JP2011218798A - Press molding method and molding thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a press molding method having simplified processes and excellent workability in producing a molding of molding material made of a reinforced fiber and a matrix resin.SOLUTION: The press molding method is implemented in a mold 1. The method for press molding a molding material 7 includes the reinforced fiber and the matrix resin. The mold 1 includes a concave mold 5 having an opening and a convex mold 2, which has a protrusion corresponding to the recess and forms a cavity with the concave mold 5. The mold 1 includes shearing mechanisms 3, 4 to eliminate a run over portion by a shearing force employing mold clamping force and/or mold opening force of a pressurizing device for activating the press molding mold as the power source in parallel with a mechanism to pressurize and press-mold the molding material 7.

Description

  The present invention relates to a press molding method using a molding material composed of a reinforcing fiber and a matrix resin such as a thermoplastic resin or a thermosetting resin, and a molded body obtained by the press molding method. The present invention relates to a press molding method that is excellent in simplification of process and workability during body manufacture.

  In recent years, industrial parts such as automobiles, electrical / electronic equipment, and home appliances that were manufactured by press molding of metal materials have been replaced by molding materials made of reinforcing fibers and thermoplastic resins. ing. This is because a molded body using such a molding material has high strength and is lightweight. Here, press molding is a method of forming, working by applying deformation such as bending, shearing, compression, etc. to various materials exemplified by metals, plastic materials, ceramic materials, etc. using a processing machine, a die, a tool, etc. It is. In addition, press molding is characterized by the ability to produce a large amount of products with relatively good reproducibility, and there are high demands for high speed, high accuracy, and stable quality for mass production. In order to realize them, market demands for improving workability, moldability, and molding cost are very high.

  In particular, in a conventional molding method of a molding material using a thermoplastic resin as a reinforcing fiber and a matrix resin, the molding material in a plasticized state by preheating above the melting temperature of the thermoplastic resin is placed between a mold consisting of a male and female pair. Although a press molding method for obtaining a molded product of a desired shape by supplying pressure and cooling to a desired shape is widely known, in the press molding of a fiber reinforced thermoplastic resin molding material, the shape of the mold cavity is used. Two to three stages of processing are required as separate processes, such as removal of excess surplus parts and burrs, and punching of holes necessary to install other members on the molded body. Although it is excellent in cost, as a result, there has been a problem regarding cost increase of the obtained molded body due to workability.

  Further, in a molding method of a molding material using a reinforcing fiber and a thermosetting resin as a matrix resin, the molding material is temperature-adjusted to a temperature at which the thermosetting resin can be cured with a mold made of a male and female pair. A press molding method in which a molding material is supplied between molds and then pressed to obtain a molded body having a desired shape is widely known. Also in the press molding of the molding material, in the same manner as the molding material using the thermoplastic resin, the removal of surplus portions, burrs and the like, and punching of the hole portion necessary for installing other members on the molded body, etc. ~ Three stages of processing are required as separate processes, and the press molding method itself is excellent in production cost, but as a result, there is a problem related to the cost increase of the obtained molded body due to workability.

  In order to solve this problem, a press molding method is disclosed in which an opening hole of a molding material composed of a reinforcing fiber and a thermoplastic resin is formed for the purpose of simplifying the process in press molding and reducing the cost of the molded body (patent) Reference 1). This is a method of obtaining a molded body having an opening by press molding, and a mechanism capable of protruding operation corresponding to the opening of the molded body is provided on one surface of a molding die composed of a male and female pair used for press molding. Further, the molding material is a molding method in which holes corresponding to the openings are formed in advance.

  However, in the above method, the molded body can be obtained by only one step of press molding. However, an opening operation to the molding material must be performed in advance, and in order to obtain a molded body substantially, two or more steps are required. This process is necessary. Further, no reference is made to the processing of surplus parts such as burrs in the molded body, and it is not a fundamental solution for molding of a fiber-reinforced thermoplastic resin molding material, especially workability.

  Furthermore, in a press molding method of a molding material composed of a thermoplastic resin foam and a skin material, as a technique proposed for the purpose of improving the end appearance of the resulting molded body and reducing the cost, molding made of a thermoplastic resin A method is disclosed in which a slide cam or a cutting blade using a hydraulic cylinder as a drive source is used for the outer peripheral portion of the body, and cutting or entrainment processing is integrated with a pressure compression process (Patent Document 2). This is because the molding material called foam is relatively easy to process, and the slide cam is operated using a hydraulic cylinder as the drive source. As a result, the mold itself becomes enormous, and as a result, the workability and the economic efficiency are remarkably inferior.

Japanese Patent Application Laid-Open No. 10-100195 JP 2004-106598 A

  Therefore, an object of the present invention relates to a press molding method using a molding material composed of reinforcing fibers and a matrix resin, and a molded body obtained by the press molding method. It is an object of the present invention to provide a press molding method that is excellent in simplification of steps and workability during the production of a molded body.

In order to solve the above problems, the present invention has the following configuration. That is,
(1) A method for press-molding a molding material composed of reinforcing fibers and a thermoplastic resin includes the following steps (I) to (V), and the following steps (III) to (V) are the same molding. It is the press molding method implemented in a type | mold (a).
Mold (a): A press mold comprising a concave mold having an opening and a convex mold having a convex corresponding to the concave and having a cavity between the concave mold. Then, using the clamping force and / or mold opening force of the pressurizing device that operates the press mold as the power source, the shearing mechanism that removes the surplus portion by shearing force, pressurizing the molding material, and press molding A mold having a structure that also has a mechanism to perform
Step (I): A step of heating the molding material to the plasticizing temperature of the thermoplastic resin constituting the molding material.
Step (II): A step of conveying the molding material heated to the plasticizing temperature and placing it on the released mold (a).
Step (III): A step of pressurizing and cooling the molding material heated to the plasticizing temperature by clamping the molding die (a).
Step (IV): After pressurization and cooling, in the molding die (a), a step of processing and removing surplus portions by shearing force while maintaining the pressure applied to the molding material.
Step (V): A step of releasing the mold (a) and taking out the molded body from the mold (a).
(2) In a method of press molding a molding material comprising a reinforcing fiber and a thermosetting resin, the method comprises the following steps (VI) to (IX), and the following steps (VII) to (IX) are the same: A press molding method carried out in the mold (a).
Mold (a): A press mold comprising a concave mold having an opening and a convex mold having a convex corresponding to the concave and having a cavity between the concave mold. Then, using the clamping force and / or mold opening force of the pressurizing device that operates the press mold as the power source, the shearing mechanism that removes the surplus portion by shearing force, pressurizing the molding material, and press molding A mold having a structure that also has a mechanism to perform
Step (VI): A step of conveying the molding material and placing it on the released mold (a) that has been heated to a temperature that can be cured in advance.
Step (VII): A step of pressurizing the molding material by clamping the molding die (a).
Step (VIII): A step of processing and removing surplus portions by shearing force while maintaining the pressure applied to the molding material in the mold (a) after pressure cooling.
Step (IX): A step of releasing the mold (a) and taking out the molded body from the mold (a).
(3) The molding die (a) includes at least a pressure cooling mechanism that pressurizes and cools the molding material, a pressure holding mechanism that holds the pressing force applied to the molding material, and shearing that removes surplus portions by shearing force. The press molding method according to (1) or (2), wherein the press molding method has a configuration having a processing mechanism.
(4) A pressing force holding mechanism that holds the pressing force applied to the molding material is provided in the mold (a), and the pressing force holding mechanism is selected from at least air, gas, oil, and a spring element. The press molding method according to any one of (1) to (3), which is any one of the mechanisms.
(5) The shearing mechanism for removing the surplus portion by shearing force is provided in the mold (a), and the shearing mechanism is selected from a slide cam structure, a pin structure, and a punch structure. The press molding method according to any one of (1) to (4), which is a mechanism using such a structure.
(6) In the step (IV) and the step (VIII), the step of processing and removing the surplus portion by shearing force is performed at a temperature equal to or lower than the temperature at which the molding material is solidified and cured. The press molding method according to any one of 5).
(7) In any one of (1) to (6), in the step (III) and the step (VII), the pressure applied to the projected area of the cavity of the concave portion of the mold (a) is in the range of 10 to 50 MPa. A press molding method according to claim 1.
(8) The press molding method according to any one of (1) and (3) to (7), wherein the step (IV) is performed at a timing when the step (III) is shifted to the step (V).
(9) The step (VIII) is performed at a timing when the step (VII) is transferred to the step (IX), (2), (3) to (6), or (8) Press molding method.
(10) In the steps (II) to (IV), (1) and (3), wherein the mold temperature is 20 ° C. to 100 ° C. lower than the solidification temperature of the thermoplastic resin constituting the molding material. ) To (8).
(11) The press molding method according to any one of (1), (3) to (8), or (10), wherein the molding material comprises the following component (A) and component (B).
Component (A): Reinforcing fiber: 25-80% by mass
Component (B): at least one thermoplastic selected from the group consisting of polycarbonate resin, styrene resin, polyamide resin, polyester resin, polyphenylene sulfide resin, modified polyphenylene ether resin, polyetherimide resin, polyolefin resin and polyacetal resin Resin: 20 to 75% by mass
(12) The press molding method according to (11), wherein the component (B) is at least one selected from polyolefin resins, polyamide resins, polyester resins, and polyetherimide resins.
(13) The press molding method according to any one of (2), (3) to (6), or (9), wherein the molding material comprises the following component (A) and component (C).
Component (A): Reinforcing fiber: 25-80% by mass
Component (C): at least one thermosetting resin selected from the group of unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol (resole type) resin, urea melamine resin and thermosetting polyimide: 20 to 75 mass%.
(14) The press molding method according to (13), wherein the component (C) is at least one selected from unsaturated polyester resins, vinyl ester resins, and epoxy resins.
(15) The press molding according to any one of (1) to (14), wherein the reinforcing fiber (component (A)) is at least one selected from carbon fiber, glass fiber, aramid fiber, and mineral fiber. Method.
(16) The press molding method according to (15), wherein the reinforcing fiber (component (A)) has a mass average fiber length in the range of 1 to 50 mm.
(17) A molded body obtained by the press molding method according to any one of (1) to (16), which is a part / member used for automobiles, electrical / electronic devices, home appliances, or aircraft applications,
It is.

