JP2009214371A - Method for manufacturing fiber-reinforced composite material and fiber-reinforced composite material, method for manufacturing integrated structural member and integrated structural member - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber-reinforced composite material which is capable of easily and strongly sticking with another member and in which a reinforcing fiber substrate is impregnated with an uncured matrix resin and it is cured, a fiber-reinforced composite material, and an integrated structural member using it. <P>SOLUTION: The method for manufacturing the fiber-reinforced composite material comprises a laminating process, a heat-pressing process and a curing process. In the laminating process, a reinforcing fiber substrate comprising a binder composition and having a sheet-like or a tape-like shape, and a thermoplastic resin sheet comprising a thermoplastic resin as a main component and having a melting point being at least 10°C or more lower than a melting point of the binder composition are laminated at least a part of the surface of the reinforcing fiber substrate. In the heat-pressing process, a film of the thermoplastic resin is formed on the surface of the reinforcing fiber substrate by melting the thermoplastic resin sheet, and the reinforcing fiber substrate on the surface of which the film of the thermoplastic resin is formed is molded into a specified shape. In the curing process, the reinforcing fiber substrate formed with the film of the thermoplastic resin is impregnated with a heat-curable resin, and a curing reaction is performed. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for producing a fiber-reinforced composite material obtained by impregnating and curing an uncured matrix resin on a reinforcing fiber substrate containing a binder composition. Furthermore, the present invention provides a fiber reinforced composite material containing a binder composition and having a thermoplastic resin coating formed on the surface thereof, and a method for producing an integrated structure member and an integrated member for joining the fiber reinforced composite material to another member. The present invention relates to a structural member.

  Fiber reinforced composite materials are excellent in moldability, thin wall, light weight, high rigidity, productivity, and economical efficiency. Electrical / electronic equipment parts, automotive equipment parts, personal computers, OA equipment, AV equipment, mobile phones, telephones, facsimiles, home appliances. Used in products, toy cover, skeleton and drive unit.

  As a material superior in thickness, light weight, and high rigidity, there is a fiber-reinforced composite material using continuous reinforcing fibers. A typical method for manufacturing fiber reinforced composite materials is a method of stacking and curing fiber reinforced prepregs in which continuous reinforced fibers are impregnated with uncured resin, but it is easy to mass-produce molded products with complex shapes. It was unsuitable for production.

  Another method for producing a fiber-reinforced composite material is a so-called resin in which a reinforcing fiber base is shaped into a mold, an uncured resin is injected, and the reinforcing fiber base is impregnated with a resin and then cured. A transfer molding (RTM) molding method can be applied. Since this molding method shapes a base material that is not impregnated with resin, it is possible to produce a molded product having a relatively complicated shape. However, it is difficult to produce a molded product having a complex shape as compared with a complex shape molded product obtained from an injection molded product or a metal molded product.

  Therefore, there is a need for a technique for integrally joining composite materials such as fiber-reinforced plastic plates and metal plates having these various advantages to other molded products.

  Patent Document 1 discloses a method for manufacturing a fiber-reinforced composite material using an RTM molding method, which can be easily and firmly bonded to another member, and a technique related to a base material used in the manufacturing method. Yes. That is, Patent Document 1 is a continuous reinforcing fiber base material in which a thermoplastic resin is disposed on at least a part of the surface of a base material made of continuous reinforcing fibers, and a molded article obtained from the continuous reinforcing fiber base material. The present invention relates to a continuous reinforcing fiber base material for a composite material surface layer for forming a thermoplastic resin layer on the surface. Further, as a specific example of a method of joining the base material as a molded product to another member, the molded product is post-processed to a predetermined size as necessary, and then the molded product is inserted into an injection mold, Thereafter, there is a technique in which another member is disposed on the thermoplastic sheet portion of the molded article and injection molded into the mold. Furthermore, as another specific example, a method in which a fiber reinforced composite material and another member are separately molded, and the other member is integrated with the thermoplastic sheet by heat welding, vibration welding, ultrasonic dressing, or the like. There is. In any case, a technique for heating and welding a thermoplastic sheet is disclosed.

  In addition, Patent Document 2 uses a binder composition for preform preparation, which has excellent adhesion to reinforcing fibers and has good storage stability in order to enhance mass productivity of the RTM molding method, and this binder composition. It is disclosed to provide a preform that has been present.

