JP2018039130A - Method for molding composite material and device for molding composite material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a composite material and a device for molding a composite material that make it possible to solve the problem of irregularities on the surface of a composite material to improve the quality of appearance.SOLUTION: In a method for molding a composite material 10, a resin 22, with which a reinforced base material 11 is impregnated, is cured to form a molding 20, a resin sheet 30 is put on at least part of the surface of the molding, and while the resin sheet receives tension from the center of the resin sheet toward the periphery of it, the resin sheet is integrated with the molding.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a composite material molding method and a composite material molding apparatus.

  In recent years, a composite material in which a reinforced base material is impregnated with a resin has been used as an automobile part in order to reduce the weight of an automobile body. Among automotive parts, particularly, outer panel parts such as roofs and bonnets are required to have high appearance quality.

  When the composite material is molded, the resin hardens and shrinks, and fine unevenness may be formed on the surface due to the difference in shrinkage between the resin and the reinforced base material. The minute unevenness on the surface is a factor that deteriorates the appearance quality after painting.

  As a method for eliminating the unevenness on the surface of the composite material, for example, in Patent Document 1 below, a resin sheet is provided on the surface of a molded body containing a reinforced base material and an uncured resin, and the molded body and the resin sheet Discloses a method of curing the resin at once and integrally forming the same. Thereby, the resin of the resin sheet tries to eliminate the surface unevenness by filling the unevenness generated on the surface of the molded body.

JP 2002-326319 A

  However, in the method according to Patent Document 1, since the resin of the molded body is uncured, the reinforced base material is impregnated while the resin of the molded body flows together with the resin of the resin sheet when integrally molded. When the reinforced base material is impregnated with the resin on the surface, the surface of the composite material may be uneven.

  Accordingly, the present invention has been made to solve the above-described problems, and provides a composite material molding method and composite material molding apparatus that can improve the appearance quality by eliminating irregularities on the surface of the composite material. The purpose is to do.

  In the method for molding a composite material according to the present invention for achieving the above object, first, a resin impregnated in a reinforced substrate is cured to form a molded body, and a resin sheet is laminated on at least a part of the surface of the molded body. . And the said resin sheet and the said molded object are integrated with the state which provided the tension | tensile_strength which goes to the outer periphery from the center of the said resin sheet to the said resin sheet.

  A molding apparatus for a composite material according to the present invention that achieves the above object includes a molded body forming portion that forms a molded body including a reinforced base material and a cured resin, and a resin on at least a part of the surface of the molded body. A laminated portion that laminates the sheet; and a composite material forming portion that integrates the molded body and the resin sheet. The laminated portion includes a tension applying unit that applies a tension from the center of the resin sheet toward the outer periphery of the resin sheet.

  According to the composite material molding method and the composite material molding apparatus according to the present invention, the surface can be smoothed by filling the resin sheet with minute irregularities generated on the surface of the molded body in which the resin is cured. Furthermore, when the resin sheet and the molded body are integrated, the resin sheet and the molded body can be integrated without causing wrinkles or kinks in the resin sheet by applying tension to the resin sheet. Thereby, the unevenness | corrugation of the surface of a composite material can be eliminated and external appearance quality can be improved.