  The press molding method using the molding material comprising the reinforcing fiber and the thermoplastic resin according to the present invention does not require a complicated process, so that it is excellent in simplification of the process and workability during the production of the molded body, and as a result, molding. Cost reduction during body production can be achieved. Furthermore, since the molded product obtained by the press molding method of the present invention is excellent in economic efficiency and workability, it is extremely useful for parts / members used in automobiles, electrical / electronic devices, household electrical appliances, or aircraft applications. .

It is the simplified figure which showed a mode that the molding material in one embodiment of the shaping | molding die (a) used for the press molding method of this invention is press-molded. It is the simplified figure which showed a mode that the molding material in one embodiment of the shaping | molding die (a) used for the press molding method of this invention is press-molded. It is the simplified figure which showed a mode that the molding material in one embodiment of the shaping | molding die (a) used for the press molding method of this invention is press-molded. It is the simple figure which showed a mode that the shaping | molding material in one embodiment of the shaping | molding die (a) used for the press molding method of this invention implements press molding and a shearing process. It is the simple figure which showed a mode that the shaping | molding material in one embodiment of the shaping | molding die (a) used for the press molding method of this invention implements press molding and a shearing process. It is a simplification figure of one embodiment of the shaping | molding die (a) used for the press molding method of this invention. In one embodiment of the forming die (a) used in the press forming method of the present invention, FIG. In one embodiment of the forming die (a) used in the press forming method of the present invention, FIG. FIG. 3 is a simplified diagram showing a state in which the D-DD cross section of FIG. 2 is enlarged and operated in one embodiment of the molding die (a) used in the press molding method of the present invention. In one Example of the shaping | molding die (a) used for the press molding method of this invention, it is the simplified figure which showed a mode that the D-DD cross section was expanded and it operate | moves. It is the simple figure which showed the temperature measurement point of the molding material in a heating apparatus from the plane direction. It is the simple figure which showed the temperature measurement point of the molding material in a heating apparatus from the thickness direction. It is the simplification figure which showed the cavity of the shaping | molding die from the opening-and-closing direction of the press apparatus.

  Below, the press molding method of this invention is demonstrated in detail with preferable embodiment.

  The method for press-molding a molding material comprising a reinforcing fiber and a thermoplastic resin of the present invention comprises the following steps (I) to (V), and the following steps (III) to (V) are the same. It is the press molding method implemented in a shaping | molding die (a).

  Further, the method for press molding a molding material comprising the reinforcing fiber and the thermosetting resin of the present invention comprises the following steps (VI) to (IX) and the following steps (VII) to (IX). Is a press molding method in which the same is performed in the same mold (a).

  That is, both are press molds comprising a concave mold having an opening and a convex mold that has a convex portion corresponding to the concave portion and a cavity is formed between the concave mold. Using a clamping force and / or opening force of a pressurizing device that operates a press mold as a power source, a shearing mechanism that removes surplus portions by shearing force, pressurizing the molding material, and press molding It is the press molding method implemented in the shaping | molding die which has the structure which also has the mechanism to perform.

  Here, press molding is a method of obtaining a molded body by applying deformations such as bending, shearing, and compression to various materials exemplified by metals, plastic materials, ceramic materials, etc. using a processing machine, a mold, a tool, and the like. However, examples of the forming form include drawing, deep drawing, flange, call gate, edge curling, and stamping. Further, the press molding method is not particularly limited as long as it does not depart from the scope of the present invention. For molding materials using plastics, a hot press method, a cold press molding method (stamping method) from the viewpoint of mass productivity of the obtained molded product. The press molding method) and the injection press molding method are preferably used.

  The mold (a) used in the present invention has a concave mold (5) having an opening and a convex (2) corresponding to the concave, as shown in FIG. Clamping force of a pressurizing device (not shown) for operating a press mold as a power source, which is a press mold composed of a convex mold in which a cavity (8) is formed with a concave mold And / or a mold having a structure having both a shearing mechanism (3, 4) for removing an excess portion by a shearing force using a mold opening force and a mechanism for press-molding a molding material to perform press molding. . Further, these molds have a cavity surface corresponding to the shape of the molded body produced by the press molding method of the present invention. Here, the cavity refers to a gap portion when the mold is clamped and corresponds to the shape of the obtained molded body.

  Next, the above steps (I) to (V), which are cases where a molding material using a thermoplastic resin as a matrix resin is used, are described below.

  Step (I) is a step of heating the molding material to the plasticizing temperature of the thermoplastic resin constituting the molding material. In a molding material composed of reinforcing fibers and a thermoplastic resin, it is necessary to heat the molding material at a temperature higher than the plasticizing temperature of the thermoplastic resin in advance, so that it can be used for far infrared heaters, heating plates, high-temperature ovens, dielectric heating, etc. This is a step of heating with an exemplified heating device to melt (soften) the thermoplastic resin (plasticization).