Therefore, in order to obtain a higher mass productivity and a strong adhesive force with another member, a fiber reinforced composite material using both a preform-forming binder composition and a thermoplastic sheet, and a molding method are used. There was a trend. However, in this method, the binder composition for preform preparation on the surface of the molded article elutes or the binder composition dissolves inside the molded article by heating when joining the fiber reinforced composite material and another member. Therefore, there are problems such as release of residual stress and generation of gas sinks and voids, causing local mechanical strength deterioration.
JP 2006-44261 A JP 2005-194456 A

  The present invention eliminates the problems of the prior art, and can easily and firmly adhere to another member, impregnated with an uncured matrix resin on a reinforcing fiber substrate, represented by RTM molding, and cured. An object of the present invention is to provide a method for manufacturing a fiber reinforced composite material, a fiber reinforced composite material, a method for manufacturing an integrated structural member using the same, and an integrated structural member.

  That is, the present invention includes at least a (A) binder composition, a reinforcing fiber base material having a sheet-like or tape-like form, and at least a part of the surface of the reinforcing fiber base material, the thermoplastic resin as a main component. A lamination step of laminating a thermoplastic resin sheet having a melting point lower by 10 ° C. or more than the melting point of the binder composition; (B) melting the thermoplastic resin sheet to form a thermoplastic resin on the surface of the reinforcing fiber base; A heating press step of forming a reinforcing fiber base on which the thermoplastic resin coating is formed into a predetermined shape on the surface thereof, and (C) a reinforcement in which the thermoplastic resin coating is formed. It is a manufacturing method of the fiber reinforced composite material which has a hardening process which inject | pours a thermosetting resin into a fiber base material, and makes it harden reaction.

  The present invention also relates to a fiber-reinforced composite material formed into a predetermined shape, comprising a binder composition, a reinforcing fiber base material having a sheet-like or tape-like form, and a thermosetting resin. The fiber reinforced composite material has a thermoplastic resin coating formed on its surface, the main component of which is a thermoplastic resin, and a melting point of 10 ° C. lower than the melting point of the binder composition.

  The thermoplastic resin coating formed on the fiber reinforced composite material is preferably coated with a fiber reinforced composite material, and more preferably another member made of a fiber reinforced composite material with a thermoplastic resin coating formed on the surface. It is preferable to provide a method for producing an integrated structure member having a joining step (step (D)) in which heating and welding are performed at a temperature lower than the melting point of the binder composition.

  Furthermore, the thermoplastic resin coating portion formed on the fiber reinforced composite material is joined to another fiber reinforced composite material, and the surface of the other fiber reinforced composite material is a thermoplastic resin. It is preferable to form an integrated structure member in which the fiber-reinforced composite materials are joined to each other on the surfaces of the respective thermoplastic resin coatings.

  As the binder composition, a composition containing a thermoplastic resin mainly composed of polyvinyl formal (that is, preferably containing 80% by mass or more, more preferably 90% by mass or more of polyvinyl formal) is used. For the coating, it is preferable to use a resin composition containing a terpolymer polyamide resin as a main component (that is, preferably containing 80% by mass or more, more preferably 90% by mass or more).

  According to the present invention, for example, by a molding method typified by RTM molding or the like, the binder composition is included, and at least a part of the surface is mainly composed of a thermoplastic resin and is lower by 10 ° C. or more than the melting point of the binder composition. When obtaining an integrated structure member joined to another member using a fiber reinforced composite material obtained by impregnating and curing an uncured matrix resin on a reinforced fiber base material laminated with a thermoplastic resin sheet having a melting point In addition, an integrated structural member with high adhesive strength can be easily obtained, and the binder composition inside the molded article made of the fiber reinforced composite material melts and flows out by heating at the time of joining with other members. Molded parts made of fiber-reinforced composite materials with integrated mechanical structure that have no degradation of local mechanical properties due to gasification or deterioration of quality (deterioration of appearance). It is possible to obtain.

  Hereinafter, the fiber-reinforced composite material of the present invention will be described in detail together with preferred embodiments.

  FIGS. 1-6 has shown the shaping | molding method of the fiber reinforced composite material which concerns on one embodiment of this invention, and the manufacturing method of an integrated structural member. In FIG. 3, the reinforcing fiber base material 10 containing the binder composition 8 and having a sheet-like or tape-like form, the thermoplastic resin sheet 3, the reinforcing fiber base material 2 has three layers, and the thermoplastic sheet 3 has The figure laminated | stacked so that it might become 1 layer is shown.