It is the schematic for demonstrating the structure of the composite material which concerns on this embodiment. It is the schematic for demonstrating the structure of the molded object which concerns on this embodiment. It is the schematic of the shaping | molding apparatus of the composite material which concerns on this embodiment. It is a flowchart which shows the shaping | molding method of the composite material which concerns on this embodiment. It is a figure for demonstrating the procedure which shape | molds a composite material using the shaping | molding apparatus of the composite material which concerns on this embodiment, and is the schematic which shows the heating process of a resin sheet, and the formation process of a molded object. It is a figure for demonstrating the procedure which shape | molds a composite material using the shaping | molding apparatus of the composite material which concerns on this embodiment, and is the schematic which shows the process of laminating | stacking a resin sheet on a molded object. It is a figure for demonstrating the procedure which shape | molds a composite material using the shaping | molding apparatus of the composite material which concerns on this embodiment, and is the schematic which shows the process of integrating a molded object and a resin sheet. It is a figure which shows the molded object which concerns on this embodiment, Comprising: It is the photograph (right figure) which image | photographed the surface of the molded object provided with the schematic (left figure) of a textile material, and a textile material in an outermost layer. It is a figure which shows a mode that the molded object which concerns on a proportionality is shape | molded, Comprising: Before hardening of a resin at the time of shape | molding the composite material which has a unidirectional material in the outermost layer (left figure), and after hardening of a resin (right figure) FIG. FIG. 9A is a partial cross-sectional view (left view) along the line A1-A1 in the left view shown in FIG. 9A and a partial cross-sectional view (right view) along the line A2-A2 in the right view shown in FIG. 9A. It is a figure which shows the example of application of the composite material shape | molded by the shaping | molding method which concerns on embodiment, and is a figure which shows the various motor vehicle parts using a composite material. It is a figure which shows the example of application of the composite material shape | molded by the shaping | molding method which concerns on embodiment, and is a figure which shows the vehicle body formed by joining the various automotive components using a composite material. It is a figure for demonstrating the procedure which shape | molds a composite material using the shaping | molding apparatus of the composite material which concerns on the modification 1. FIG. It is a figure for demonstrating the procedure which shape | molds a composite material using the shaping | molding apparatus of the composite material which concerns on the modification 1. FIG. It is a figure for demonstrating the procedure which shape | molds a composite material using the shaping | molding apparatus of the composite material which concerns on the modification 1. FIG. FIG. 10 is a diagram for explaining a procedure for molding a composite material using a composite material molding apparatus according to Modification 2. FIG. 10 is a diagram for explaining a procedure for molding a composite material using a composite material molding apparatus according to Modification 2. FIG. 10 is a diagram for explaining a procedure for molding a composite material using a composite material molding apparatus according to Modification 2.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In addition, the following description does not limit the technical scope and terms used in the claims. In addition, the dimensional ratios in the drawings are exaggerated for convenience of explanation, and may differ from actual ratios.

  The composite material 10 includes a reinforced substrate 11 and resins 22 and 31. By combining the resins 22 and 31 with the reinforced substrate 11, the composite material 10 having higher strength and rigidity than the resins 22 and 31 alone is obtained. As shown in FIGS. 10A and 10B, the composite material 10 is applied to, for example, outer plate parts such as a roof 401 and a bonnet 402 of an automobile body 400. By applying the composite material 10, the vehicle body 400 can be significantly reduced in weight as compared with the case where a steel material is used.

  As shown in FIG. 1, the composite material 10 according to the present embodiment is formed by laminating a resin sheet 30 so as to cover at least a part of the surface of the molded body 20 including the reinforced base material 11 and the cured resin 22. It is formed by integrating. Hereinafter, the resin 22 included in the molded body 20 is referred to as “base resin 22”, and the resin 31 constituting the resin sheet 30 is referred to as “coating resin 31”.

  The molded body 20 is formed from a prepreg sheet 21. The prepreg sheet 21 includes a sheet-like reinforced substrate 11 and a resin 22 that is impregnated in the reinforced substrate 11 and is in an uncured or semi-cured state. As shown in FIG. 2, the molded body 20 is formed by laminating a plurality of prepreg sheets 21 and curing the base material resin 22.

  The reinforced substrate 11 can be formed of, for example, carbon fiber, glass fiber, aramid fiber, polyamide (PA) fiber, polypropylene (PP) fiber, acrylic fiber, or the like. In the present embodiment, an example in which carbon fibers are used as the reinforcing substrate 11 will be described. Since the carbon fiber has a small coefficient of thermal expansion, excellent dimensional stability, and little deterioration in mechanical properties even at high temperatures, the composite material 10 used for the automobile body 400 (see FIG. 10B) is used. It can be suitably used as the reinforcing substrate 11.

  The reinforced base material 11 applied to the prepreg sheet 21 includes a woven material 12 (see FIG. 8) in which fibers are woven in a horizontal and vertical direction into a plain or twill, or a unidirectional material 13 in which fibers are aligned in one direction. (See the left figure in FIG. 9A) can be used. As shown in FIGS. 1 and 2, a prepreg sheet 21 including a woven material 12 is disposed as the reinforcing base 11 on the outermost layer of the molded body 20 according to the present embodiment.

