JP2013129064A - Method for manufacturing fiber-reinforced resin material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a fiber-reinforced resin material which can effectively prevent the displacement of a continuous fiber-reinforced resin material arranged in a cavity in its manufacturing process when is charged with a non-continuous fiber-reinforced resin material regarding the method for manufacturing the fiber-reinforced resin material obtained by reinforcing part of the non-continuous fiber resin member using the continuous fiber-reinforced material.SOLUTION: In the method for manufacturing the fiber-reinforced resin material J, a movable member 4 is provided to protrude to a side of a lower mold 2 of the cavity in an upper mold 1 including a molding die 10, the continuous fiber-reinforced material J1 is housed in the cavity so that a protruding material 5 is disposed on the continuous fiber-reinforced material and the protruding material 5 is positioned to a position corresponding to the movable member 4, and the protruding material 5 and the continuous fiber-reinforced material J1 are embedded in the non-continuous fiber-reinforced material J2' while securing a non-movable posture of the continuous fiber-reinforced material J1 via the protruding material 5 by the movable member 4 by charging and press-molding the melting non-continuous fiber resin material J2'.

Description

  The present invention relates to a method for producing a fiber reinforced resin material in which a part of a discontinuous fiber resin material is partially reinforced with a continuous fiber reinforcing material.

  Fiber reinforced resin material (fiber reinforced plastic (FRP)), which is made by mixing a reinforcing fiber material with resin, is lightweight and strong, so it is used in various industrial fields such as the automobile industry, construction industry, and aviation industry. Has been.

  For example, in the automobile industry, the above-mentioned fiber reinforced resin material is applied to vehicle skeletal structural members such as pillars, lockers, and underfloor floors, and non-structural members such as door outer panels and hoods that require design properties. Attempts have been made to reduce weight while guaranteeing and to produce low fuel consumption and environmentally friendly vehicles.

  In the skeletal structure member described above, all of the skeletal structure member is manufactured with a continuous fiber material that is a fiber material such as carbon fiber or glass fiber, and is formed of continuous fibers having a length of 50 mm or more with a certain orientation. As this increases costs, a portion of continuous fibers (non-continuous fiber resin material) in which long fibers with a fiber length of less than 50 mm and short fibers with a shorter fiber length are randomly oriented, for example, are continuous. Attempts have been made to manufacture skeletal structural members by reinforcing them with fiber reinforcing materials. Moreover, in the non-structural member, a part of the resin member (non-continuous fiber resin material) containing no fiber material is reinforced with a continuous fiber reinforcing material as necessary. Yes. In addition, the technique which reinforces a fiber reinforced resin material by arrange | positioning a reinforcing material partially in this way is disclosed by patent document 1. FIG.

  In the conventional manufacturing method of a fiber reinforced resin material obtained by reinforcing a part of a non-continuous fiber resin material with a continuous fiber reinforcing material, the continuous fiber reinforcing material is placed in a mold and then made of, for example, a thermoplastic resin. In general, a fiber reinforced resin material in which a part of a cured non-continuous fiber resin material is reinforced with a continuous fiber reinforcing material is formed by charging the molten resin into a cavity and curing the molten resin. Is.

  In this "charge", a method of containing a preheated molten resin mass in a cavity, a method of injection molding of a molten resin, and a fiber material such as short fiber or long fiber in addition to continuous fiber reinforcement are contained in the cavity. In addition, transfer molding in which a molten resin is injected is included. And in the method of accommodating the lump of molten resin in the cavity, the step of press-molding the non-continuous fiber resin material and the continuous fiber reinforcement material and then embedding the continuous fiber reinforcement material inside the non-continuous fiber resin material continues. become.

  However, when a continuous fiber reinforcing material is arranged in the cavity of the mold and the melted discontinuous fiber resin material is charged, the continuous fiber reinforcing material is displaced due to the pressure during charging. ing. For example, taking a method of accommodating a non-continuous fiber resin material softened as a charge in a cavity, in the next step of press molding of a non-continuous fiber resin material and a continuous fiber reinforcing material, This is a problem that the continuous fiber reinforcing material positioned in the cavity moves and is displaced, and the continuous fiber reinforcing material cannot be embedded at a desired position of the discontinuous fiber resin material.