  Step (II) is a step of conveying the molding material heated to the plasticizing temperature and placing it on the released mold (a). The heated molding material is conveyed manually or by a robot and placed in the released mold. When transporting, a manpower or a robot is appropriately selected from the viewpoint of work safety and placement accuracy of a molding material on a molding die in which press molding is performed.

  Step (III) is a step of pressurizing and cooling the molding material heated to the plasticizing temperature by clamping the mold (a). Here, FIGS. 1B to 1C show a series of operations in the pressure cooling process. FIG. 1B illustrates a state in which the molding material heated and arranged is pushed into the cavity (FIGS. 1-a, 8) of the molding die by clamping the molding die (a). At this time, the members constituting the shearing mechanism shown in 3 of FIG. 1-b slide in the lateral direction, and 4 in FIG. 1-b is the upper mold convex portion (6- in FIG. 1-b). It is made not to contact a). Next, FIG. 1C illustrates a state in which the mold is clamped to a preset mold cavity thickness by the mold clamping operation of the press apparatus, and the molding material is molded. At that time, in the shearing mechanism, 3 in FIG. 1-c, which is a member constituting the mechanism, is bitten to the lower side of 4 in FIG. 1-c to prepare for the subsequent step (IV) and step (VIII). It becomes a state. Step (IV) is a step of processing and removing surplus portions by shearing force while maintaining the pressure applied to the molding material in the mold (a) after cooling under pressure. A series of operations for a specific aspect of the step (IV) is shown in FIGS. In FIG. 1-c, by pressurization and cooling, molding of the molding material into the molding die is completed, and then the operation proceeds to the operation of releasing the molding die as shown in FIG. However, at this time, the molding material is pressed against the lower mold 5 of the molding die by the pressure holding mechanism (FIGS. 1-d, 6-a), and the pressure is held. While maintaining the applied pressure, 4 in FIG. 1-d operates according to 3 in FIG. 1-d to remove the surplus portion of the molded body by shearing force, and FIG. As shown, the surplus portion is removed.

  Step (V) is a step of releasing the mold (a) and taking out the molded body from the mold (a) as shown in FIG. 1-e.

  Here, the molding die (a) has at least a pressure cooling mechanism that pressurizes and cools the molding material, a pressure holding mechanism that holds the pressure applied to the molding material, and a surplus portion is removed by a shearing force. It is preferable to have a configuration having a shearing mechanism. When the molding die (a) is equipped with these mechanisms, it is generated through a process of molding the molding material into the shape of the molded body and a process of solidifying the molded molding material while applying pressure to form a molded body. The excess portion of the molded body to be removed can be removed without taking out from the mold, and the removal of unnecessary portions in the molded body to be a product and the workability of processing can be improved.

  The pressure cooling mechanism that pressurizes and cools the molding material has a structure in which a flow path of cooling oil or cooling water is provided inside the mold, and the pressure mechanism has a load that exceeds the load resistance of the press molding machine. It is preferable to have a material and a structure that can be handled in view of shortening the molding cycle.

  The pressure holding mechanism for holding the pressure applied to the molding material is provided in the mold (a) (for example, FIG. 1-a), and in particular, the pressure holding mechanism is at least air, gas, oil. In the case of any mechanism selected from spring elements, since it is possible to effectively perform shearing while pressing the molded body during shearing, from the viewpoint of improving processing accuracy and the beauty of the processed surface preferable. The pressure holding mechanism is appropriately selected depending on the required pressure holding force. In particular, the use of a gas spring using a gas element can express and hold a high pressure with good reproducibility. Therefore, it can be preferably used.

  A shearing mechanism that removes the surplus portion by the shearing force is provided in the mold (a) (for example, FIG. 1-a), and in particular, the shearing mechanism includes a slide cam structure, a pin structure, and a punch. A mechanism using any structure selected from the structures is preferable from the viewpoint of space saving of the mold and workability of removing the surplus portion. The shearing mechanism can be selected from a slide cam structure, a pin structure, and a punch structure in accordance with a necessary shape. If the shearing process is performed over a relatively wide range, a punch structure or a pin structure can be suitably used from the viewpoint of durability of the structure for slide cam structures, circular shapes, drilling of relatively small parts, and the like.

  It is preferable from the viewpoint of cost reduction of the molded body that the step (IV) is performed at the timing when the step (III) is shifted to the step (V), in order to simplify the step. By carrying out at this timing, since the molding material is sufficiently solidified in the cavity of the molding die, the process proceeds to step (IV), so that the finish of the cut surface after removing the surplus portion becomes beautiful. Because.

  Next, the above steps (VI) to (IX), which are cases where a molding material using a thermosetting resin as a matrix resin is used, will be described.

  Step (VI) is a step of conveying the molding material and placing it on the released mold (a) that has been heated to a temperature that can be cured in advance. This is a step of transporting the molding material laminated in advance so as to have a desired thickness and placing it on the released mold (a). The heated molding material is conveyed manually or by a robot and placed in the released mold. When transporting, a manpower or a robot is appropriately selected from the viewpoint of work safety and placement accuracy of a molding material on a molding die in which press molding is performed.

  Step (VII) is a step of pressurizing the molding material by clamping the molding die (a), and a step of curing the molding material while pressing it by clamping the molding die (a). is there. Here, it demonstrates using a figure similarly to process (III) at the time of using a thermoplastic resin for the above-mentioned matrix resin. FIG. 1B to FIG. 1C show a series of operations in the process of curing while applying pressure. FIG. 1B illustrates a state in which the laminated and arranged molding materials are pushed into the cavities (FIGS. 1-a and 8) of the molding die by clamping the molding die (a). At this time, the members constituting the shearing mechanism shown in 3 of FIG. 1-b slide in the lateral direction, and 4 in FIG. 1-b is the upper mold convex portion (6- in FIG. 1-b). It is made not to contact a). Next, FIG. 1C illustrates a state in which the mold is clamped to a preset mold cavity thickness by the mold clamping operation of the press apparatus, and the molding material is molded. At that time, in the shearing mechanism, 3 in FIG. 1-c which is a member constituting the mechanism is engaged to the lower side of 4 in FIG. 1-c, and the process proceeds to the subsequent step (VIII).

  Step (VIII) is the same as step (IV), and step (IX) is the same as step (V).

  From the viewpoint of cost reduction of the molded body, the process (VIII) is performed at the timing of transition from the process (VII) to the process (IX) to the process (VIII) so that the process can be simplified. preferable. By carrying out at this timing, since the molding material is sufficiently solidified in the cavity of the molding die, the process proceeds to step (VIII), so that the finish of the cut surface after removing the surplus portion becomes beautiful. Because.

  In the step (IV) and the step (VIII), it is affected by molding shrinkage of the molded body that the step of processing and removing the surplus portion by shearing force is performed at a temperature lower than the temperature at which the molding material solidifies. Since it is difficult to improve the dimensional accuracy and simplify the process, it is preferable from the viewpoint of cost reduction of the molded body. The temperature at which the molding material solidifies can be determined by DSC (Differential Scanning Calorimetry). The measurement is performed at a temperature rising rate of 10 ° C./min, and the rising point of the melting peak in the obtained DSC curve is defined as a solidification temperature.

  In the step (III) and the step (VII), the applied pressure applied to the projected area of the cavity of the concave portion of the mold (a) is in the range of 10 to 50 MPa. It is preferable from the viewpoint of ease of handling and ease of control of the thickness of the molded body. In particular, the range of 15 MPa to 30 MPa is preferable from the viewpoint of the equipment cost of the press molding machine. Here, the projected area of the cavity of the concave portion of the mold (a) is a two-dimensional flat area viewed from the opening and closing direction of the mold, and is exemplified by the hatched portion (8) in FIG. When it has an uneven shape, it is smaller than the development area of the actual molded product.