  As the base material resin 22, an epoxy resin, a phenol resin, or the like, which is a thermosetting resin, is used. In the present embodiment, an epoxy resin having excellent mechanical characteristics and dimensional stability is used. Epoxy resin is mainly a two-component type, and a main agent and a curing agent are mixed and used. The main agent is generally a bisphenol A-type epoxy resin, and the curing agent is an amine-based one, but is not limited to this, and can be appropriately selected according to desired material characteristics.

  The coating resin 31 constituting the resin sheet 30 is formed of a sheet-like thermoplastic resin. As the thermoplastic resin, for example, polypropylene (PP) resin, ABS resin, or the like can be used.

  In general, a thermoplastic resin is superior in impact resistance compared to a thermosetting resin. Chipping that is damaged by an impact caused by a stepping stone that is thrown up when the automobile is running occurs in an outer plate part for an automobile. Since the outermost layer of the composite material 10 according to the present embodiment is covered with the resin sheet 30 formed from a thermoplastic resin, the thermosetting resin is more resistant to impact than the composite material disposed on the outermost layer. Since it is excellent, damage caused by chipping can be reduced. In addition, since the thermoplastic resin has an effect of suppressing crack propagation as compared with the thermosetting resin, it is possible to suppress deterioration of the appearance quality in long-term use.

  With reference to FIG. 3, the molding apparatus 100 according to the present embodiment includes a molded body forming unit 110 that forms the molded body 20, a heating unit 120 that heats the resin sheet 30, and a resin sheet 30 on the surface of the molded body 20. A laminated portion 130 for laminating, a composite material forming portion 140 for integrating the molded body 20 and the resin sheet 30, and a control portion 150 for controlling the operation of the entire molding apparatus 100.

  The molded body forming unit 110 and the composite material forming unit 140 share one molding die 160. The molding die 160 includes a pair of upper and lower upper molds 161 (movable molds), a lower mold 162 (fixed mold), and a temperature adjusting unit 163 that adjusts the temperature of at least one of the upper mold 161 and the lower mold 162. Have.

  The temperature adjustment unit 163 heats the molding die 160 to the curing temperature of the base material resin 22 to cure the base material resin 22 of the prepreg sheet 21. The temperature adjustment unit 163 includes, for example, a heat medium such as oil or water that circulates in the upper mold 161 and the lower mold 162, and an electric heater that heats the heat medium.

  The heating unit 120 is arranged so as to sandwich the resin sheet 30 between both sides of the resin sheet 30 and is configured by an electric heater that heats from both sides. The heating unit 120 may be disposed only on one side of the resin sheet 30.

  The stacked unit 130 includes a gripper (corresponding to a tension applying unit) 131 that applies tension to the resin sheet 30 from the center of the resin sheet 30 toward the outer periphery.

  The gripper 131 grips at least a part of the outer periphery of the resin sheet 30 and applies a tension from the center of the resin sheet 30 toward the outer periphery. The resin sheet 30 is laminated so that the resin sheet 30 is pressed against the surface of the molded body 20 while the tension is applied to the resin sheet 30. The gripper 131 may be fixed and interlocked with the upper mold 161 of the mold 160. The configuration for applying tension to the resin sheet 30 is not limited to the configuration for gripping the resin sheet 30 like the gripper 131, and other mechanical configurations such as fastening and joining may be applied.

  The control unit 150 includes a memory including a ROM and a RAM, a CPU, and the like, and is electrically connected to the heating unit 120, the temperature adjustment unit 163, the gripper 131, and the like, and controls the overall operation of the molding apparatus 100.

  Hereinafter, a method for forming the composite material 10 will be described.

  As shown in FIG. 4, the molding method of the composite material 10 includes a preparation process (step S10), a molding process of the molded body 20 (step S20), a heating process of the resin sheet 30 (step S30), and integral molding. A process (step S40) and demolding (step S50). Hereinafter, each process is explained in full detail.

  In the preparation step (step S <b> 10), as shown in FIG. 3, the resin sheet 30 is placed in the heating unit 120 while the gripper 131 holds the outer periphery of the resin sheet 30. At the same time, the prepreg sheets 21 are stacked and placed on the lower mold 162 of the mold 160. At this time, as shown in FIG. 2, the prepreg sheet 21 is laminated so that the prepreg sheet 21 including the woven material 12 as the reinforcing base material 11 is disposed on the outermost layer. Further, the mold 160 is heated to a predetermined temperature in advance by the temperature adjustment unit 163.