Japanese Patent Laid-Open No. 7-9589

  The present invention has been made in view of the above-described problems, and relates to a method for manufacturing a fiber reinforced resin material obtained by reinforcing a part of a discontinuous fiber resin material with a continuous fiber reinforcing material, and is disposed in a cavity during the manufacturing process. It is an object of the present invention to provide a method for producing a fiber reinforced resin material that can effectively prevent displacement of the continuous fiber reinforcing material when the discontinuous fiber resin material is charged.

  In order to achieve the above object, the method for producing a fiber reinforced resin material according to the present invention is a mold composed of an upper mold and a lower mold, and the upper mold is movable in a cavity so as to be able to project to the lower mold side. A mold having a member is prepared, and a protrusion is disposed on the continuous fiber reinforcement, and the protrusion is aligned with the movable member in a position corresponding to the movable member. Contain continuous fiber reinforcing material and projection material, charge at least the molten non-continuous fiber resin material onto the projection material, press the upper mold and lower mold close to each other, and move the movable member and projection The material passes through the discontinuous fiber resin material and is brought into contact with each other, and is further press-molded while guaranteeing the fixed posture of the continuous fiber reinforcing material with the movable member via the projection material, thereby allowing the discontinuous fiber resin material to Protruding material and continuous fiber reinforcement are buried inside, discontinuous And Wei resin material is cured a portion of the non-continuous fiber resin material is continuous fiber reinforcement is to produce a fiber-reinforced resin material made reinforced.

  The method for producing a fiber-reinforced resin material according to the present invention is a method of reinforcing a non-continuous fiber resin material in which short fibers or long fibers are randomly blended with a continuous fiber reinforcing material in which continuous fibers are partially blended, and fibers. Regarding a method for producing a reinforced resin material, the continuous fiber reinforcing material disposed in the cavity of the mold is subjected to the pressure of the non-continuous fiber resin material charged in the cavity (more specifically, the pressure during press molding). Therefore, it is possible to manufacture a fiber reinforced resin material in which a continuous fiber reinforcing material is accurately embedded at a desired position of the discontinuous fiber resin material.

  Here, “charge” means that a discontinuous fiber resin material lump or sheet (preliminary shaped body by preheating) is disposed in the cavity in such a manner that a part of the lump or sheet is in contact with the protruding material disposed above the continuous fiber reinforcing material. Next, a fiber reinforced resin material in which a continuous fiber reinforcing material is embedded in a press-molded discontinuous fiber resin material by press-molding by closing the upper mold and the lower mold Is manufactured.

  In the present specification, the “continuous fiber reinforcing material” means a reinforcing material (prepreg material or the like) contained in a matrix resin in which continuous fibers are made of a thermoplastic resin or the like, for example, as defined by JIS. A fiber material (continuous fiber) exceeding 50 mm may be a unidirectional material (UD material) oriented in one direction in a matrix resin, or a pseudo-isotropic material (a woven fabric composed of multiaxial laminated materials, warps and wefts) Etc.). Furthermore, the “non-continuous fiber resin material” is a fiber member or material thereof in which long fibers shorter than continuous fibers or shorter fibers are randomly contained in a matrix resin made of a thermoplastic resin or the like, or It means a resin member made only of a matrix resin not containing a fiber material and its material (design members and the like are targets).

  In addition, when the resin forming the discontinuous fiber resin material is made of a thermoplastic resin, the softening of the matrix resin means that the glass transition point Tg when the thermoplastic resin is made of an amorphous plastic such as polystyrene (PS). In the case of crystalline plastics such as nylon (PA: nylon 6, nylon 66, etc.), it will "melt" near its melting point Tm.

  For example, preheated and softened (or plasticized) non-continuous fiber resin material and non-preheated and therefore relatively hard continuous fiber reinforcement is contained in a cavity and press-molded. Thus, the relatively hard continuous fiber reinforcing material is embedded in the softened discontinuous fiber resin material. At this time, a relatively hard projection material is similarly arranged on the continuous fiber reinforcing material that is relatively hard compared to the discontinuous fiber resin material and at a position corresponding to the movable member. By press molding, the relatively hard protrusion material and the continuous fiber reinforcing material are embedded in the discontinuous fiber resin material.