  In the above steps (II) to (IV), the plasticizing molding material is applied in such a manner that the temperature of the molding die is 20 ° C. to 100 ° C. lower than the solidification temperature of the thermoplastic resin constituting the molding material. It is preferable from the viewpoint of ease of shape and surface appearance of the molded body. For example, when a polyamide 6 resin is used as the matrix resin (component (B)), a preferable range is 120 ° C. to 160 ° C., and when a polypropylene resin is used, a preferable range is 80 ° C. to 120 ° C.

  Furthermore, in order to carry out the steps (III) to (V) in the same mold (a), at least the thermoplasticity constituting the molding material while pressing the molding material in the cooling and pressing step. Cooling to below the solidification temperature of the resin (component (B)) facilitates the processing of the shearing process in the subsequent step (IV), improves the durability of the shearing jig, and further the surface of the molded body This is preferable because the appearance is improved. Furthermore, by carrying out the steps (III) to (V) in the same mold (a), the cooling and pressurizing step and the shearing step are conventionally separated into one step. Therefore, the cost of the molded product can be reduced as a result of simplification of the process and saving of equipment.

  By carrying out in the same mold (a) in the step (IX) to the step (IX), the pressure step and the shearing step are conventionally separate steps as one step. Therefore, as a result, the cost of the molded body can be reduced by simplifying the process and saving equipment.

In addition, the press molding method of the present invention can further simplify the molding operation and prevent molding troubles when a process for operating the ejector that assists the process (V) or the process (IX) is included. Is preferable. In addition, the ejector can be preferably used by either a method of blowing compressed air or a method of pushing up by a mechanical structural member.
The molding material composed of the reinforced fiber and the thermoplastic resin is not particularly limited as long as it is a thermoplastic resin reinforced with the reinforced fiber. For example, a needle is inserted into a plurality of strand-shaped reinforced fibers and the fibers are entangled with each other. A molding material obtained by laminating a thermoplastic resin on mat-like strand reinforcing fibers and heating and pressing them, a molding material obtained by attaching a molten thermoplastic resin to a reinforcing fiber bundle and pressing, only reinforcing fibers, or Powdered and fiber-shaped thermoplastic resin is dispersed, and this is heated and pressed to obtain a molding material. Reinforced fiber and powder-shaped and fiber-shaped thermoplastic resin are dispersed and mixed in water to make a paper. The molding material obtained by heating and pressurizing the nonwoven material obtained in this way, the nonwoven material obtained by making paper from a suspension in which only reinforcing fibers are dispersed in water, powder shape, fiber shape, film shape, Heating the thermoplastic resin woven shape, pressurized, and known molding materials, such as molding material formed by bonding a thermoplastic resin to the nonwoven material of the reinforcing fibers obtained by paper making is. Among these, a molding material obtained by adhering the thermoplastic resin to the nonwoven material of the reinforcing fiber is preferable from the viewpoints of dispersibility of the reinforcing fiber and freedom of the form of the thermoplastic resin, and economics of the manufacturing method. Can be used.
Similarly, the molding material composed of reinforcing fibers and thermosetting resin is not particularly limited as long as it is a thermosetting resin reinforced with reinforcing fibers. For example, a thermosetting resin is laminated on a plurality of strand-like reinforcing fibers. The molding material obtained by impregnating the thermosetting resin into the strand-like reinforcing fibers, cut into 5 to 50 mm, arranged so as to be random, and the molding material obtained by pressurizing the reinforcing fiber bundle Pressed and impregnated thermosetting resin into a molding material obtained by impregnating a woven fabric with a thermosetting resin, and a non-woven material obtained by making a paper from a suspension obtained by dispersing and mixing reinforcing fibers in water. The molding material obtained by the above is mentioned. Among these, a molding material obtained by impregnating the thermosetting resin into the nonwoven material of the reinforcing fiber, and after impregnating the thermosetting resin into the strand-like reinforcing fiber, the reinforcing fiber is cut so that it becomes random. Can be preferably used from the viewpoints of ease of production and economy.

  Further, the component (A) is preferably at least one selected from carbon fiber, glass fiber, aramid fiber, and mineral fiber, which can be expected to greatly enhance the reinforcing effect of the reinforcing fiber, and the glass fiber is low-cost, The carbon fiber is more preferable because a high reinforcing effect can be obtained, and carbon fiber having a large reinforcing effect on the matrix resin by the reinforcing fiber is particularly preferable.

  Furthermore, it is preferable that this component (A) is contained in the ratio of 25-80 mass%. Considering the mechanical properties of the molded article obtained by the present invention, it is more preferably contained in a proportion of 30 to 75% by mass, particularly preferably 35 to 70% by mass. When the mass content of the carbon fiber is 25% by mass or more, the reinforcing effect of the reinforcing fiber of the molded body obtained by the press molding method of the present invention is exhibited, so that the bending strength required when used as a structural member is obtained. Can demonstrate. Moreover, when the mass content of the carbon fibers is 80% by mass or less, the matrix impregnation between the reinforcing fibers and the matrix resin can be satisfied, and the moldability can be ensured.

  Furthermore, it is preferable that the mass average fiber length of the said component (A) is 1-50 mm. The mass average fiber length of the reinforcing fibers is more preferably 1.5 to 26 mm, and further preferably 2 to 6.5 mm. When the mass average fiber length of the reinforcing fiber is longer than 1 mm, the fiber reinforcing effect is large, which is suitable for use as a structural member. Further, when the mass average fiber length of the reinforcing fibers is shorter than 50 mm, the steric hindrance due to the entanglement of the reinforcing fibers can be reduced, so that the occurrence of defects in the molded body obtained by the press molding method of the present invention can be suppressed. This is preferable because it is possible. The average fiber diameter of the reinforcing fibers is not particularly limited, but is preferably in the range of 1 to 20 μm and in the range of 3 to 15 μm from the viewpoint of mechanical properties and surface appearance of the obtained molded product. More preferred.

  The reinforcing fiber may be included as a reinforcing fiber bundle in which single yarns of a plurality of reinforcing fibers are combined. In this case, the number of single yarns of the reinforcing fiber bundle is not particularly limited, and can be used within the range of 100 to 350,000, and particularly within the range of 1,000 to 250,000. preferable. Further, from the viewpoint of productivity of reinforcing fibers, those having a large number of single yarns are preferable, and it is preferable to use them within a range of 20,000 to 100,000. When reinforcing fibers are included as reinforcing fiber bundles, a composition such as urethane resin, polyamide resin, epoxy resin, acrylic resin, etc., is given as appropriate in order to give the reinforcing fiber bundle a converging property and improve handling. It may be what you did. Furthermore, in order to make dispersion | distribution of a reinforced fiber favorable, you may use what cut the reinforced fiber bundle. In addition, the reinforcing fiber is preferably in the form of a web or mat-like sheet in which reinforcing fibers are randomly oriented from the viewpoint of obtaining a mechanically isotropic fiber.