  In the molding process of the molded body 20 (step S20), as shown in FIG. 5, the upper mold 161 of the molding die 160 is closed and the laminated prepreg sheet 21 is hot press molded. The upper mold 161 and the lower mold 162 are heated to the curing temperature of the base resin 22 by the temperature adjusting unit 163, and the base resin 22 of the prepreg sheet 21 is cured. In the preparation step, since the mold 160 is heated in advance, the heating time can be shortened. After the base material resin 22 is cured and the molded body 20 is molded, the upper mold 161 of the mold 160 is opened.

  In the molding process of the molded body 20, the matrix resin 22 is softened by heat and flows between the fibers of the reinforced substrate 11 until the matrix resin 22 is cured. If the unidirectional material 13 in which a plurality of fiber bundles 11a in which a plurality of fibers are bundled is arranged in the same direction as shown in the left diagram of FIG. 9A is disposed on the outermost layer of the molded body 20, the unidirectional material 13 Has weak binding force in the direction orthogonal to the fiber orientation direction. For this reason, as shown in the right diagram of FIG. 9A, even a slight flow of the base material resin 22 easily disturbs the fiber orientation. Further, when the fiber orientation is disturbed, the fiber bundle 11a is peeled off at the single fiber level as shown in the left diagram of FIG. 9B. The disturbance in the fiber orientation of the reinforced substrate 11 may be wrinkled or twisted and appear on the surface, or may cause a local decrease in strength. Further, in the part where the fiber is peeled off, the appearance quality may be deteriorated by causing local sink S as shown in the right diagram of FIG. 9B.

  In this embodiment, as shown in FIG. 2, since the fabric material 12 is arranged on the outermost layer of the molded body 20, the fibers are less likely to be disturbed by the flow of the base material resin 22 generated in the molding process of the molded body 20. . For this reason, generation | occurrence | production of the wrinkle and twist which arise on the surface of the molded object 20 can be suppressed, and a local strength fall can be prevented. In the woven material 12, bubbles are likely to remain at a portion where the fiber bundle 11a intersects (portion indicated by a broken line in FIG. 8). For this reason, minute irregularities may occur on the surface of the molded body 20. Thus, the minute unevenness generated on the surface of the molded body 20 can be eliminated in the subsequent integrated molding step (step S40). Details will be described later.

  The heating process (step S30) of the resin sheet 30 is performed in parallel with the molding process (step S20) of the molded body 20, as shown in FIG. Thereby, since the resin sheet 30 can be heated while the molded body 20 is being molded, an increase in cycle time due to the heating process of the resin sheet 30 can be minimized. First, a tension from the center toward the outer periphery is applied to the resin sheet 30 by the gripper 131. Next, with the tension applied to the resin sheet 30, the heating unit 120 is operated to heat both surfaces of the resin sheet 30 to soften the resin sheet 30. In the heating process of the resin sheet 30, only one side of the resin sheet 30 may be heated.

  In the integrated molding step (step S40), first, as shown in FIG. 6, the resin sheet 30 is pressed against the surface of the molded body 20 arranged in the lower mold 162 while the tension is applied to the resin sheet 30. Cover and laminate. By laminating the molded body 20 with the tension applied to the resin sheet 30, it is possible to suppress the occurrence of wrinkles and kinks in the resin sheet 30.

  If the resin sheet 30 is laminated on the molded body 20 in which the base material resin 22 is in an uncured or semi-cured state, the surface of the molded body 20 is soft, so that the resin sheet 30 is easily deformed by a pressing force. For this reason, it becomes difficult to make the resin sheet 30 adhere to the molded body 20, and the resin sheet 30 is molded with the void V (see the right figure in FIG. 8) left between the resin sheet 30 and the molded body 20. Sometimes. Thereby, unevenness | corrugation is formed in the surface of the composite material 10, and there exists a possibility that external appearance quality may fall.

  In the present embodiment, after the base material resin 22 of the molded body 20 is cured, the resin sheet 30 is disposed so as to be pressed against the surface of the molded body 20, so that the molded body 20 and the resin sheet 30 can be brought into close contact with each other. Thereby, it can suppress that the void V arises between the molded object 20 and the resin sheet 30, and can improve the external appearance quality of the composite material 10. FIG.