  Here, the “movable member” is fixed to the tip of movable means (spring, cylinder mechanism, piston mechanism, etc.) provided in the upper mold, can be protruded to the lower mold side in the cavity, and is opened in the upper mold. This is a member that can be accommodated in the accommodation groove, and is a member (movable pin or the like) that abuts against the projection material disposed on the continuous fiber reinforcing material to guarantee this immovable posture. The movable member is made of a material that is harder than a continuous fiber reinforcing material or a discontinuous fiber resin material, such as a metal or ceramic.

  By press molding, a non-continuous fiber resin material having a shape and size corresponding to a cavity having a desired shape is formed, and a continuous fiber reinforcing material is embedded at an appropriate position inside this, and a protrusion material positioned thereon is also embedded. .

  And in the case of complete press, a movable member is pulled back in the accommodation groove | channel opened in the upper mold | type, and is extracted from a discontinuous fiber resin material.

  As described above, the manufacturing method of the present invention is to eliminate the positional deviation by pressing the continuous fiber reinforcing material with the protruding material on which the continuous fiber reinforcing material is arranged and the movable member pressing the protruding material, This can be realized by a simple manufacturing method improvement in which a protruding material is disposed on the continuous fiber reinforcing material, and a movable member is provided on the upper die so as to protrude into the cavity.

  Preferably, the projection material is formed of a resin having adhesiveness, and when the movable member comes into contact with each other, the both are bonded with an appropriate adhesive force, thereby further ensuring the holding posture of the continuous fiber reinforcing material. It is good. The projecting material having adhesiveness can be bonded to the continuous continuous fiber reinforcing material below, and the misalignment can be eliminated.

  For example, the protrusion material embedded in the discontinuous fiber resin material made of thermoplastic resin is formed of a thermoplastic resin having adhesiveness, more preferably a thermoplastic resin of the same material as the discontinuous fiber resin material. It is desirable from the viewpoint of good compatibility between the two and high interfacial adhesion. More preferably, in addition to the non-continuous fiber resin material and the projection material, the continuous fiber reinforcing material may be formed of the same thermoplastic resin.

  By applying the manufacturing method of the present invention described above, the continuous fiber reinforcing material can be efficiently embedded in a desired portion of the non-continuous fiber resin material, so that the weight of pillars, lockers, underfloor floors, etc. can be reduced. It is suitable for mass production of non-structural members such as door outer panels and hoods as well as skeletal structural members of vehicles that require strength.

  As can be understood from the above description, according to the method for manufacturing a fiber reinforced resin material of the present invention, a movable member is provided on the upper mold constituting the mold so as to protrude freely toward the lower mold within the cavity. The fiber reinforcing material is accommodated in the cavity of the molding die in a posture in which the protruding material is disposed on the fiber reinforcing material, and in a posture in which the protruding material is aligned with the position corresponding to the movable member, and the discontinuous fiber resin material is at least of the protruding material. By charging and pressing the upper part, the movable member and the protruding material are passed through the non-continuous fiber resin material and brought into contact with each other, and the stationary posture of the continuous fiber reinforcing material is guaranteed by the movable member through the protruding material. While being further press-molded, the position shift of the continuous fiber reinforcing material can be eliminated, and thus a fiber reinforced resin material in which the continuous fiber reinforcing material is precisely embedded in the desired part of the non-continuous fiber resin material is manufactured. Can do.

It is the schematic diagram explaining the manufacturing method of the fiber reinforced resin material of this invention. It is a perspective view of one embodiment of a continuous fiber reinforcement. It is the schematic diagram explaining the manufacturing method of the fiber reinforced resin material following FIG. (A) is a schematic diagram which shows the shaping | molding die used by the adhesiveness confirmation test of a projection material and a discontinuous fiber resin material, (b) is a schematic diagram which shows the state by which the fiber reinforced resin material was manufactured with the shaping | molding die. It is.