  The component (B) includes, for example, polyesters such as polyethylene terephthalate, polybutylene terephthalate, polytrimethylene terephthalate, polyethylene naphthalate, and liquid crystal polyester, polyolefins such as polyethylene, polypropylene, and polybutylene, polyoxymethylene, polyamide, Fluorine resins such as polyphenylene sulfide, polyketone, polyetherketone, polyetheretherketone, polyetherketoneketone, polyethernitrile, polytetrafluoroethylene, crystalline resins such as liquid crystal polymer, styrene resin, polycarbonate, Polymethyl methacrylate, polyvinyl chloride, polyphenylene ether, polyimide, polyamideimide, polyetherimide, polysulfone, polyether Amorphous resins such as rusulphone, polyarylate, phenolic resin, phenoxy resin, polystyrene, polyolefin, polyurethane, polyester, polyamide, polybutadiene, polyisoprene, fluorine, acrylonitrile, etc. And thermoplastic resins selected from these copolymers and modified products. In the present invention, at least one of these can be employed as the thermoplastic resin. Preferably, from the viewpoint of economy, the component (B) is a polycarbonate resin, a styrene resin, a polyamide resin, a polyester resin, a polyphenylene sulfide resin, a modified polyphenylene ether resin, a polyetherimide resin, a polyolefin resin, or a polyacetal resin. It is at least one thermoplastic resin selected from the group, and more preferably at least one selected from polyolefin resins, polyamide resins, polyester resins, and polyetherimide resins. This is from the viewpoint of moldability in which a thermoplastic resin is impregnated between the reinforcing fibers.

Furthermore, it is preferable that the compounding quantity of the said component (B) is a ratio of 20-75 mass%. Like the viewpoint of the content of the reinforcing fiber, it is more preferably contained in a proportion of 25 to 70 mass%, particularly preferably 30 to 65 mass%.
Examples of the component (C) include unsaturated polyesters, vinyl esters, epoxies, phenols (resol type), urea melamine, polyimides, copolymers thereof, modified products, and blends of two or more. Used resin can be used. Furthermore, an elastomer or a rubber component may be added to the thermosetting resin in order to improve impact resistance. Among these, an epoxy resin is particularly preferable from the viewpoint of rigidity and strength of a molded product. Furthermore, it is preferable that the compounding quantity of the said component (C) is a ratio of 20-75 mass%. Like the viewpoint of the content of the reinforcing fiber, it is more preferably contained in a proportion of 25 to 70 mass%, particularly preferably 30 to 65 mass%.

  In addition, the component (B) can include a mixture of the above-described thermoplastic resins or a polymer alloy using these thermoplastic resins and a modified product thereof, if necessary. Includes all of these. Such thermoplastic resins may optionally contain various compounding agents that are usually compounded, such as stabilizers, pigments, and fillers. Further, the component (C) may optionally contain various compounding agents that are usually compounded such as a stabilizer, a pigment, and a filler.

  The molded body obtained by the press molding method of the present invention can be developed for various uses. Parts for automobiles and motorcycles such as various modules such as instrument panels, door beams, under covers, lamp housings, pedal housings, radiator supports, spare tire covers, front ends, notebook computers, mobile phones, digital still cameras, PDAs, plasmas Electrical and electronic parts such as displays, telephones, facsimiles, VTRs, photocopiers, televisions, microwave ovens, audio equipment, toiletries, refrigerators, air conditioners and other household and office electrical parts, civil engineering and construction parts, aircraft parts, etc. In particular, it is preferably used for electronic device parts and automobile parts.

  Hereinafter, the present invention will be described in more detail with reference to examples. In addition, the raw material used for the Example is as follows.

(Reference Example 1)
Component (A) Reinforcing fiber (PAN-based carbon fiber)
The PAN-based carbon fiber that is a reinforcing fiber was produced as follows.

Using a copolymer composed of 99.4 mol% of acrylonitrile (AN) and 0.6 mol% of methacrylic acid, an acrylic fiber bundle having a single fiber denier 1d and a filament number of 24,000 was obtained by a dry and wet spinning method. The obtained acrylic fiber bundle is heated at a draw ratio of 1.05 in air at a temperature of 240 to 280 ° C., converted to flame-resistant fiber, and then heated in a temperature range of 300 to 900 ° C. in a nitrogen atmosphere. After 10% stretching at a rate of 200 ° C./min, the temperature was raised to a temperature of 1,300 ° C. and fired. This carbon fiber bundle was subjected to an electrolytic surface treatment of 3 coulombs per gram of carbon fiber with an aqueous solution containing sulfuric acid as an electrolyte, and dried in heated air at a temperature of 120 ° C. to obtain a PAN-based carbon fiber bundle.
Total number of filaments: 24,000 Single fiber diameter: 7 μm
Mass per unit length: 0.8 g / m
Specific gravity: 1.8 g / cm ³
Tensile strength (Note 1): 4.2 GPa
Tensile modulus (Note 2): 230 GPa.
(Note 1) Measurement conditions for tensile strength and (Note 2) tensile modulus

  It calculated | required by the method described in Japanese Industrial Standard (JIS) -R-7601 "resin impregnation strand test method". However, the resin-impregnated strand of carbon fiber to be measured is impregnated with “BAKELITE” (registered trademark) ERL 4221 (100 parts by mass) / 3 boron fluoride monoethylamine (3 parts by mass) / acetone (4 parts by mass). And cured at 130 ° C. for 30 minutes. The number of strands measured was 6, and the average value of each measurement result was the tensile strength and tensile modulus of the carbon fiber.

(Reference Example 2)
As the component (B-1) thermoplastic resin, an unmodified polypropylene resin (manufactured by Prime Polymer Co., Ltd., “Prime Polypro (registered trademark)” J105G, specific gravity: 0.91, plasticizing temperature: 160 ° C.) was used.

  Use a Teflon (registered trademark) sheet (thickness 1 mm) as a release sheet between the hot platen surfaces of a hydraulic press machine composed of upper and lower hot platen surfaces heated to 200 ° C., and sandwich polypropylene resin between them. Arranged. Polypropylene resin was added and arranged so that there was no bias. Then, it was pressed at 3 MPa. Next, it is placed between cooling plates of a hydraulic press machine composed of upper and lower hot plate surfaces controlled to a temperature of 30 ° C., and is cooled and pressed at 3 MPa, and has a length of 1000 mm, a width of 1000 mm, and a thickness of 0.13 mm. Of polypropylene film (hereinafter abbreviated as PP).

(Reference Example 3)
As the component (B-2) thermoplastic resin, polyamide 6 resin (manufactured by Toray Industries, Inc., “Amilan (registered trademark)” CM1001, specific gravity: 1.13, plasticization temperature: 225 ° C.) was used.

  Use a Teflon (registered trademark) sheet (thickness 1 mm) as a release sheet between the hot platen surfaces of a hydraulic press machine composed of upper and lower hot platen surfaces heated to 240 ° C., and sandwich the polyamide 6 resin. Arranged. Polyamide 6 resin was added and arranged so that there was no bias. Then, it was pressed at 3 MPa. Next, it is placed between the cooling plates of a hydraulic press machine composed of upper and lower hot plate surfaces controlled to a temperature of 30 ° C., cooled at 3 MPa, and has a length of 1000 mm, a width of 1000 mm, and a thickness of 0.1 mm. A polyamide film (hereinafter abbreviated as PA) was obtained.

(Reference Example 4)
As a component (A), the carbon fiber continuous bundle obtained in Reference Example 1 was cut with a cartridge cutter to obtain a chopped yarn having a fiber length of 6.4 mm. Surfactant (manufactured by Wako Pure Chemical Industries, Ltd., “Sodium n-dodecylbenzenesulfonate” (product name), 100 liters of a 1.5 wt% aqueous solution was stirred to prepare a pre-foamed dispersion. 100 g of the chopped yarn obtained was put into the liquid, stirred for 10 minutes, then poured into a paper machine having a paper surface of 1000 mm length × width 1000 mm, dehydrated by suction, and then at a temperature of 150 ° C. for 2 hours. It dried and obtained the nonwoven fabric (henceforth CF) which consists of carbon fibers.