  Next, as shown in FIG. 7, the upper mold 161 of the mold 160 is closed and the resin sheet 30 is joined to the surface of the molded body 20 to be integrated. Since the resin sheet 30 is softened, the molten coating resin 31 enters the irregularities on the surface of the molded body 20. Thereby, the unevenness generated on the surface of the molded body 20, in particular, the unevenness on the surface generated by the void V formed in the portion where the fiber bundle 11 a of the fabric material 12 intersects (the portion indicated by the broken line in FIG. 8) is coated resin 31. The surface becomes smooth by filling and filling. Thereby, the unevenness | corrugation of the surface of the molded object 20 can be eliminated, and the external appearance quality after the coating of the composite material 10 can be improved.

  The base material resin 22 is made of a thermosetting resin, and the coating resin 31 is made of a thermoplastic resin. If the base resin 22 flows together with the coating resin 31 in the integrated molding process, the thermoplastic resin and the thermosetting resin may differ from the thermoplastic resin due to differences in material properties such as viscosity and thermal shrinkage. Wrinkles are likely to occur at the interface with the thermosetting resin. As a result, there is a risk that irregularities are formed on the surface of the composite material 10 or wrinkles or kinks occur.

  In this embodiment, since the integral molding process is performed in a state where the base material resin 22 of the molded body 20 is cured, the base material resin 22 of the molded body 20 does not flow together with the coating resin 31. For this reason, it can suppress that an unevenness | corrugation is formed in the surface by the difference in material characteristics, such as the viscosity of the coating resin 31 and the base material resin 22, and a thermal contraction rate, or a wrinkle and a twist generate | occur | produce. Therefore, the appearance quality of the composite material 10 can be improved.

  Moreover, since only the resin sheet 30 is molded in the integral molding process, low pressure molding can be performed. For this reason, the clamping pressure of the shaping | molding die 160 can be restrained low, and the expense concerning equipment investment can be reduced.

  Finally, the composite material 10 is removed from the mold 160 to complete the molding (step S50).

  As described above, according to the molding method of the composite material 10 and the molding apparatus 100 of the composite material 10 according to the present embodiment, the base material resin 22 impregnated in the reinforced base material 11 is cured to form the molded body 20. The resin sheet 30 is laminated on at least a part of the surface of the molded body 20. And the resin sheet 30 and the molded object 20 are integrated with the state which provided the tension | tensile_strength which goes to the outer periphery from the center of the resin sheet 30 to the resin sheet 30. FIG.

  According to the molding method of the composite material 10 configured as described above, the resin sheet 30 is disposed on the surface of the molded body 20 after the base material resin 22 of the molded body 20 is cured. For this reason, it can suppress that the coating resin 31 of the resin sheet 30 flows with the base material resin 22 of the molded body 20 and impregnates the reinforced substrate 11. This suppresses wrinkles and kinks caused by the flow of the coating resin 31 together with the base resin 22, and suppresses unevenness of the surface formed by the outermost coating resin 31 impregnating the reinforced substrate 11. Can do. As described above, the coating resin 31 can fill the unevenness of the surface of the molded body 20 and smooth the surface. Furthermore, when the resin sheet 30 and the molded body 20 are integrated, the resin sheet 30 and the molded body 20 are integrated without causing wrinkles or kinks in the resin sheet 30 due to tension applied to the resin sheet 30. can do. Thereby, the unevenness | corrugation of the surface of the composite material 10 can be eliminated, and external appearance quality can be improved.

  Moreover, the resin sheet 30 is formed of a thermoplastic resin. By disposing the thermoplastic resin on the outermost layer of the composite material 10, it is possible to form the composite material 10 having excellent impact resistance compared to the case of disposing the thermosetting resin. Moreover, since delamination and crack growth due to chipping and the like can be suppressed, it is possible to suppress deterioration in appearance quality in long-term use of the outer plate component to which the composite material 10 is applied.

  In addition, the resin sheet 30 is heated before the resin sheet 30 is laminated on the molded body 20. By preheating and softening the resin sheet 30, the coating resin 31 easily enters the irregularities on the surface of the molded body 20. Thereby, the appearance quality of the composite material 10 can be further improved.