  As shown in FIG. 2, the reinforcing fiber base material 10 is dispersed with a binder composition 8 containing a thermoplastic resin. Here, the binder composition 8 preferably contains a thermoplastic resin. The thermoplastic resin is preferably contained in the binder composition 8 in an amount of 30 to 80% by mass, more preferably 40 to 70% by mass. In addition, as the resin other than the thermoplastic resin included in the binder composition 8, a thermosetting resin represented by an epoxy resin is used.

  In FIG. 2, the binder 8 is sprayed only on the front side of the reinforcing fiber base 2, but the binder composition 8 may be sprayed on both surfaces of the reinforcing fiber base 2. In FIG. 4, another reinforcing fiber substrate 2 is laminated on a surface different from the surface of the reinforcing fiber substrate 10 on which the binder composition 8 is dispersed.

  As the thermoplastic resin contained in the binder composition 8, polyvinyl acetal resins such as polyvinyl formal and polyvinyl butyral, polyvinyl alcohol, and phenoxy resins are preferably used. A thermoplastic resin mainly composed of polyvinyl formal is preferably used. The thermoplastic resin mainly composed of polyvinyl formal may be composed entirely of polyvinyl formal, but is preferably 80% by mass or more, more preferably 90% by mass or more of polyvinyl formal. It means that it may be a composition.

  The form of the reinforcing fiber substrate 2 includes a woven fabric composed of fiber bundles, a reinforcing fiber bundle in which a large number of reinforcing fibers are arranged in one direction (unidirectional fiber bundle), and the unidirectional fiber bundle. In addition, a combination of these, such as a unidirectional woven fabric, and a plurality of layers are arranged. Of these, woven fabrics and unidirectional fiber bundles are preferred from the viewpoint of substrate productivity. The reinforcing fiber base 2 may be composed of a plurality of fiber bundles having the same form or may be composed of a plurality of fiber bundles having different forms. The number of reinforcing fibers constituting one reinforcing fiber bundle is usually 300 to 48,000. Examples of the fiber material of the reinforcing fiber base 2 used include glass fiber, carbon fiber, metal fiber, aromatic polyamide fiber, polyaramid fiber, alumina fiber, silicon carbide fiber, boron fiber, and basalt fiber. These are used alone or in combination of two or more. Among these, carbon fibers are more preferable because these fibers have higher strength and higher elastic modulus, and thus a fiber-reinforced composite material having excellent mechanical properties can be obtained.

  Further, as shown in FIG. 3, as the thermoplastic resin constituting the thermoplastic resin sheet 3 laminated on at least a part of the surface of the reinforcing fiber substrate 2, polyethylene terephthalate, polybutylene terephthalate, polyamide resin, etc. are preferable. From the viewpoint of increasing the adhesive strength with the member 16, the solubility parameter δ (SP value) is preferably 8 to 16, more preferably 9 to 16, further preferably 10 to 15, and particularly preferably 11 to 14. . Further, as the polyamide resin which is a thermoplastic resin constituting the preferred thermoplastic resin sheet 3, it is more preferable to use a resin composition containing a terpolymer copolymer polyamide resin as a main component. However, it is particularly preferable to use polyamide 6/66/610 resin from the viewpoint of further increasing the adhesive strength with another member 16. The resin composition mainly composed of the terpolymer polyamide resin may be composed of the terpolymer polyamide resin, but the terpolymer polyamide resin is preferably 80% by mass or more. More preferably, it means that the resin composition may contain 90% by mass or more.

  The thermoplastic resin sheet 3 is preferably in the form of a combination of at least two or more of non-woven fabric, woven fabric, particles, film, and the like. By adopting the above form, the reinforced fiber base material can be sufficiently impregnated with the thermoplastic resin, and the surface of the fiber reinforced composite material can be appropriately covered, and a strong adhesive force with another member can be expressed. it can.

  Next, the manufacturing method of the fiber reinforced composite material of this invention is demonstrated in detail with desirable embodiment.