(Reference Example 5)
One non-woven fabric made of carbon fiber obtained in Reference Example 4 was sandwiched between both sides of the non-woven fabric made of carbon fiber and PP obtained in Reference Example 2 to obtain a sheet having a structure of [PP / CF / PP]. Further, a Teflon (registered trademark) sheet (thickness: 1 mm) was used as the release sheet, and the sheet was disposed so as to be sandwiched. Subsequently, it arrange | positioned between the hot platen surfaces of the hydraulic press machine comprised from the upper and lower hot platen surface heated to the temperature of 200 degreeC, and pressed at 5 MPa. Next, it was placed between cooling plates controlled at a temperature of 30 ° C. and cooled and pressed at 5 MPa to obtain a molding material composed of reinforcing fibers and a thermoplastic resin having a length of 1000 mm, a width of 1000 mm, and a thickness of 0.31 mm. .

(Reference Example 6)
One non-woven fabric made of carbon fiber obtained in Reference Example 4 and one sheet of PA obtained in Reference Example 3 are sandwiched between both sides of the non-woven fabric made of carbon fiber, and the sheet has a configuration of [PA / CF / PA]. It was. Further, a Teflon (registered trademark) sheet (thickness: 1 mm) was used as the release sheet, and the sheet was disposed so as to be sandwiched. Subsequently, it arrange | positioned between the hot platen surfaces of the hydraulic press machine comprised from the upper and lower hot platen surface heated to the temperature of 240 degreeC, and pressed at 5 MPa. Next, it was placed between cooling plates controlled at a temperature of 30 ° C. and cooled and pressed at 5 MPa to obtain a molding material composed of reinforcing fibers having a length of 1000 mm, a width of 1000 mm, and a thickness of 0.26 mm and a thermoplastic resin. .

(Reference Example 7)
Toray Co., Ltd. carbon fiber ("Treka (registered trademark)" M46J (tensile strength 4200 MPa, tensile elastic modulus 436 GPa, number of filaments 6000, fiber basis weight 0.2 g / m)) as component (A) ) Prepreg made of 130 ° C. curable epoxy resin has a carbon fiber basis weight of 116 g / m ² and a resin content (Wr) of 30% unidirectional (UD) prepreg (“Torayca (registered trademark)” manufactured by Toray Industries, Inc. Prepreg P6053-12) was used. The fiber direction is set to 0 ° so that the conditions shown in Table 4 are satisfied, and the six prepregs are adjusted so that the fiber direction is 45 °, −45 °, 90 °, 90 °, −45 °, 45 ° from the top. Lamination was performed to obtain a molding material.

(Reference Example 8)
As component (A), carbon fiber manufactured by Toray Industries, Inc. ("Treka (registered trademark)" T300B (tensile strength 3500 MPa, tensile elastic modulus 230 GPa, number of filaments 3000, fiber basis weight 0.2 g / m)) is used as the reinforcing fiber. The carbon fiber fabric used as warp and weft and plain weave so that the warp and weft are 5 pieces / cm has a carbon fiber basis weight of 198 g / m ^{2 made of} a 130 ° C.-curable epoxy resin as component (C), A cross prepreg having a resin content (Wr) of 40% ("Torayca (registered trademark)" prepreg F6343B-05 manufactured by Toray Industries, Inc.) was used. This was laminated so as to satisfy the conditions in Table 4 to obtain a molding material. (Reference Example 9)
One direction (UD) prepreg described in Reference Example 7 ("Torayca (registered trademark)" prepreg P6053-12 manufactured by Toray Industries, Inc.) was used, and this was 250 mm in the fiber direction and perpendicular to the fiber using a cutter knife. And was cut to 12 mm. The prepregs cut into SUS flat plates are dispersed by hand so that the prepreg is randomly arranged, and the molding material is adjusted by adjusting the amount so that the thickness after molding of the molding material becomes the thickness described in Table 4. Obtained.

  The evaluation criteria obtained in each example are as follows.

(Reference Example 10)
As shown in FIG. 5-a and FIG. 5-b, the point (11) where the center point on the plane of the molding material (7) and the center point in the thickness direction of the molding material intersect was taken as the center in the thickness direction. The measurement was performed at 1 second intervals using a K-type thermocouple and a Keyence data logger “NR600”. The K thermocouple was sandwiched between molding materials and carefully placed in a heating device so as not to be displaced during temperature measurement.

(Evaluation 1) Evaluation of shear workability The sheared surface of the molded product obtained by the press molding method was visually observed and judged according to the following criteria.
A: There is no need for additional processing of the shearing surface, and the cut residue of component (A), component (B) or component (C) is not attached to the shearing surface.
B: Although there is no need for additional processing of the shearing surface, the scraps of component (A), component (B), and component (C) are attached to the shearing surface.
C: Additional processing of the shearing surface is required.

(Evaluation 2) Evaluation of workability The sheared surface of the molded body obtained by the press molding method was visually observed and judged according to the following criteria.
A: The cooling process and the shearing process are completed in one process.
B: Although the cooling process and the shearing process are completed in one process, the molded body is shaken during the shearing process.
C: The cooling process and the shearing process are not completed in one process.
In any evaluation, A and B were acceptable and C was not.

Example 1
Using the component (A) for the reinforcing fiber and the component (B-1) for the thermoplastic resin, the sheet-like molding material obtained in the manner described in Reference Example 5 is laminated so as to satisfy the conditions described in Table 1. It was adjusted. As a shearing mechanism for removing surplus material, a mold (FIG. 1-a) having a slide cam structure and a gas spring as a pressure holding mechanism was used. Further, the mold temperature was adjusted to 5 and 6-b in FIG. Thereafter, preheating was carried out for 500 seconds in an oven equipped with a far-infrared heater until the center reached 235 ° C. in the thickness direction of the molding material as described in Reference Example 7. Next, as shown in 7 of FIG. 1-a, the molding material was placed on the projection surface of the concave portion of the mold cavity surface. Immediately thereafter, the convex mold of the mold is lowered at a speed of 20 mm / second, and the mold material is filled in the cavity while continuously shifting to the state shown in FIGS. The mold was clamped until the thickness of the cavity shown in 1-c was 1.2 mm. Thereafter, pressurization and cooling are performed for 50 seconds so as to maintain this state, and then the molding die is continuously opened as shown in FIGS. Got. 3A, FIG. 3B, FIG. 4-A, and FIG. 4-B show the operation of each structure during the surplus portion removal processing. The evaluation conditions and results are summarized in Table 1.

(Example 2)
A molded body was obtained in the same manner as in Example 1 except that a punching structure was used as a shearing mechanism for removing excess wall, and a molding die equipped with a gas spring was used as a pressure holding mechanism. The evaluation conditions and results are summarized in Table 1.

(Example 3)
A molded body was obtained in the same manner as in Example 1 except that a pin structure and a molding die equipped with a gas spring as a pressure holding mechanism were used as a shearing mechanism for removing excess wall. The evaluation conditions and results are summarized in Table 1.

Example 4
A molded body was obtained in the same manner as in Example 1 except that a slide cam structure and a punch structure were used in combination as a shearing mechanism for removing excess wall, and a molding die equipped with a gas spring was used as a pressure holding mechanism. . The evaluation conditions and results are summarized in Table 1.

(Example 5)
A molded body was obtained in the same manner as in Example 1 except that a slide cam structure and a pin structure were used in combination as a shearing mechanism for removing excess wall, and a molding die equipped with an air spring was used as a pressure holding mechanism. . The evaluation conditions and results are summarized in Table 1.

(Example 6)
A molded body was obtained in the same manner as in Example 1, except that a slide cam structure and a pin structure were used in combination as a shearing mechanism for removing excess wall, and a molding die equipped with a spring was used as a pressure holding mechanism. The evaluation conditions and results are summarized in Table 1.