  Further, the molded body 20 is formed by a prepreg sheet 21 including the reinforced base material 11 and a base material resin 22 in an uncured or semi-cured state. Compared to the RTM molding method in which the reinforced base material 11 is impregnated with a resin, the molding time of the composite material 10 can be shortened. Moreover, since the unidirectional material 13 can be used by using the prepreg sheet 21, the selection range of fiber orientation can be expanded.

  Further, the base material resin 22 of the molded body 20 is a thermosetting resin. Thermosetting resins generally have higher heat resistance and superior dimensional stability than thermoplastic resins. Moreover, according to the shaping | molding method which concerns on this invention, after hardening the base material resin 22 of the molded object 20, the resin sheet 30 and the molded object 20 are integrated. For this reason, when a thermoplastic resin is used for the coating resin 31 of the resin sheet 30 and a thermosetting resin is used for the base material resin 22 of the molded body 20, the viscosity and the thermal shrinkage of the thermoplastic resin and the thermosetting resin are reduced. Due to the difference, it is possible to suppress the formation of irregularities on the surface of the composite material 10 and the generation of wrinkles and kinks.

  In addition, at least a part of the reinforced base material 11 disposed in the outermost layer of the molded body 20 among the reinforced base material 11 is a woven material 12 in which fibers are woven. Thereby, when forming the molded body 20, in the portion where the woven material 12 is arranged, the disturbance of the fibers caused by the flow of the base material resin 22 is suppressed, and the formation of surface irregularities and the generation of wrinkles and kinks are suppressed. Thus, the appearance quality of the composite material 10 can be further improved.

<Modification 1>
A modification 1 of the above-described embodiment will be described with reference to FIGS. 11A to 11C. In addition, about the structure similar to embodiment mentioned above, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

  The composite material forming unit 240 of the molding apparatus for the composite material 10 according to the modified example 1 does not share the molded body forming unit 110 and the upper mold 161, and instead of the upper mold 161, a divided mold (corresponding to a pressure unit) 261 is used. It differs from the above-described embodiment in that it is provided. The composite material forming unit 240 shares only the lower mold 162 (fixed mold) of the mold 160 with the molded body forming unit 110.

  As shown in FIG. 11A, the split mold 261 includes a central pressing portion 261a that applies a pressing force to the central portion of the resin sheet 30, and an outer peripheral pressing portion 261b that applies a pressing force to the outer peripheral portion of the resin sheet 30. .

  When laminating the resin sheet 30 on the molded body 20 in the integrated molding step (step S40), first, as shown in FIG. 11B, the central portion of the resin sheet 30 is pressed by the central pressing portion 261a of the split mold 261. The pressure is applied to the resin sheet 30 in the direction in which the resin sheet 30 approaches the molded body 20.

  Next, as shown in FIG. 11C, the outer peripheral portion of the resin sheet 30 is pressed by the outer peripheral pressing portion 261b of the split mold 261 while the central portion of the resin sheet 30 is pressed by the central pressing portion 261a. Pressure is applied to the resin sheet 30 in a direction in which 30 is close to the molded body 20. In this way, pressure is applied to the resin sheet 30 by the split mold 261 in order from the center of the resin sheet 30 toward the outer periphery in a direction in which the resin sheet 30 approaches the molded body 20. Further, in a state where the resin sheet 30 is pressed by the split mold 261, the resin sheet 30 is joined and integrated with the surface of the molded body 20.

  As described above, according to the method for manufacturing the composite material 10 and the composite material forming unit 240 of the molding apparatus according to the first modification, when the resin sheet 30 is laminated on the molded body 20, the outer periphery from the center of the resin sheet 30 is obtained. The pressure is applied to the resin sheet 30 in the direction in which the resin sheet 30 approaches the molded body 20 in order. Thereby, both can be made to contact | adhere, discharging the air which remains between the resin sheet 30 and the molded object 20 outside. For this reason, it can suppress that a bubble remains between the resin sheet 30 and the molded object 20, and can prevent the swelling of the surface of the composite material 10 by a bubble, and the increase in surface roughness. Thereby, the appearance quality of the composite material 10 can be further improved.

