JP6054714B2 - Forming method and forming mold - Google Patents

Description

The present invention comprises a reinforcing carbon fiber and a matrix resin. For example, a forming method and a forming mold for forming a fiber reinforced resin member such as an automobile or an aircraft into a three-dimensional shape using the forming mold. About.

  Conventionally, as a method of molding a fiber reinforced resin using carbon fiber as a reinforcing fiber, a flat laminated product is placed on a mold, the mold is evacuated, and the resin is injected into the flat laminated product. A resin transfer molding method in which a resin is diffused and impregnated is known.

  Patent Document 1 discloses a forming method capable of automatically and accurately producing a flat laminated molded product having a three-dimensional shape suitable for use in this resin transfer molding method. It was.

Japanese Patent Laid-Open No. 2003-21447

The forming method disclosed in Patent Document 1 uses a flat laminated molded article made of reinforcing fibers and a thermosetting resin, and the laminated article of carbon fibers and a thermosetting resin molding material is cured at a curing temperature. At the time of compression molding, only the thermosetting resin flows out from the laminated product from the upper and lower mold dividing surfaces, and a sufficient thickness cannot be obtained in the molded product. When measures are taken by providing a stopper in the mold clamping direction of the upper and lower molds to restrict mold clamping, sufficient clamping pressure is not applied to the product part, and sufficient strength cannot be given to the obtained molded product. .
In view of the above problems in the prior art, the present invention provides a forming method that can efficiently produce a strong molded product using a molding raw material made of a reinforcing fiber and a thermosetting resin. Objective.

That is, the forming method of the present invention cuts and laminates a forming raw material in which a resin material mainly composed of a thermosetting resin is attached to at least one surface of a textile base material including a plurality of reinforcing fiber bundles. The laminated molding material is placed in a molding die, pressed and heated to cure the resin material adhering to the fabric substrate including a plurality of reinforcing fiber bundles, and between the fibers and the interlayer of the molding raw material. In the forming method for bonding, at least one of a preheating step of preheating the laminated molding material and placing it in the molding die, a step of clamping and pressurizing the molding die, and an upper and lower die in the vicinity of the dividing line of the upper and lower die A step of heating the mold to a required temperature higher than that of the mold at the curing temperature of the thermosetting resin, and a step of heating the mold to the curing temperature to open and release the mold. At least one of the upper and lower molds in the vicinity of the dividing line is set to the curing temperature of the thermosetting resin. And wherein the step of temperature is a step of irradiating a laser beam to the upper and lower molds parting line.
By this forming method of the present invention, the mold is heated to the curing temperature of the thermosetting resin material so that the thermosetting resin is impregnated in the reinforcing fibers, and is sufficiently reinforced by fiber lamination. It becomes possible to mold a thermosetting resin material having a strong molded product strength. In addition, it can be prevented by preheating that the cycle time becomes excessive due to the long heating time.

Further, in the forming process using the molding die composed of the upper die and the lower die, the resin material protrudes from the divided portion of the upper die and the lower die due to the expansion pressure due to the temperature rise. A part of the resin material of the laminated molding material protrudes from the die joint portion due to thermal expansion from the inside. This protrusion is also called flash, burr, or spew, and the lines generated at the protrusions of the divided parts are called parting lines and flash lines.

If there is no countermeasure even in the forming method of the present invention, if the laminated product of reinforcing fiber and thermosetting resin molding material is simply heated to its curing temperature and compression molded, the thermosetting resin from the mold dividing surface Only the spills out and the thickness becomes thin.

Therefore, according to the forming method of the present invention, there is provided a step of heating at least one of the upper and lower molds in the vicinity of the dividing line of the upper and lower molds to a required temperature higher than that of the mold at the curing temperature of the thermosetting resin. .
By curing at least one of the upper and lower molds at a part of the thermosetting resin that has been partially heated by the process of raising the temperature to a required temperature higher than that of the mold at the curing temperature of the thermosetting resin, Protrusion to the outside is prevented and resin spillage can be prevented. The required temperature higher than that of the mold is a temperature at which the portion of the thermosetting resin whose temperature has been raised enough to prevent the protrusion to the outside is cured in a short time.