(Comparative Example 1)
A molded body was obtained in the same manner as in Example 1 except that a shearing mechanism for removing excess wall and a mold having no pressure holding mechanism were used. The evaluation conditions and results are summarized in Table 1.

(Comparative Example 2)
A molded body was obtained in the same manner as in Example 1 except that a slide cam using a hydraulic cylinder, which is a separate device, was used as a shearing mechanism for removing surplus material, and a molding die without a pressure holding mechanism was used. The evaluation conditions and results are summarized in Table 1.

(Example 7)
Using the component (A) for the reinforcing fiber and the component (B-2) for the thermoplastic resin, the sheet-like molding material obtained in the manner described in Reference Example 5 is laminated so as to satisfy the conditions described in Table 2. It was adjusted. As a shearing mechanism for removing surplus material, a mold (FIG. 1-a) having a slide cam structure and a gas spring as a pressure holding mechanism was used. The mold temperature was adjusted to 5 and 6-b in FIG. Thereafter, preheating was performed for 500 seconds in an oven equipped with a far infrared heater until the center reached 270 ° C. in the thickness direction of the molding material as described in Reference Example 7. Next, the molding material was placed in the concave portion of the mold cavity surface. Immediately thereafter, the convex mold of the mold is lowered at a speed of 20 mm / second, and the mold material is filled in the cavity while continuously shifting to the state shown in FIGS. The mold was clamped until the thickness of the cavity shown in 1-c was 1.3 mm. Thereafter, pressurization and cooling are performed for 50 seconds so as to maintain this state, and then the molding die is continuously opened as shown in FIGS. Got. 3A, FIG. 3B, FIG. 4-A, and FIG. 4-B show the operation of each structure during the surplus portion removal processing. The evaluation conditions and results are summarized in Table 2.

(Example 8)
A molded body was obtained in the same manner as in Example 7, except that a punching structure was used as a shearing mechanism for removing excess wall, and a molding die equipped with a gas spring was used as a pressure holding mechanism. The evaluation conditions and results are summarized in Table 2.

Example 9
A molded body was obtained in the same manner as in Example 7 except that a pin structure and a molding die equipped with a gas spring as a pressure holding mechanism were used as a shearing mechanism for removing excess material. The evaluation conditions and results are summarized in Table 2.

(Example 10)
A molded body was obtained in the same manner as in Example 7 except that a slide cam structure and a punch structure were used in combination as a shearing mechanism for removing excess wall, and a molding die equipped with a gas spring was used as a pressure holding mechanism. . The evaluation conditions and results are summarized in Table 2.

(Example 11)
A molded body was obtained in the same manner as in Example 7 except that a slide cam structure and a pin structure were used in combination as a shearing mechanism for removing excess wall, and a molding die equipped with an air spring was used as a pressure holding mechanism. . The evaluation conditions and results are summarized in Table 2.

(Example 12)
A molded body was obtained in the same manner as in Example 7, except that a slide cam structure and a pin structure were used in combination as a shearing mechanism for removing surplus material, and a molding die equipped with a spring was used as the pressure holding mechanism. The evaluation conditions and results are summarized in Table 2.

(Comparative Example 3)
A molded body was obtained in the same manner as in Example 7 except that a shearing mechanism for removing excess wall and a molding die without a pressure holding mechanism were used. The evaluation conditions and results are summarized in Table 2.

(Comparative Example 4)
A molded body was obtained in the same manner as in Example 7, except that a slide cam using a hydraulic cylinder, which is a separate device, was used as a shearing mechanism for removing surplus material, and a molding die without a pressure holding mechanism was used. The evaluation results are summarized in Table 2.

(Example 13)
Using the component (A) for the reinforcing fiber and the component (B-2) for the thermoplastic resin, the sheet-like molding material obtained in the manner described in Reference Example 5 is laminated so as to satisfy the conditions described in Table 3. It was adjusted. As a shearing mechanism for removing surplus material, a mold (FIG. 1-a) having a slide cam structure and a gas spring as a pressure holding mechanism was used. The mold temperature was adjusted to 5 and 6-b in FIG. Thereafter, preheating was performed for 500 seconds in an oven equipped with a far infrared heater until the center reached 270 ° C. in the thickness direction of the molding material as described in Reference Example 7. Next, the molding material was placed in the concave portion of the mold cavity surface. Thereafter, the convex mold is immediately lowered at a speed of 20 mm / second, and the molding material is filled in the cavity while continuously shifting to the state shown in FIGS. Clamping was performed until the thickness of the cavity shown in c was 1.1 mm. Thereafter, pressurization and cooling are performed for 50 seconds so as to maintain this state, and then the molding die is continuously opened as shown in FIGS. Got. 3A, FIG. 3B, FIG. 4-A, and FIG. 4-B show the operation of each structure during the surplus portion removal processing. The evaluation conditions and results are summarized in Table 3.

(Example 14)
As a shearing mechanism for removing surplus material, a punch structure and a molding die equipped with a gas spring as a pressure holding mechanism were used, and the molded body was molded in the same manner as in Example 7 except that the thickness of the cavity was 1.2 mm. Obtained. The evaluation conditions and results are summarized in Table 3.

(Example 15)
As a shearing mechanism for removing surplus material, a mold having a pin structure and a gas spring as a pressure holding mechanism was used, and the molded body was molded in the same manner as in Example 7 except that the cavity thickness was 1.1 mm. Obtained. The evaluation conditions and results are summarized in Table 3.

(Comparative Example 5)
A molded body was obtained by the same method as in Example 7 except that a mold having no shearing mechanism and a pressure holding mechanism for removing excess wall was used, and the thickness of the cavity was changed to 0.8 mm. The evaluation conditions and results are summarized in Table 3.

(Comparative Example 6)
Example 7 except that the slide cam using a hydraulic cylinder, which is a separate device, is used as a shearing mechanism for removing excess wall, and a mold without a pressure holding mechanism is used, and the cavity thickness is 1.2 mm. A molded body was obtained by the method described above. The evaluation conditions and results are summarized in Table 3.

(Example 16)
The sheet-shaped molding material obtained in Reference Example 7 was used. As a shearing mechanism for removing surplus material, a mold (FIG. 1-a) having a slide cam structure, a punch structure, and a gas spring as a pressure holding mechanism was used. The mold temperature was adjusted to 5 and 6-b in FIG. Next, as shown in 7 of FIG. 1-a, the molding material was placed on the projection surface of the concave portion of the mold cavity surface. Immediately thereafter, the convex mold of the mold is lowered at a speed of 20 mm / second, and the mold material is filled in the cavity while continuously shifting to the state shown in FIGS. Clamping was performed as shown in 1-c. Thereafter, pressurization was performed for 1 hour so as to maintain this state, and thereafter, as shown in FIGS. 1-d and 1-e, the mold was continuously opened, and the excess portion was removed and a molded body was obtained. . 3A, FIG. 3B, FIG. 4-A, and FIG. 4-B show the operation of each structure during the surplus portion removal processing. The evaluation conditions and results are summarized in Table 4.

(Example 17)
A molded body was obtained in the same manner as in Example 16 except that the sheet-like molding material obtained in Reference Example 8 was used, and was subjected to evaluation. The conditions and results are summarized in Table 4.

(Example 18)
A molded body was obtained in the same manner as in Example 16 except that the sheet-like molding material obtained in Reference Example 9 was used, and was subjected to evaluation. The conditions and results are summarized in Table 4.

(Comparative Example 7)
A molded body was obtained in the same manner as in Example 16 except that a shearing mechanism for removing excess wall and a molding die without a pressure holding mechanism were used. The evaluation conditions and results are summarized in Table 4.