  The split mold 261 includes a central pressing portion 261 a that applies a pressing force to the central portion of the resin sheet 30 and an outer peripheral pressing portion 261 b that applies a pressing force to the outer peripheral portion of the resin sheet 30. By adjusting the order in which the central pressing portion 261a and the outer peripheral pressing portion 261b are operated, the resin sheet 30 is relatively easily moved from the center of the resin sheet 30 toward the outer periphery in the direction in which the resin sheet 30 approaches the molded body 20. A pressure can be applied to the sheet 30.

<Modification 2>
A modification 2 of the above-described embodiment will be described with reference to FIGS. 12A to 12C. In addition, about the structure similar to embodiment mentioned above, the same code | symbol is attached | subjected and the description is abbreviate | omitted.

  The composite material forming unit 340 of the molding apparatus for the composite material 10 according to the modified example 2 does not share the molded body forming unit 110 and the upper mold 161, and includes an upper mold (pressurization) including an air flow generating unit 362 instead of the upper mold 161. This is different from the above-described embodiment in that it includes a 361. The composite material forming section 340 shares only the lower mold 162 (fixed mold) of the mold 160 with the molded body forming section 110, as in the first modification described above.

  The air flow generation unit 362 generates an air flow and applies pressure to the resin sheet 30 in a direction in which the resin sheet 30 approaches the molded body 20. The gas that generates the airflow is not particularly limited, but it is preferable to use an inert gas such as nitrogen or argon.

  When laminating the resin sheet 30 on the molded body 20 in the integrated molding step (step S40), first, as shown in FIG. 12A, an air current is generated at the central portion of the resin sheet 30 by the air current generating unit 362, and then the resin sheet. Pressure is applied to the resin sheet 30 in a direction in which 30 is close to the molded body 20.

  Next, as shown in FIG. 12B, an air flow is generated on the outer peripheral portion of the resin sheet 30 by the air flow generation unit 362 and pressure is applied to the resin sheet 30 in a direction in which the resin sheet 30 approaches the molded body 20. To do. As described above, the air flow generated by the air flow generation unit 362 applies pressure to the resin sheet 30 in the direction from the center of the resin sheet 30 toward the outer periphery toward the molded body 20. .

  Thereafter, as shown in FIG. 12C, the upper mold 361 is closed, and the resin sheet 30 is joined to the surface of the molded body 20 to be integrated.

  As described above, according to the method for manufacturing the composite material 10 and the composite material forming unit 340 of the molding apparatus according to the modified example 2, when the resin sheet 30 is laminated on the molded body 20, the outer periphery from the center of the resin sheet 30 is obtained. The pressure is applied to the resin sheet 30 in the direction in which the resin sheet 30 approaches the molded body 20 in order. Thereby, both can be made to contact | adhere, discharging the air which remains between the resin sheet 30 and the molded object 20 outside. For this reason, it can suppress that a bubble remains between the resin sheet 30 and the molded object 20, and can prevent the swelling of the surface of the composite material 10 by a bubble, and the increase in surface roughness. Thereby, the appearance quality of the composite material 10 can be further improved.

  Further, the upper mold 361 has an air flow generation unit 362 that applies pressure to the resin sheet 30 by an air flow. Thereby, the position which gives a pressure with respect to the resin sheet 30 can be finely adjusted by adjusting the position which generate | occur | produces an airflow.

  As described above, the molding method and the molding apparatus of the composite material have been described through the embodiment and the modified examples. However, the present invention is not limited to the configuration described in the embodiment, and may be appropriately changed based on the description of the claims. Is possible.

  For example, the molded body is not limited to a configuration in which prepreg sheets are laminated, and an RTM (Resin Transfer Molding) molding method in which a reinforced base material is placed in a molding die and impregnated with a resin or other molding methods is used. May be molded.

  Moreover, the base material resin constituting the molded body is not limited to the thermosetting resin, and a thermoplastic resin can be used. In this case, the molded body can be formed by closing the mold in a state where the base resin, which is a thermoplastic resin, is heated and softened, and then cooling and curing.

  Moreover, the coating resin which comprises a resin sheet is not limited to a thermoplastic resin, A thermosetting resin can be used.

  The molding die of the molded body forming portion and the molding die of the composite material forming portion are not limited to the configuration sharing the same molding die as in the above-described embodiment, and for example, each may have a dedicated molding die. However, only the lower mold or the upper mold may be shared.