  1 in FIG. 1 shows a shaping mold, and three layers of reinforcing fiber substrate 10 (reinforcing fiber substrate 2 containing binder composition 8) are formed by clamping the upper die 1a and the lower die 1b. The thermoplastic resin sheet 3 is pressurized to a predetermined thickness and shape by pressing a base material group having a single layer structure, and at the same time, the reinforcing fiber base material 10 (shaped mold 1) is heated, and the binder composition 8 and heat are heated. The plastic resin sheet 3 is softened (melted) to adhere and adhere to the reinforcing fiber base 2. At this time, the thermoplastic resin sheet 3 is softened (melted) so that a film is formed on the surface of the reinforcing fiber base 2. In addition, the coating film of the thermoplastic resin here does not need to cover the entire surface of the reinforcing fiber base 2 with the thermoplastic resin, and after that, the integrated structural member is bonded to another member. There is no problem even if there is a portion not covered with the thermoplastic resin within the range that can be obtained.

  FIG. 3 shows an enlarged schematic view of the enlarged (1) 5 portion of FIG. Thereafter, the shaping mold 1a1b is cooled, and the binder composition 8 and the thermoplastic resin sheet 3 are cured while maintaining the adhesive force, and the laminate is easily separated after being removed from the shaping mold 1. The preform 4 integrated to such an extent that it does not become is formed.

  FIG. 5 shows a schematic diagram of an RTM molding die preferably used in the present invention. In the mold, a cavity 12 having a desired uneven shape can be formed inside by clamping the upper mold 11a and the lower mold 11b. The preform 4 is placed in the cavity 12, and after mold clamping, a thermosetting resin is injected from the injection port, and it is confirmed that the resin has come out from the discharge port. As a result, the resin injection is stopped and then a curing reaction is performed at a predetermined temperature.

  The production method according to the present invention includes a laminating step in which the thermoplastic resin sheet 3 is laminated on at least a part of the surface of the laminated product of the reinforcing fiber base material 2 to which the binder composition 8 has been dispersed and adhered in advance. A heating step (FIGS. 1b and 4) in which the binder composition 8 and the thermoplastic resin sheet 3 are softened so that the laminated reinforcing fiber bases 10 are brought into close contact with each other and a film of the thermoplastic resin is formed on the reinforcing fiber base 2 Next, it is important to have a step (FIG. 5) of injecting and curing the thermosetting resin into the reinforcing fiber base 2 on which the thermoplastic resin film is formed. In the preheating step (FIGS. 1b and 4), the respective reinforcing fiber bases 2 on which the binder composition 8 is laminated are joined, and the reinforcing fiber base 2 is impregnated with the thermoplastic sheet 3 and a film is formed on the surface. Therefore, a fiber-reinforced composite material that can be firmly bonded to another member can be manufactured by injecting and curing a thermosetting resin. In the heating step, a thermoplastic resin film is formed, and the reinforcing fiber base 2 is shaped into a predetermined shape by the shaping mold 1a1b (the heating step and the shaping step are combined and heated). The fiber-reinforced composite material is formed into a predetermined shape by calling the pressing step.

  Moreover, in a heating process (FIG. 4), in order to efficiently impregnate the reinforced fiber base material 2 with the thermoplastic resin derived from the thermoplastic resin sheet 3, it is preferably performed in a state where a pressure of 0.01 to 10 MPa is applied. More preferably, it is 0.03-5 MPa. The pressure can be applied in a process such as temporarily closing the mold. The reinforcing fiber base 2 is heated, the binder composition and the 8 thermoplastic resin sheet 3 are softened, and the pressure within the above range is applied, whereby the reinforcing fiber base 2 is easily impregnated with the thermoplastic resin, and the reinforcing fiber A thermoplastic resin film can be effectively formed on the surface of the substrate 2. In order to form a thermoplastic resin coating on the surface, the substrate thickness of the reinforcing fiber substrate 2, the substrate thickness of the cavity, the substrate thickness of the thermoplastic sheet, etc. It is necessary to adjust so that the impregnation of the thermoplastic resin and the coating on the surface of the reinforcing fiber base 2 are compatible.

  The melting point of the thermoplastic resin sheet 3 (after the coating is formed on the surface of the reinforcing fiber substrate 2) needs to be 10 ° C. or more lower than the melting point of the binder composition 8 to be used. Is lower by 20 ° C. or more. By setting each melting point to such a range, an integrated structural member with high adhesive strength can be easily obtained, and the heating temperature at the time of joining with other members is set lower than the melting point of the binder composition. From the fiber reinforced composite material in which the binder composition inside the molded product comprising the fiber reinforced composite material does not melt and flow out, and the local mechanical property deterioration or quality deterioration due to gasification is suppressed. This is because a molded product is obtained. In addition, from the viewpoint of workability and process stability, the melting point of the thermoplastic resin sheet 3 (the film after the film is formed on the surface of the reinforcing fiber base 2) has a melting point of the binder composition 8 used. It is preferably 30 ° C. or lower than the melting point.