The mold is equipped with a product part mold and a heat storage panel on the back of the product part mold, and the product part mold heater and the heat conduction from the heat storage panel raise the mold part temperature of the product part mold to store heat. Due to the presence of the board, the temperature of the product part mold is increased, and the capacity of the product part heater can be reduced.

The process of heating at least one of the upper and lower molds in the vicinity of the upper and lower mold dividing lines to the curing temperature of the thermosetting resin is heated with near infrared rays, the temperature is detected with a far infrared temperature sensor, It can be set as the process of adjusting intensity | strength and heating up to required temperature. Alternatively, the upper and lower parting lines may be irradiated with laser light.

  By preheating and pre-molding the laminated molding material and then placing it in the molding die, it becomes possible to simply and efficiently place it in the molding die. Further, by preparing a pre-formed product obtained by pre-forming a laminated molding material, the molding efficiency can be further improved. As a form of pre-molding, for example, the laminated molding material is preheated to a shape along the inner shape of the portion where the laminated molding material is placed in the mold, and drawing is performed.

The preheating process is a process of heating with near infrared rays, detecting the temperature with a far infrared temperature sensor, adjusting the intensity of the near infrared rays and raising the temperature to a required temperature, thereby allowing the molecules to be preheated to be heated with the near infrared rays. It can be heated and heated to the center, and the far-infrared sensor can detect the accurate temperature without contact. By adjusting the near-infrared intensity with a continuous voltage drop and raising the temperature to a required temperature, the molecules to be preheated can be heated with the near infrared rays, and the preheated object can be efficiently heated to the center.

In the preheating process, the laminated molding material is placed in a mold that is being heated to the curing temperature, heated with near infrared rays, the temperature is detected with a far infrared temperature sensor, and the intensity of near infrared rays is adjusted to the required temperature. By being the step of raising the temperature, the molecule to be preheated can be heated to the middle core with near infrared rays, and the accurate temperature can be detected in a non-contact manner by the far infrared sensor. In addition, the laminated molding material in the process of raising the temperature to the curing temperature is placed in a mold that has been heated, so that the time can be efficiently reduced and preheated.

By lowering the upper mold block and pushing up the lower mold block to sandwich the laminated molding material, the relative speed of mold movement can be improved and the molding cycle time can be further shortened.

Further, the forming mold of the present invention is formed by cutting and molding a forming raw material in which a resin material mainly composed of a thermosetting resin is attached to at least one surface of a fabric base material including a plurality of reinforcing fiber bundles. The laminated molding material is placed in a molding die, pressed and heated to cure the resin material adhering to the fabric substrate including a plurality of reinforcing fiber bundles, and between the fibers and the interlayer of the molding raw material. In the forming method for bonding, at least one of a preheating step of preheating the laminated molding material and placing it in the molding die, a step of clamping and pressurizing the molding die, and an upper and lower die in the vicinity of the dividing line of the upper and lower die A forming method having a step of raising the temperature to a required temperature higher than that of the molding die at a curing temperature of the thermosetting resin, and a step of raising the molding die to a curing temperature and opening and releasing the die A forming mold that is used, and a forming mold comprising an upper mold and a lower mold for shaping A temperature raising means for raising the temperature of at least one of the upper and lower molds in the vicinity of the dividing line of the upper and lower molds to a curing temperature of the thermosetting resin, a means for clamping and pressurizing the mold, and a curing temperature of the mold was heated to have a means for releasing the mold is opened, wherein said a is placed frame heating means.

The temperature raising means can be a slot. Further, the step of raising the temperature of at least one of the upper and lower molds in the vicinity of the upper and lower mold dividing lines to the curing temperature of the thermosetting resin is heated with near infrared rays, the temperature is detected with a far infrared temperature sensor, and the near infrared rays are detected. In the case of adjusting the intensity of the light and raising the temperature to a required temperature, such an infrared device becomes the temperature raising means. Further, when irradiating the upper and lower parting lines with laser light, a laser emitting device serves as the temperature raising means.

The fiber reinforced resin molded product produced by the above forming method of the present invention can be applied to various applications because it can be manufactured with high strength, light weight, efficiency and low cost, and also can be shaped with complex shapes. It becomes.

According to the forming method and the forming mold according to the present invention, it is possible to form a strong molded product into a three-dimensional shape with a high degree of freedom in shape using a forming raw material.