  Moreover, although the modification 1 and the modification 2 are examples of the structure which gives a pressure in the direction which a resin sheet adjoins with respect to a molded object in order toward the outer periphery from the center of a resin sheet, the shaping | molding method of a composite material The composite material molding apparatus may be any method or configuration that exhibits the above-described functions, and is not limited to the method or configuration described in Modification 1 and Modification 2 described above.

  Moreover, the laminated structure of the prepreg sheet 21 is not limited to the embodiment described above.

10 Composite materials,
11 Reinforced substrate,
12 Weaving materials
20 molded body,
21 prepreg sheet,
22 Base material resin (resin),
30 resin sheet,
31 Coating resin (resin),
100 molding equipment,
110 molded body forming part,
120 heating section,
130 lamination part,
131 Gripper (tension applying part),
140, 240, 340 composite material forming part,
150 control unit,
160 mold,
161 Upper mold,
162 Lower mold,
163 temperature adjustment unit,
261 split type (pressurizing part),
261a center pressing part,
261b outer peripheral pressing part,
361 Upper mold (pressure part),
362 Airflow generator,
400 body,
401 roof,
402 Bonnet.

Claims (16)

The molded body is formed by curing the resin impregnated in the reinforced substrate,
Laminating a resin sheet on at least a part of the surface of the molded body,
A molding method for a composite material, in which the resin sheet and the molded body are integrated while a tension from the center of the resin sheet toward the outer periphery is applied to the resin sheet.   When laminating the resin sheet on the molded body, in order from the center of the resin sheet toward the outer periphery, the resin sheet applies pressure to the resin sheet in a direction close to the molded body. The molding method of the composite material according to claim 1.   The method for molding a composite material according to claim 1, wherein the resin sheet is formed of a thermoplastic resin.   The method for molding a composite material according to claim 3, wherein the resin sheet is heated before the resin sheet is laminated on the molded body.   The method for molding a composite material according to claim 1, wherein the molded body is formed by a prepreg sheet including the reinforced base material and the resin in an uncured or semi-cured state. .   The method for molding a composite material according to claim 1, wherein the resin of the molded body is a thermosetting resin.   The composite according to any one of claims 1 to 6, wherein at least a part of the reinforcing base disposed in the outermost layer of the molded body among the reinforcing base is a woven material in which fibers are woven. Material forming method. A molded body forming part for forming a molded body including a reinforced base material and a cured resin;
A laminated portion that laminates a resin sheet on at least a part of the surface of the molded body;
A composite material forming unit that integrates the molded body and the resin sheet,
The said lamination | stacking part is a shaping | molding apparatus of a composite material containing the tension | tensile_strength provision part which provides the tension | tensile_strength which goes to the outer periphery from the center of the said resin sheet with respect to the said resin sheet.   The composite material forming unit includes a pressurizing unit that applies pressure to the resin sheet in a direction from the center of the resin sheet toward the outer periphery in a direction in which the resin sheet approaches the molded body. Item 9. The composite material molding apparatus according to Item 8.   The said pressurization part has a split type | mold containing the center press part which provides pressing force to the center part of the said resin sheet, and the outer periphery press part which provides pressing force to the outer peripheral part of the said resin sheet, The molding apparatus of the composite material described in 1.   The said pressurization part is a shaping | molding apparatus of the composite material of Claim 9 or Claim 10 which has an airflow generation | occurrence | production part which provides a pressure to the said resin sheet with an airflow.   The said resin sheet is a shaping | molding apparatus of the composite material of any one of Claims 8-11 formed with a thermoplastic resin.   The composite material molding apparatus according to claim 12, further comprising a heating unit configured to heat the resin sheet.   The said molded object is a shaping | molding apparatus of the composite material of any one of Claims 8-13 formed by the prepreg sheet | seat containing a reinforcement base material and a thermoplastic resin or a thermosetting resin.   The said resin of the said molded object is a shaping | molding apparatus of the composite material of any one of Claims 8-14 which is a thermosetting resin.   The composite according to any one of claims 8 to 15, wherein at least a part of the reinforcing base disposed in the outermost layer of the molded body among the reinforcing base is a woven material in which fibers are woven. Material molding equipment.