  Since the fiber-reinforced composite material obtained in this way has a thermoplastic resin coating on the surface, it can be easily joined with another member (separate member) 16 as shown in FIG. An integral structural member can be obtained. In particular, when a fiber reinforced composite material is used as the separate member 16, the thermoplastic resin coating portion of the fiber reinforced composite material 15 according to the present invention is joined to the separate member 16, thereby providing an integrated structural member having high adhesive strength. This is preferable. Furthermore, when a thermoplastic resin coating is also formed on the surface of the fiber reinforced composite material that is the separate member 16, an integrated structure with higher adhesive strength can be obtained by bonding on the surface of each thermoplastic resin coating. It becomes a member and is more preferable.

  The evaluation of the characteristics used in the examples is as follows.

[Vertical adhesive strength]
From the part where the fiber reinforced composite material and another member are joined from the integrated structural member, a vertical adhesive strength evaluation sample was cut out in a size of 10 mm × 10 mm (the whole sample is a joint).

  Next, the sample was fixed to a jig of a measuring device. As the measuring device, “Instron” (registered trademark) 5565 type universal material testing machine (manufactured by Instron Japan Co., Ltd.) was used. For fixing the sample, if the sample can be held by an Instron chuck, the sample is held in the chuck as it is and a tensile test is performed. If the sample cannot be held, an adhesive (Three Bond 1782, manufactured by Three Bond Co., Ltd.) is applied to the sample. It may be allowed to stand for 4 hours at ± 5 ° C. and 50 ± 5% RH to adhere to the jig.

  The tensile test was performed at an ambient temperature of 25 ° C. in a test chamber in which the ambient temperature can be adjusted.

 Before starting the test, after the sample has been kept in the test chamber for at least 5 minutes without being subjected to a tensile test load, and a thermocouple is placed on the sample to ensure that it is equivalent to the ambient temperature A tensile test was performed.

  The tensile test was performed by pulling from the adhesion surface of both at 90 ° direction at a tensile speed of 1.27 mm / min, and the value obtained by dividing the maximum load by the adhesion area was defined as the vertical adhesion strength (unit: MPa). The number of samples was n = 5.

Example 1
[Plate-like integrated structural member]
(Fiber reinforced composite material)
Toray Industries, Inc. “Torayca fabric” CO6343 (weight per unit (W) 200 g / m ² , fiber reinforced base material thickness (t) 0.29 mm) cut to a predetermined size, polyvinyl formal Toray Co., Ltd. as a thermoplastic resin sheet on the outermost surface was sprayed uniformly about 20 g / m ² of powder with a melting point of 200 ° C. or higher as the main component, and the spread fiber reinforced base material was laminated in the mold. A ternary copolymerized polyamide resin CM4000 (nylon 6/66/610, melting point 150 ° C., solubility parameter δ (SP value) 13.3) film (weight per unit: 60 g / m ² ) is the same size as the molded body The cut pieces were stacked and laminated, and the molds were clamped. Next, the mold temperature is heated to 155 ° C. and held for 5 minutes, and then cooled to 80 ° C. or lower, and the laminate of the reinforcing fiber base is removed from the mold. The demolded reinforcing fiber laminate is composed of 60 parts by mass of a powder composed mainly of polyvinyl formal (polyvinyl formal “Vinylec” K type (produced by Nitrogen Co., Ltd.)), liquid bisphenol A epoxy resin “Epicoat 828” (Japan Epoxy) Resin Co., Ltd.) 10 parts by mass, solid bisphenol A type epoxy resin “Epicoat 1001” (Japan Epoxy Resin Co., Ltd.) 30 parts by mass) is held in the mold shape, This is called renovation.