(A) It is a conceptual diagram of the shaping | molding raw material used with the forming method of this invention. (B) It is a conceptual diagram of the textile base material which comprises the shaping | molding raw material shown to Fig.1 (a). It is explanatory drawing of the shaping apparatus used with the shaping method of 1st embodiment of this invention. (A) It is explanatory drawing of the type | mold structure used with the forming method of this invention. (B) It is another explanatory drawing of the type | mold structure used with the forming method of this invention. (A) It is a perspective view of the type | mold structure used with the shaping method of this invention. (B) It is another perspective view of the type | mold structure used with the shaping method of this invention. It is explanatory drawing of the shaping apparatus used with the shaping method of 2nd embodiment of this invention. It is explanatory drawing of the shaping apparatus used with the shaping method of 3rd embodiment of this invention.

The forming method of the present invention is performed using a forming raw material 1 shown in FIG. As shown in FIG. 1A, the molding material 1 has a resin material 4 mainly composed of a thermosetting resin attached to at least one surface of a woven fabric base 3 including a plurality of reinforcing fiber bundles 2. Do it.

As shown in FIG. 1B, the fabric base 3 is a bi-directional fabric formed by weaving a plurality of reinforcing fiber bundles 2 aligned in one direction so as to be parallel to each other in two orthogonal directions. The bi-directional woven fabric has the advantage that it is easy to be deformed due to a change in the relative position between the reinforcing fiber bundles 2 and is easily deformed into a three-dimensional shape, and that it is easy to obtain a laminated molding material that is mechanically pseudo-isotropic with a small number of sheets. .

By using the reinforced fiber bundle 2, the mechanical properties of the fiber reinforced resin molded product as the final product can be made high.

The reinforcing fiber bundle 2 may be a carbon fiber bundle, a graphite fiber bundle, a glass fiber bundle, an aramid fiber bundle, or the like, and is preferably a carbon fiber bundle. By using the carbon fiber bundle, the mechanical properties of the fiber reinforced resin molded product as the final product can be improved.

The resin material 4 adhering to the surface of the woven fabric base 3 is mainly composed of a thermosetting resin capable of obtaining an action of bonding the layers of the woven fabric base 3. As the thermosetting resin, for example, epoxy can be used. When the resin material 4 has a thermosetting resin as a main component, the forming raw fabric material 1 is laminated, deformed into a three-dimensional shape, and then handled between the layers of the fabric base material 3. Improve productivity. The main component is a component having the largest ratio among the components constituting the resin material 4.

Hereinafter, the forming method according to the first embodiment of the present invention will be described in detail with reference to FIG.

First, the forming raw material 1 is laminated, and a laminated molding material 5 preliminarily compression-molded with a preliminary lamination mold (not shown) is preheated with a preheating mold 6.

In the preheating, the laminated molding material 5 placed on the heating plate 8 in the preheating mold 6 is heated by the near infrared radiation device 7 from the upper part with the near infrared rays. The far-infrared temperature sensor (not shown) detects the temperature of the laminated molding material 5, adjusts the intensity of near infrared rays by the near-infrared radiation device 7, and raises the laminated molding material 5 to a required temperature.

On the other hand, the forming die 9 which is a shaping die having a three-dimensional shape is preheated and the temperature is raised to the curing temperature of the forming raw material 1. Next, the laminated molding material 5 is accommodated in a preheated molding die 9, and the laminated molding material 5 is compressed by the molding die 9. As a result, the resin material 4 adhering to the fabric base material 3 is cured, the layers of the laminated molding material 5 are bonded, and the shape is maintained.

Thereafter, the mold 9 is opened and released. The forming raw material 1 is laminated by the above steps and shaped into a three-dimensional shape.

As described above, in the preheating step, the laminated molding material 5 is placed in the heated mold 9 and heated by the near infrared radiation device 7 using near infrared rays, the temperature is detected by the far infrared temperature sensor, and the near infrared rays are detected. By adjusting the intensity and raising the temperature to a required temperature, the molecules to be preheated can be heated to near the core with near infrared rays. In addition, the far-infrared sensor can accurately detect the temperature without contact. In addition, the laminated molding material 5 in the process of raising the temperature to the curing temperature is placed and placed in the mold 9 which has been heated, so that the time can be efficiently reduced and preheated.