(Comparative Example 8)
A molded body was obtained in the same manner as in Example 17 except that a slide cam using a hydraulic cylinder, which was a separate device, was used as a shearing mechanism for removing surplus material, and a molding die without a pressure holding mechanism was used. The evaluation conditions and results are summarized in Table 4.

(Comparative Example 9)
A molded body was obtained in the same manner as in Example 18 except that a slide cam using a hydraulic cylinder, which was a separate device, was used as a shearing mechanism for removing surplus material, and a molding die without a pressure holding mechanism was used. The evaluation conditions and results are summarized in Table 4.

  As mentioned above, in Examples 1-18, the press molding method excellent in both shear workability and workability was able to be obtained. In addition, in the press molding methods of Examples 4 to 6, 10 to 12, and 15 to 18, good results excellent in molding cost that a molded body having a shape having two types of shearing mechanisms can be produced. was gotten.

  On the other hand, in Comparative Examples 1 and 3, since there was no cooling and pressurizing mechanism and shearing mechanism, the press working method was inferior in workability, that is, in molding cost. In Comparative Examples 2, 4, and 7 to 8, since there is no pressurization holding mechanism and the shearing mechanism is a separate device, workability is inferior as a press molding method, and the device cost is high, that is, the molding cost is inferior. As a result. In Comparative Examples 5 and 6, it was found that shearing was impossible even when the contents of the reinforcing fibers and the thermoplastic resin were too low and too high.

1 Mold (a)
2 Mold of convex part of mold (a) 3 Part of shearing mechanism provided in mold (a) (sliding cam operating member)
4 Part of the shearing mechanism (slide cam) provided in the mold (a)
5 Recessed Mold of Mold (a) 6-a Pressure Holding Mechanism (Gas Spring) Provided in Mold (a)
6-b Projection of molding die (a) 7 Molding material 8 Cavity 9 Excess portion 10 of molded body subjected to shearing process Molding body 11 Measurement point of central temperature in thickness direction of molding material C On molding die (a) Part of the shearing mechanism provided in the molding die (a) D Part of the shearing mechanism provided in the mold (a) DD Part of the shearing mechanism provided in the mold (a)

Claims (17)

In the method of press-molding a molding material comprising a reinforcing fiber and a thermoplastic resin, the following steps (I) to (V) are included, and the following steps (III) to (V) are performed in the same mold ( Press forming method carried out in a).
Mold (a): A press mold comprising a concave mold having an opening and a convex mold having a convex corresponding to the concave and having a cavity between the concave mold. Then, using the clamping force and / or mold opening force of the pressurizing device that operates the press mold as the power source, the shearing mechanism that removes the surplus portion by shearing force, pressurizing the molding material, and press molding A mold having a structure that also has a mechanism to perform
Step (I): A step of heating the molding material to the plasticizing temperature of the thermoplastic resin constituting the molding material.
Step (II): A step of conveying the molding material heated to the plasticizing temperature and placing it on the released mold (a).
Step (III): A step of pressurizing and cooling the molding material heated to the plasticizing temperature by clamping the molding die (a).
Step (IV): After pressurization and cooling, in the molding die (a), a step of processing and removing surplus portions by shearing force while maintaining the pressure applied to the molding material.
Step (V): A step of releasing the mold (a) and taking out the molded body from the mold (a). A method for press-molding a molding material comprising a reinforcing fiber and a thermosetting resin, comprising the following steps (VI) to (IX), wherein the following steps (VII) to (IX) are the same mold (A) The press molding method implemented within.
Mold (a): A press mold comprising a concave mold having an opening and a convex mold having a convex corresponding to the concave and having a cavity between the concave mold. Then, using the clamping force and / or mold opening force of the pressurizing device that operates the press mold as the power source, the shearing mechanism that removes the surplus portion by shearing force, pressurizing the molding material, and press molding A mold having a structure that also has a mechanism to perform
Step (VI): A step of conveying the molding material and placing it on the released mold (a) that has been heated to a temperature that can be cured in advance.
Step (VII): A step of pressurizing the molding material by clamping the molding die (a).
Step (VIII): A step of processing and removing surplus portions by shearing force while maintaining the pressure applied to the molding material in the mold (a) after pressure cooling.
Step (IX): A step of releasing the mold (a) and taking out the molded body from the mold (a). The mold (a) includes at least a pressure cooling mechanism that pressurizes and cools the molding material, a pressurization holding mechanism that holds the pressing force applied to the molding material, and a shearing mechanism that removes the surplus portion by shearing force. 3. The press molding method according to claim 1 or 2, wherein the press molding method has a combined structure. A pressing force holding mechanism that holds the pressing force applied to the molding material is provided in the mold (a), and the pressing force holding mechanism is selected from at least air, gas, oil, and a spring element. The press molding method according to any one of claims 1 to 3, wherein the mechanism is a mechanism. The mold (a) is provided with a shearing mechanism for removing surplus portions by a shearing force, and the shearing mechanism is any structure selected from a slide cam structure, a pin structure, and a punch structure The press molding method according to any one of claims 1 to 4, wherein the press molding method is a mechanism using the above. 6. The process according to claim 1, wherein, in the step (IV) and the step (VIII), the step of processing and removing the surplus portion by shearing force is performed at a temperature equal to or lower than a temperature at which the molding material is solidified and cured. A press molding method according to claim 1. In the said process (III) and the said process (VII), the applied pressure concerning the projection area of the cavity of the recessed part of a shaping | molding die (a) is in the range of 10-50 Mpa. Press molding method. The press molding method according to any one of claims 1 and 3 to 7, wherein the step (IV) is performed at a timing when the step (III) is shifted to the step (V). The press molding method according to any one of claims 2, 3 to 6, or 8, wherein the step (VIII) is performed at a timing when the step (VII) is shifted to the step (IX). In any one of the steps (II) to (IV), the mold temperature is carried out within a temperature range 20 ° C to 100 ° C lower than the solidification temperature of the thermoplastic resin constituting the molding material. A press molding method according to claim 1. The press molding method according to any one of claims 1, 3 to 8, or 10, wherein the molding material comprises the following component (A) and component (B).
Component (A): Reinforcing fiber: 25-80% by mass
Component (B): at least one thermoplastic selected from the group consisting of polycarbonate resin, styrene resin, polyamide resin, polyester resin, polyphenylene sulfide resin, modified polyphenylene ether resin, polyetherimide resin, polyolefin resin and polyacetal resin Resin: 20 to 75% by mass The press molding method according to claim 11, wherein the component (B) is at least one selected from a polyolefin resin, a polyamide resin, a polyester resin, and a polyetherimide resin. The press molding method according to any one of claims 2, 3 to 6, or 9, wherein the molding material comprises the following component (A) and component (C).
Component (A): Reinforcing fiber: 25-80% by mass
Component (C): at least one thermosetting resin selected from the group of unsaturated polyester resin, vinyl ester resin, epoxy resin, phenol (resole type) resin, urea melamine resin and thermosetting polyimide: 20 to 75 mass%. The press molding method according to claim 13, wherein the component (C) is at least one selected from unsaturated polyester resins, vinyl ester resins, and epoxy resins. The press molding method according to any one of claims 1 to 14, wherein the reinforcing fiber (component (A)) is at least one selected from carbon fiber, glass fiber, aramid fiber, and mineral fiber. The press molding method according to claim 15, wherein a mass average fiber length of the reinforcing fibers (component (A)) is within a range of 1 to 50 mm. A molded body obtained by the press molding method according to any one of claims 1 to 16, which is a part / member used for automobiles, electrical / electronic devices, home appliances, or aircraft applications,