  Next, 90 parts by mass of a matrix resin (epoxy resin “Epicoat” 828 (manufactured by Japan Epoxy Resin Co., Ltd.)), which is preliminarily shaped into a predetermined shape, placed in a mold and preheated to 60 ° C. 10 parts by mass of “ERISYS” GE-20 (manufactured by CVC) and 32 parts by mass of “Ancamine” 2049 (manufactured by PTI Japan) were injected into the mold at an injection pressure of 0.2 MPa using a resin injection device. Then, the reinforcing fiber substrate was impregnated. The thickness of the molded product was adjusted to 1.1 mm so that the volume content of the reinforcing fibers was 60%. After impregnation, it was held at a temperature of 155 ° C. for 2 hours, then cooled to a temperature of 30 ° C. and demolded to obtain a fiber-reinforced composite material. The resulting fiber reinforced composite material has a thickness of 1.1 mm.

(Separate parts)
The same fiber reinforced composite material as the above fiber reinforced composite material was used as a separate member.

(Integrated)
The fiber reinforced composite material and the separate member are heated on a hot plate at 160 ° C. for 3 minutes, and then the surfaces having a coating derived from a thermoplastic resin sheet are bonded together as a joining surface, and held at a pressure of 20 MPa for 2 minutes to be integrated. Into a plate-like integrated structural member. Attempts were made to evaluate the vertical bond strength of the obtained integrated structural member. At 6 MPa, the fixed part by the adhesive between the sample and the jig peeled off before the bonded part peeled off. It was evaluated that there was.

It is one embodiment illustration of the shaping die which produces the reinforced fiber composite material of this invention. It is the schematic diagram which spread | dispersed the binder composition on the reinforced fiber base material of this invention. It is a cross-sectional schematic diagram of the lamination | stacking state of the reinforced fiber base material of this invention. It is a schematic diagram of the state which pressurized the reinforcing fiber equipment and thermoplastic sheet of this invention. It is a schematic diagram of the RTM molding die of this invention. It is a schematic diagram of the state which joined the fiber reinforced composite material of this invention, and another member.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1a: Upper mold | type 1b: Lower mold | type 2: Reinforcement fiber base material 3: Thermoplastic resin sheet 4: Preform 5: Expansion (1)
6: Expansion (2)
7: Expansion (3)
8: Binder composition 10: Reinforcing fiber substrate (with binder composition)
11a: Upper mold 11b: Lower mold 12: Cavity 13: Resin injection machine 14: Waste resin tank 15: Fiber reinforced molded product 16: Separate member

Claims (7)

A method for producing a fiber-reinforced composite material comprising at least the following steps (A) to (C).
(A) A reinforcing fiber base material containing a binder composition and having a sheet-like or tape-like form, and at least a part of the surface of the reinforcing fiber base material, based on a thermoplastic resin as a main component, from the melting point of the binder composition Laminating step (B) of laminating a thermoplastic resin sheet having a melting point lower by 10 ° C. or more, melting the thermoplastic resin sheet to form a thermoplastic resin film on the surface of the reinforcing fiber base, and its surface And (C) a heat pressing step of shaping the reinforcing fiber substrate on which the thermoplastic resin coating is formed into a predetermined shape. (C) applying a thermosetting resin to the reinforcing fiber substrate on which the thermoplastic resin coating is formed. Injecting and curing reaction A fiber reinforced composite material, which includes a binder composition and has a sheet-like or tape-like form and a thermosetting resin, and is molded into a predetermined shape, on the surface thereof, A fiber-reinforced composite material in which a thermoplastic resin film having a melting point of 10 ° C. or more lower than the melting point of the binder composition is mainly formed of a thermoplastic resin. As the binder composition, a composition containing a thermoplastic resin mainly composed of polyvinyl formal is used, and a resin composition mainly composed of a terpolymer polyamide resin is used for the thermoplastic resin film. The fiber-reinforced composite material according to claim 2, which is used. The thermoplastic resin coating part formed on the fiber-reinforced composite material obtained through the steps (A) to (C) according to claim 1, and (D) another member is further added to the binder composition. The manufacturing method of the integrated structure member which has a joining process heated and welded at temperature lower than melting | fusing point. The manufacturing method of the integrated structure member according to claim 4, wherein a fiber-reinforced composite material is used as the other member. The fiber-reinforced composite material produced by the method according to claim 1 or the thermoplastic resin coating portion formed on the fiber-reinforced composite material according to claim 2 or 3 is made of another fiber-reinforced composite material. An integrated structural member that is joined. The thermoplastic resin film is formed on the surface of the other fiber reinforced composite material, and the fiber reinforced composite materials are bonded to each other on the surface of the thermoplastic resin film. Integrated structural member.