  Hereinafter, an embodiment of a method for producing a fiber-reinforced resin material of the present invention will be described with reference to the drawings. In the illustrated example, there are various forms with respect to the shape of the fiber reinforced resin material to be manufactured, the embedment position and the number of bases of the continuous fiber reinforcing material, and the molding die also corresponds to the shape dimension of the fiber reinforced resin material to be manufactured. Those with cavities are applied.

(Manufacturing method of fiber reinforced resin material)
FIGS. 1 and 3 are flowcharts illustrating an embodiment of the method for producing a fiber-reinforced resin material of the present invention in this order.

  In the manufacturing method of the fiber reinforced resin material, first, a mold 10 shown in FIG. 1 is prepared. The illustrated mold 10 includes a slidable upper mold 1 and a lower mold 2, and FIG. 1 shows a state in which these molds are opened.

  The lower die 2 has a concave groove 2a, and the convex portion 1a of the upper die 1 is fitted here to form a cavity, and a charged matrix resin is molded into the cavity.

  In the manufacturing method of the present invention, the convex portion 1a of the upper mold 1 is provided with a housing groove 1b for housing a spring 3 which is one of the movable mechanisms, and a rigid movable member 4 is fixed to the tip of the spring 3 housed therein. ing. The spring 3 has such a spring constant that the movable member 4 is completely accommodated in the accommodating groove 1b when the press molding is completed while the upper die 1 and the lower die 2 are closed (at the time of complete pressing). The length of the movable member 4 is also long enough to form this state. In addition, as a movable mechanism, a piston mechanism, a cylinder unit mechanism, etc. can be mentioned besides the spring 3 of the example of illustration.

  A continuous fiber reinforcing material J1 in which a continuous fiber S1 is contained in a matrix resin M1 made of a thermoplastic resin is accommodated in the concave groove 2a of the lower mold 2 forming the cavity.

  As the matrix resin M1 made of a thermoplastic resin that forms the continuous fiber reinforcing material J1, polyethylene (PE), which is a crystalline plastic having a high ratio of crystal regions in which molecular chains are regularly arranged and having a high degree of crystallinity, is used. ), Polypropylene (PP), nylon (PA: nylon 6, nylon 66, etc.), polyacetal (POM), polyethylene terephthalate (PET) and other non-crystalline plastics that have very low crystallinity or do not crystallize. Any one of polystyrene (PS), polyvinyl chloride (PVC), polymethyl methacrylate (PMMA), ABS resin, thermoplastic epoxy and the like can be applied.

  The continuous fiber S1 contained in the matrix resin M1 includes ceramic fibers such as boron, alumina, silicon carbide, silicon nitride, and zirconia, inorganic fibers such as glass fibers and carbon fibers, copper, steel, aluminum, and stainless steel. Any one or two or more mixed materials of metal fibers and organic fibers such as polyamide and polyester can be mentioned.

  The continuous fiber reinforcing material J1 is a prepreg material or the like in which the continuous fiber S1 is contained in the matrix resin M1, and the continuous fiber S1 exceeding 50 mm is defined in the matrix resin M1 as shown in the JIS. Further, it may be a unidirectional material (UD material) oriented in one direction, or a pseudo-isotropic material (such as a multiaxial laminated material or a woven fabric made of warp and weft).

  As shown in FIG. 1, when the mold 10 is opened and the continuous fiber reinforcing material J1 is placed in a proper position in the concave groove 2a of the lower mold 2, a resin material projection 5 is disposed thereon.

  The position of the projection 5 is a position corresponding to the movable member 4 positioned above (position in the X direction in the figure), and the movable member 4 displaces the discontinuous fiber resin material J2 ′ during press molding. It penetrates and reaches the upper surface of the projection material 5.

  The protruding material 5 is disposed on the continuous fiber reinforcing material J1, and then the lump of the discontinuous fiber resin material J2 'preheated on the protruding material 5 is charged.

  In the illustrated example, the pre-heated and softened discontinuous fiber resin material J2 ′ is accommodated in the cavity C as “charge”. In this charge mode, the discontinuous fiber resin material J2 ′ Press molding continues.

  Here, the discontinuous fiber resin material J2 ′ also has a matrix resin M2 made of a thermoplastic resin like the continuous fiber reinforcement material J1, and fiber materials S2 such as short fibers and long fibers are randomly contained in the matrix resin M2. It consists of the contained material.