The temperature at which the laminated molding material 5 is heated is a temperature at which the resin material 4 is cured and the layers of the laminated molding material 5 are bonded together. By heating the laminated molding material 5 while being pressurized, the fabric base materials 3 including the plurality of reinforcing fiber bundles 2 constituting the laminated molding material 5 are strongly pressed against each other. Next, when the temperature of the laminated molding material 5 is increased, the resin material 4 penetrating between the single yarns of the reinforcing fiber bundles constituting the fabric base material bonds the reinforcing fiber bundles facing each other, The layers of the laminated molding material 5 are bonded.

In this way, by deforming the laminated molding material 5 into a three-dimensional shape and bonding the layers, a three-dimensional shaped product having no wrinkles can be manufactured. Further, since this molded body is bonded between the layers of the laminated molding material 5, it has high rigidity and excellent shape retention, and can be handled efficiently.

The mold 9 includes a product part mold 10 and a heat storage board 11, and raises the mold temperature of the mold 9 by heat conduction from the heater 12 and the heat storage board 11 provided in the product part mold 10. The product part mold 10 is composed of an upper mold 10a and a lower mold 10b, and the upper mold 10a is fitted into the lower mold 10b to perform mold matching, thereby molding the product. The mold 9 includes a temperature raising water passage 13 for a fluid medium such as warm water containing air and steam, and the mold 9 is rapidly heated by passing water through the temperature raising water passage 13. The temperature raising water passage 13 can efficiently draw and drop water by applying air. That is, after the mold temperature of the mold 9 reaches a required temperature, the temperature rise of the mold 9 is terminated by stopping the water flow in the temperature raising water passage 13 and applying air. After taking out the product, the temperature rise of the mold 9 can be started efficiently.

In this forming method, at least one of the upper mold 10a and the lower mold 10b in the vicinity of the dividing line of the upper mold 10a and the lower mold 10b is set to a required temperature higher than that of the molding mold at the curing temperature of the thermosetting resin. This is performed using a temperature raising means PM for raising the temperature. As shown in FIGS. 3A and 3B, the temperature raising means PM is arranged on the lower mold 10b outside the edge of the laminated molding material 5 placed on the lower mold 10b so as to face only the edge of the upper mold 10a. It is arranged as a frame type. The insert piece type PM is formed to have a shape of a mating surface of the upper die 10a and the lower die 10b or an inner shape that matches the outer shape of the laminated molding material 5 placed on the lower die 10b. The upper mold 10a is fitted inside the insert piece mold PM, and the upper mold 10a and the lower mold 10b are mated to form the laminated molding material 5 to be placed on the lower mold 10b.

After the preheating process in which the laminated molding material 5 is preheated and placed in the molding die 9, the upper die 10a and the lower die 10b are matched with each other to mold the product. In the process, the upper mold 10a and the lower mold 10b in the vicinity of the dividing line of the upper mold 10a and the lower mold 10b are molded simultaneously with the compression molding by matching the upper mold 10a and the lower mold 10b at the curing temperature of the thermosetting resin. A temperature raising step for raising the temperature to a higher required temperature is performed using the insert piece type PM. Thus, in the case where the temperature raising process using the insert piece type PM is not performed, the resin on the surface of the laminated molding material 5 is expanded by the expansion pressure due to the temperature rise in the molding process from the divided part of the upper mold 10a and the lower mold 10b. A part protrudes into the mold joint part to form a burr. However, by performing the temperature raising process using the insert piece type PM, the resin on the surface of the laminated molding material 5 is heated and cured at the mold joint portion, which acts as a barrier to prevent the resin from flowing out. Formation is minimized.

FIG. 4A shows the upper die 10a, and FIG. 4B shows the lower die 10b. As shown in the figure, the lower mold 10b has a concave portion PM1 on the upper surface for placing the frame type PM. The concave portion PM1 is formed so as to surround the four sides of the cavity in which the laminated molding material 5 is accommodated. The frame type PM is accommodated in the recess PM1 via the heat insulating layer PM2, and supported on the lower mold 10b by a point contact portion (not shown) with the lower mold 10b. On the other hand, in the state where the upper mold 10a and the lower mold 10b shown in FIG. 4A are combined, a gap is formed between the upper surface portion of the insert piece mold PM and the lower surface of the upper mold 10a, and there is no mutual contact.

