45° to 90°; and   one or both ends of the glass fiber are exposed on the entire foamed resin article, the exposed glass fiber being impregnated and bound to the binding layer and the fiber-reinforced composite layer.   
     
     
         2 . The vehicle sandwich structure according to  claim 1 , wherein the height of the exposed portion of said glass fiber is0.5˜10 mm. 
     
     
         3 . The vehicle sandwich structure according to  claim 1 , wherein the structure has the flexural fatigue resistance of more than 100,000. 
     
     
         4 . The vehicle sandwich structure according to  claim 1 , wherein:
 a fiber is using for the fiber-reinforced composite layer is one or more fibers selected from the group consisting of a glass fiber, a carbon fiber, an aramid fiber, and a synthetic fiber; and   the type thereof the fiber is one or two types selected from the group consisting of a weaving fabric, a uni-directional fabric, a continuous strand mat, a chopped strand mat, and a bulky mat.   
     
     
         5 . A manufacturing method for a vehicle sandwich structure, comprises the steps of:
 providing a large number of glass fibers on a mold;   spraying the foamed resin onto a large number of said glass fibers;   producing a foamed resin article wherein glass fiber is inserted by foaming said foamed resin;   slicing said foamed resin article longitudinally so as to give fixed thicknesses;   removing the foamed resin of the end portion of the foamed resin article by undergoing physical or chemical treatments at one or both ends of said sliced foamed resin article; and   undergoing an integrated molding process of said foamed resin article wherein glass fiber is exposed (core material) and the fiber-reinforced composite layer (surface material), so that the fiber-reinforced composite layer is impregnated with the glass fiber which is exposed on said foamed resin article.   
     
     
         6 . The manufacturing method for a vehicle sandwich structure according to  claim 5 , wherein:
 the reinforced fiber used for manufacture of said foamed resin article, is in the form of more than one or two types selected from the group consisting of a continuous strand mat, a chopped strand mat, a bulky mat, a weaving fabric, and a uni-directional fabric; and   the foamed resin used for manufacture of said foamed resin article, is more than one or two types of foamed resin selected from the group consisting of a polyurethane resin, a polyisocyanurate resin, a polystyrene resin, a polyethylene resin and a phenolic resin.   
     
     
         7 . The manufacturing method for a vehicle sandwich structure according to  claim 5 , wherein the physical treatment for removing the foamed resin of one or both ends of said sliced foamed resin article being one type of method selected from the group consisting of a method of adjusting the extent of the cut using cutting devices, and a method of using a brush or a chisel. 
     
     
         8 . The manufacturing method for a vehicle sandwich structure according to  claim 5 , wherein the chemical treatment for removing the foamed resin of one or both ends of said sliced foamed resin article undergoing treatments is carried with one or more organic chemical solvents selected from the group consisting of a hydrocarbon-based, a halogenated hydrocarbon-based, an alcohol-based, an aldehyde-based, an ether-based, an ester-based, a ketone-based, and a glycol ether-based compound. 
     
     
         9 . The manufacturing method for a vehicle sandwich structure according to  claim 5 , wherein the method of binding together a foamed resin article (core material) is any one method selected from the group consisting of a method of binding with the use of a binder between a foamed resin article in which glass fiber is exposed and a fiber-reinforced composite layer, and a method of infusing the synthetic resin by laminating a fiber-reinforced composite layer to a foamed resin article in which the glass fiber is exposed. 
     
     
         10 . The manufacturing method for a vehicle sandwich structure according to  claim 9 , wherein:
 the method of infusing the synthetic resin by laminating a fiber-reinforced composite layer (surface material) to a foamed resin article in which the glass fiber is exposed (core material) is more than one or two types of method selected from the group consisting of a hand lay-up, a resin transfer molding, an infusion molding, an autoclave molding, a vacuum bag molding, and a press compression molding, and   said synthetic resin for integrated molding is more than one or two types of resin selected from the group consisting of an unsaturated polyester resin, a vinyl ester resin, an epoxy resin, a polyurethane resin, a phenolic resin, a polyethylene resin, a nylon resin, a polyacetal resin, a polyvinyl chloride resin, a polystyrene resin and an ABS resin.   
     
     
         11 . A vehicle sandwich structure, which is manufactured in a curved shape by finely cutting the vehicle sandwich structure produced along to any one of the  claims 5 - 10  or the foamed resin article for core materials with the use of notch cutting and by binding or integrated molding of many of the cut pieces in one type of shape which is selected from the group consisting of a doughnut type (O-shape), an arched type (⊂-shape), and circular shape.