  Here, the projection material 5 is preferably formed of a thermoplastic resin having good adhesion so as to adhere to each other when it contacts the movable member 4, and desirably the matrix resin M1 of the continuous fiber reinforcing material J1. And the softened discontinuous fiber resin material J2 ′ and the matrix resin M2 are preferably formed from the same thermoplastic resin.

  In addition, while the non-continuous fiber resin material J2 ′ to be charged is in a molten state by preheating, the continuous fiber reinforcing material J1 previously accommodated in the groove 2a is not softened and melted. It is good that it is in a relatively hard state as compared to the discontinuous fiber resin material J2 ′ in the state. This is because it is desirable that the continuous fiber reinforcing material J1 is embedded while maintaining the original shape as much as possible in the process of forming the discontinuous fiber resin material J2 ′ into a cavity shape during press molding. .

  The continuous fiber reinforcing material J1 is accommodated in a suitable position in the concave groove 2a of the lower mold 2, and a protruding material 5 is disposed on the continuous fiber reinforcing material J1 so as to correspond to the upper movable member 4. When the continuous fiber resin material J2 ′ is charged, the upper mold 1 is slid to the lower mold 2 side (Y1 direction in FIG. 1), and the upper mold 1 and the lower mold 2 are continuous with the discontinuous fiber resin material J2 ′ in the cavity. The fiber reinforcing material J1 is press-molded.

  As shown in FIG. 3, at the time of press molding, the movable member 4 and the protruding material 5 penetrate each other through the discontinuous fiber resin material J2 ′ formed into a cavity shape, and the protruding material 5 is interposed therebetween. Thus, the continuous fiber reinforcing material J1 is guaranteed to be stationary by the movable member 4, and the press molding is continued, so that the protruding material 5 and the continuous fiber reinforcing material J1 are placed inside the molded non-continuous fiber resin material J2 ′. Buried.

  In this way, since the continuous fiber reinforcing material J1 is prevented from being displaced by the movable member 4 via the protruding material 5 during press molding, the continuous fiber reinforcing material J1 is desired in the discontinuous fiber resin material J2 ′. It can be embedded precisely in the position.

  Then, at the stage of complete pressing shown in FIG. 3, the movable member 4 is completely retracted into the receiving groove 1b of the upper mold 1 (Y2 direction), and the molten discontinuous fiber resin material J2 ′ is cured in this state. (Molding of the cured non-continuous fiber resin material J2), a fiber-reinforced resin material J is produced in which the continuous fiber reinforcing material J1 reinforces a part of the non-continuous fiber resin material J2.

  In the fiber reinforced resin material J, when the material resin of the discontinuous fiber resin material J2 and the continuous fiber reinforcing material J1 and the projection material 5 embedded in the material is made of the same thermoplastic resin, mutual familiarity and adhesion And good product integrity can be guaranteed.

[Adhesion confirmation test of protrusion material and discontinuous fiber resin material and results]
The present inventors use a molding die composed of an upper die and a lower die shown in FIG. 4, and manufacture a test body of a fiber reinforced resin material using members of the following materials and dimensions to constitute the test body. A test was conducted to confirm the adhesion between the protrusion material and the discontinuous fiber resin material.

  As a non-continuous fiber resin material, a thermoplastic stampable sheet (Vf40% for PP / CF) with dimensions of 106mm x 106mm x 4mm (thickness) is used. As a continuous fiber reinforcement, the dimensions are 50mm x 50mm x 2mm ( Thickness) thermoplastic continuous fiber sheet (PP / CF type, Vf50%) (4 thermoplastic continuous fiber sheets with a thickness of 0.5 mm are laminated and manufactured by hot press). A protrusion material having a size of 20 mm × 20 mm × 2 mm (thickness) previously produced by hot pressing was bonded to the substrate.

  On the other hand, as shown in FIG. 4a, the mold used is an iron pin having a diameter of 15 mm fixed to the tip of the spring of the receiving groove formed in the center of the upper die, and the tip of the pin protrudes 5 mm toward the lower die side. We prepared an upper mold in the state and a lower mold with a groove diameter of 150 mm.