As a result, the heat conduction between the upper mold 10a and the lower mold 10b, which is maintained at the preheating temperature of the laminated molding material 5, and the insert piece mold PM is minimized. The temperature rise area by the insert piece type PM is exclusively the upper mold 10a in the area near the dividing line of the upper mold 10a and the lower mold 10b around the cavity for housing the laminated molding material 5 when the upper mold 10a and the lower mold 10b are matched. It becomes.

It explained in detail below second embodiment excipient type method of the present invention with reference to FIG. 5 (a) ~ (c) .
In the forming method of the second embodiment, at least one of the upper mold 10a and the lower mold 10b in the region near the dividing line of the upper mold 10a and the lower mold 10b is heated with near infrared radiation by the near infrared radiation device 20, By detecting the temperature with a far-infrared temperature sensor, adjusting the intensity of near-infrared light and raising the temperature to a required temperature, the temperature of the thermosetting resin in the region near the dividing line of the upper mold 10a and the lower mold 10b is set. Raise the temperature. Also in the second embodiment, after the preheating process in which the laminated molding material 14 is preheated and placed in the molding die 9, the upper mold 10a and the lower mold 10b are matched with each other to mold the product. The upper mold 10a and the lower mold 10b in the region near the dividing line of the upper mold 10a and the lower mold 10b are thermoset simultaneously with the compression molding by the mold matching of the upper mold 10a and the lower mold 10b in the process of clamping and pressurizing the mold. The step of raising the temperature to a required temperature higher than that of the mold at the curing temperature of the conductive resin is performed using the near infrared radiation device 20.

The intensity of the near infrared light described above is adjusted by a continuous drop of the conduction voltage to the near infrared radiation device 7. When the heating by near infrared rays and the stop thereof are repeated with ON / OFF of the conduction voltage, the pulsation of the temperature change of the heating target is largely unstable. On the other hand, by adjusting the intensity of near infrared rays not by ON / OFF of the voltage but by the continuous voltage drop, the near infrared rays are continuously irradiated and no pulsation occurs in the temperature change. Therefore, the temperature of the object to be heated can be stabilized efficiently at the set temperature.

Next, the forming method according to the third embodiment of the present invention will be described.

In the forming method of the third embodiment, as shown in FIG. 6, the laminated molding material 14 is preheated to a shape along the inner shape of the molding die 9 in the input arrangement portion of the laminated molding material 14 and drawn as a pre-molding. I do. In the forming method of the third embodiment, the dividing line of the upper mold 10a and the lower mold 10b is simultaneously formed by compression molding by mold matching of the upper mold 10a and the lower mold 10b in the process of clamping and pressurizing the mold. The step of raising the temperature of the upper mold 10a and the lower mold 10b in the vicinity region to the curing temperature of the thermosetting resin is performed by local heating using the laser radiation device 21. Specifically, a high-power semiconductor diode laser provided in the laser radiation device 21 is used as a heat source, and a region near the dividing line of the upper mold 10a and the lower mold 10b, particularly the dividing line is locally heated in a non-contact manner, and compression molding is performed. The periphery of the laminated molding material 14 in the process is partially cured. The laser has a single wavelength and can be narrowed down to standard φ0.4, φ0.6 (minimum 0.2 mm), suitable for local heating. In this embodiment, the laminated molding material 14 can be formed in a very short time by laser light irradiation. Can be partially cured.

On one surface of the bi-directional woven fabric substrate 3, a plurality of 100 mm × 100 mm square forming raw material 1 having a resin material 4 mainly composed of epoxy adhered to the surface was prepared. Each forming raw material 1 had a fiber axis direction of approximately 0 ° and 90 ° when the directions of the square sides were 0 ° and 90 °, respectively.

A laminated molding material 14 is obtained by laminating each of the raw molding materials 1 with the uppermost reinforcing fiber woven fabric having the resin material 4 attached to the lower side and the other side having the resin material 4 attached to the upper side. It was.

