Fiber-reinforced resin molding material and method for manufacturing same, and fiber-reinforced resin molded article

Abstract

Provided are a fiber-reinforced resin molding material with which a lightweight and high-strength fiber-reinforced resin molded article can be easily obtained and a method for manufacturing the fiber-reinforced resin molding material. A fiber-reinforced resin molding material in which a reinforcement fiber sheet whose basis weight is 200 g/m2 or greater and 3,000 g/m2 or less is impregnated with a resin composition such that a content of the resin composition is 25 volume % or greater and 55 volume % or less, in which in a case where a total amount of the resin composition contained in the fiber-reinforced resin molding material is 100 mass %, a thickness from a first surface in a thickness direction of the fiber-reinforced resin molding material to a position occupied by 10 mass % of the resin composition is represented by d1 (μm), and a thickness from a second surface opposite to the first surface to a position occupied by 10 mass % of the resin composition is represented by d2 (μm), an absolute value (|d1−d2|) of a difference between d1 and d2 is 50 μm or less. A method for manufacturing a fiber-reinforced resin molding material, including: impregnating a reinforcement fiber sheet formed of at least one selected from the group consisting of a unidirectional sheet in which a plurality of continuous fibers are arranged in parallel in one direction, a woven fabric in which continuous fibers are woven, and a non-crimp fabric containing continuous fibers with a resin composition having an initial viscosity of 1 Pa·s or less and having a viscosity of 5,000 Pa·s or greater and 150,000 Pa·s or less after leaving for 7 days at 25° C.

1 . A fiber-reinforced resin molding material comprising:
 a reinforcement fiber sheet whose basis weight is 200 g/m 2  or greater and 3,000 g/m 2  or less; and   a resin composition which is impregnated into the reinforcement fiber sheet such that a content of the resin composition is 25 volume % or greater and 55 volume % or less,   wherein in a case where a total amount of the resin composition contained in the fiber-reinforced resin molding material is 100 mass %, a thickness from a first surface in a thickness direction of the fiber-reinforced resin molding material to a position occupied by 10 mass % of the resin composition is represented by d1 (μm), and a thickness from a second surface opposite to the first surface to a position occupied by 10 mass % of the resin composition is represented by d2 (μm), an absolute value (|d1−d2|) of a difference between d1 and d2 is 50 μm or less.   
     
     
         2 . The fiber-reinforced resin molding material according to  claim 1 ,
 wherein the reinforcement fiber sheet is formed of at least one selected from the group consisting of a unidirectional sheet in which a plurality of continuous fibers are arranged in parallel in one direction, a woven fabric in which continuous fibers are woven, and a non-crimp fabric containing continuous fibers.   
     
     
         3 . The fiber-reinforced resin molding material according to  claim 2 ,
 wherein the reinforcement fiber sheet is a non-crimp fabric.   
     
     
         4 . The fiber-reinforced resin molding material according to  claim 1 ,
 wherein R representing a ratio of the sum of d1 and d2 to the basis weight of the reinforcement fiber sheet is 0.2 or greater and 0.5 or less.   
     
     
         5 . The fiber-reinforced resin molding material according to  claim 1 ,
 wherein at least one of d1 and d2 is within a range of 5 μm or greater and 750 μm or less.   
     
     
         6 . The fiber-reinforced resin molding material according to  claim 1 ,
 wherein the basis weight of the reinforcement fiber sheet is 400 g/m 2  or greater.   
     
     
         7 . The fiber-reinforced resin molding material according to  claim 1 ,
 wherein the resin composition contains a vinyl ester resin.   
     
     
         8 . A fiber-reinforced resin molded article which is obtained by molding the fiber-reinforced resin molding material according to  claim 1 . 
     
     
         9 . A method for manufacturing a fiber-reinforced resin molding material, the method comprising:
 impregnating a reinforcement fiber sheet formed of at least one selected from the group consisting of a unidirectional sheet in which a plurality of continuous fibers are arranged in parallel in one direction, a woven fabric in which continuous fibers are woven, and a non-crimp fabric containing continuous fibers with a resin composition having an initial viscosity of 1 Pa·s or less and having a viscosity of 5,000 Pa·s or greater and 150,000 Pa·s or less after leaving for 7 days at 25° C.