  A thermoplastic continuous fiber sheet with projection material bonded upwards is housed in the lower groove of the lower mold, the mold temperature is adjusted to 120 ° C, the internal temperature is preheated to 240 ° C with an IR heater, and the molten state The thermoplastic stampable sheet was charged and the upper mold was lowered as shown in FIG. 4b to press-mold the molten thermoplastic stampable sheet. Here, the press load is 450 kN, the press speed is 3 mm / sec, and the cooling time is 60 sec.

  A test body formed by press molding and curing the thermoplastic stampable sheet was taken out of the mold, and it was confirmed that the embedded position of the thermoplastic continuous fiber sheet was within ± 1 mm of the initial position.

  Furthermore, the step on the upper surface of the test specimen was within ± 0.2 mm, and it was confirmed that the flatness was ensured in appearance.

  Furthermore, it can be visually confirmed that there is no gap at the interface between the projection material and the molded thermoplastic stampable sheet, and further, a predetermined region including this interface is cut out and a tensile test is performed, and the adhesive strength at the interface is 20 MPa or more. It was confirmed that there was.

  From the results of this test, when manufacturing a fiber reinforced resin material by a manufacturing method in which a continuous fiber reinforcing material is embedded in place while forming a discontinuous fiber resin material by press molding, the manufacturing method of the present invention is applied. It has been demonstrated that a continuous fiber reinforcing material can be precisely embedded at a desired position, and thus a fiber reinforced resin material with high product quality can be manufactured.

  The embodiment of the present invention has been described in detail with reference to the drawings. However, the specific configuration is not limited to this embodiment, and there are design changes and the like without departing from the gist of the present invention. They are also included in the present invention.

  DESCRIPTION OF SYMBOLS 1 ... Upper mold | type, 1a ... Convex part, 1b ... Accommodating groove, 2 ... Lower mold, 2a ... Concave groove, 3 ... Movable mechanism (spring), 4 ... Movable member (movable pin), 5 ... Projection material, 10 ... Molding Mold, J: Fiber reinforced resin material, J1: Continuous fiber reinforcement material, J2: Non-continuous fiber resin material, J2 ': Non-continuous fiber resin material (softened by preheating), S1: Continuous fiber, S2: Fiber Material (short fiber, long fiber), M1, M2 ... Matrix resin (thermoplastic resin)

Claims (5)

A mold composed of an upper mold and a lower mold, and a mold having a movable member provided so as to protrude toward the lower mold in the cavity is prepared for the upper mold,
Containing the continuous fiber reinforcing material and the protruding material in the cavity of the molding die in a posture in which the protruding material is arranged on the continuous fiber reinforcing material, and in a posture in which the protruding material is aligned with the position corresponding to the movable member, Furthermore, the molten non-continuous fiber resin material is charged on at least the projection material,
The upper die and the lower die are pressed close to each other, and at this time, the movable member and the protruding material are in contact with each other through the non-continuous fiber resin material, and the continuous fiber reinforcing material does not move through the protruding material. As a result of further press molding with a movable member assured, the discontinuous fiber resin material is embedded inside the discontinuous fiber resin material, and the discontinuous fiber resin material is cured and the discontinuous fiber resin material is cured. The manufacturing method of the fiber reinforced resin material which manufactures the fiber reinforced resin material which a continuous fiber reinforcement material reinforces a part.   The method for producing a fiber-reinforced resin material according to claim 1, wherein the charge is a method of accommodating a lump of discontinuous fiber resin material preheated and softened in a cavity.   A movable means is provided in the cavity side region of the upper mold, a movable member is fastened to the tip of the movable means, the projection material is formed of an adhesive resin, and the movable member projects. The method for producing a fiber-reinforced resin material according to claim 1 or 2, wherein both of them are bonded when contacted with the material.   The said protrusion material is a manufacturing method of the fiber reinforced resin material in any one of Claims 1-3 currently formed from the resin of the same material as the matrix resin of the said discontinuous fiber reinforcement material.   The method for producing a fiber-reinforced resin material according to claim 4, wherein the continuous fiber reinforcing material, the matrix resin of the discontinuous fiber resin material, and the protrusion material are both formed from the same material resin.

Images