The laminated molding material 14 was placed on the heating platen 8, and the laminated molding material 14 was heated by near infrared radiation from the upper part by the near infrared radiation device 7. The temperature of the laminated molding material 14 was detected by a far infrared temperature sensor, the intensity of the near infrared rays by the near infrared radiation device 7 was adjusted, and the laminated molding material 14 was heated and preheated.

The intensity of the near infrared ray was adjusted by a continuous drop of the conduction voltage to the near infrared radiation device 7.

On the other hand, it consists of a product part mold 10 and a heat storage board 11, and preheated by raising the mold temperature of the mold 9 by heat conduction from the heater 12 and the heat storage board 11 provided in the product part mold 10. The preheated laminated molding material 14 is accommodated in the preheated mold 9, and the upper mold 10a and the lower mold 10b in the vicinity of the dividing line of the upper mold 10a and the lower mold 10b are placed at the curing temperature of the thermosetting resin. The temperature was raised using PM.

Next, while being pressurized, it was deformed into the shape of a flat plate laminated molded product provided by the mold 9 and heated by passing the mold 9 through the temperature rising water passage 13. Thereby, a flat plate molded product 15 cured by heating was obtained.

Table 1 shows the temperature, pressure, and required time in each of the above steps.

DESCRIPTION OF SYMBOLS 1 ... Molding raw material, 2 ... Reinforcement fiber bundle, 3 ... Textile base material, 4 ... Resin material, 5,14 ... Laminated molding material, 6 ... Preheating type, DESCRIPTION OF SYMBOLS 7 ... Near-infrared radiation | emission apparatus, 9 ... Mold, 10 ... Product part type | mold, 11 ... Heat storage board, 13 ... Temperature rising water passage, 12 ... Heater, 15 ... Flat plate molded product, 17 ... Lower mold, 17a ... Lower mold center block, 16 ... Upper mold, 16a ... Upper mold center block, 18 ... Counter mold, 19: Concave type.

Claims (3)

Laminate molding material, which is made by cutting and laminating a raw material with a resin material consisting mainly of thermosetting resin on at least one surface of a woven fabric substrate containing multiple reinforcing fiber bundles, is placed in the mold. In the forming method in which the resin material adhering to the textile substrate containing a plurality of reinforcing fiber bundles is cured by pressurization and heating to bond between the fibers and between the layers of the molding raw material, lamination molding At least one of a preheating step of preheating the material and placing it in the mold, a step of clamping and pressurizing the mold, and an upper and lower mold in the vicinity of the dividing line of the upper and lower molds. And raising the mold to a required temperature higher than the mold, and raising the mold to the curing temperature, opening the mold and releasing the mold,
The step of raising the temperature of at least one of the upper and lower molds in the vicinity of the upper and lower mold dividing lines to the curing temperature of the thermosetting resin is a process of irradiating the upper and lower mold dividing lines with laser light. Forming method. The step of raising the temperature of at least one of the upper and lower molds in the vicinity of the upper and lower mold dividing lines to the curing temperature of the thermosetting resin is heated by near infrared rays, the temperature is detected by a far infrared temperature sensor, 2. The forming method according to claim 1, which is a step of adjusting the strength and raising the temperature to a required temperature. Laminate molding material, which is made by cutting and laminating a raw material with a resin material consisting mainly of thermosetting resin on at least one surface of a woven fabric substrate containing multiple reinforcing fiber bundles, is placed in the mold. In the forming method in which the resin material adhering to the textile substrate containing a plurality of reinforcing fiber bundles is cured by pressurization and heating to bond between the fibers and between the layers of the molding raw material, lamination molding At least one of a preheating step of preheating the material and placing it in the mold, a step of clamping and pressurizing the mold, and an upper and lower mold in the vicinity of the dividing line of the upper and lower molds. A forming mold used in a forming method having a step of raising the temperature to a required temperature higher than the mold and a step of raising the mold to a curing temperature and opening and releasing the mold , A forming die consisting of an upper die and a lower die for shaping, and an area near the dividing line of the upper and lower die A temperature raising means for raising the temperature of at least one of the upper and lower molds to the curing temperature of the thermosetting resin, a means for clamping and pressurizing the molding die, and raising the mold temperature to the curing temperature to open and release the mold. have a means for the mold, excipient shape type, wherein the a is placed piece Atsushi Nobori means.

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