Fiber-reinforced resin structure and method for producing fiber-reinforced resin structure

Abstract

[Task] It is to provide a fiber-reinforced resin structure having improved surface properties and reinforced with carbon fibers or glass fibers while keeping lightweight properties. [Solution] A fiber-reinforced resin structure is constructed by forming a thermal sprayed coating composed mainly of boron carbide on a fiber-reinforced plastic substrate as a top coating.

1 . A fiber-reinforced resin structure comprising a fiber-reinforced plastic substrate and a thermal sprayed coating formed thereon and composed mainly of boron carbide as a top coating. 
     
     
         2 . The fiber-reinforced resin structure according to  claim 1 , wherein the fiber-reinforced plastic substrate is a carbon fiber-reinforced plastic substrate. 
     
     
         3 . The fiber-reinforced resin structure according to  claim 1 , wherein an intermediate layer A made from a metal is disposed between the substrate and the top coating. 
     
     
         4 . The fiber-reinforced resin structure according to  claim 3 , wherein the metal is a simple substance selected from aluminum, titanium and magnesium or an alloy containing one or more of these elements. 
     
     
         5 . The fiber-reinforced resin structure according to  claim 1 , wherein an intermediate layer A made from a ceramic is disposed between the substrate and the top coating. 
     
     
         6 . The fiber-reinforced resin structure according to  claim 5 , wherein the ceramic is one or more oxide ceramics selected from aluminum oxide, zirconium oxide, yttrium oxide, silicon oxide, magnesium oxide, chromium oxide and titanium oxide. 
     
     
         7 . The fiber-reinforced resin structure according to  claim 1 , wherein the fiber-reinforced resin structure is provided with an intermediate layer A made from a mixture of a resin and ceramic particles between the substrate and the top coating. 
     
     
         8 . The fiber-reinforced resin structure according to  claim 7 , wherein the resin contained in the intermediate layer A includes a resin of the same kind as the resin contained in the substrate. 
     
     
         9 . The fiber-reinforced resin structure according to  claim 7 , wherein at least a part of the melted and solidified resins is integrally formed at a boundary face between the fiber-reinforced plastic substrate and the intermediate layer A. 
     
     
         10 . The fiber-reinforced resin structure according to  claim 7 , wherein the ceramic particles contained in the intermediate layer A are oxide ceramic particles containing one or more selected from aluminum oxide, zirconium oxide, yttrium oxide, silicon oxide, magnesium oxide, chromium oxide and titanium oxide. 
     
     
         11 . The fiber-reinforced resin structure according to  claim 3 , wherein the fiber-reinforced resin structure is provided with an intermediate layer B made from one or more materials selected from ceramic, metal and alloy between the intermediate layer A and the top coating. 
     
     
         12 . The fiber-reinforced resin structure according to  claim 11 , wherein the intermediate layer B is a layer made from one or more oxide ceramics selected from aluminum oxide, zirconium oxide, yttrium oxide, silicon oxide, magnesium oxide, chromium oxide and titanium oxide. 
     
     
         13 . A method for producing a fiber-reinforced resin structure as claimed in  claim 1 , characterized in that the top coating is formed by a controlled atmosphere thermal spraying process. 
     
     
         14 . The fiber-reinforced resin structure according to  claim 5 , wherein the fiber-reinforced resin structure is provided with an intermediate layer B made from one or more materials selected from ceramic, metal and alloy between the intermediate layer A and the top coating. 
     
     
         15 . The fiber-reinforced resin structure according to  claim 7 , wherein the fiber-reinforced resin structure is provided with an intermediate layer B made from one or more materials selected from ceramic, metal and alloy between the intermediate layer A and the top coating. 
     
     
         16 . The fiber-reinforced resin structure according to  claim 14 , wherein the intermediate layer B is a layer made from one or more oxide ceramics selected from aluminum oxide, zirconium oxide, yttrium oxide, silicon oxide, magnesium oxide, chromium oxide and titanium oxide. 
     
     
         17 . The fiber-reinforced resin structure according to  claim 15 , wherein the intermediate layer B is a layer made from one or more oxide ceramics selected from aluminum oxide, zirconium oxide, yttrium oxide, silicon oxide, magnesium oxide, chromium oxide and titanium oxide.