JP2013216078A5 - - Google Patents

Description

Molding apparatus and molding method for composite molded article containing fiber material

In the present invention, a material comprising a solid or semi-solid prepreg is supplied to the lower mold, and after the material comprising the solid or semi-solid prepreg is compression-molded between the upper mold and the lower mold, further injection molding or injection compression is performed. The present invention relates to a molding apparatus and a molding method for a composite molded product including a fiber material that is molded to form a composite molded product.

Including a fiber material that supplies a solid or semi-solid prepreg material to the lower mold, compresses the prepreg material between the upper mold and the lower mold, and then performs injection compression molding to form a composite molded product. As a molding apparatus for a composite molded product, one described in Patent Document 1 is known. In Patent Document 1, a fiber-reinforced thermoplastic is stamped and formed to form a skeleton layer, and then a thermoplastic plastic skin layer that does not contain fibers is formed into a fiber-reinforced thermoplastic by injection compression molding using the same mold. It is described that it is integrally formed on the surface of the plastic skeleton layer. However, in the case of Patent Document 1, it is not described how to supply the heated blank sheet between the molding dies.

Moreover, although it is not related to the molded article containing a fiber material, what was described in patent document 2 is known as a synthetic resin composite molding apparatus which performs flow stamping molding and injection compression molding. Patent Document 2 shows the relationship among a material supply mechanism for performing flow stamping molding, a mold clamping unit, and a molding unit for injection compression molding.

JP-A-5-185466 (Claim 1, FIG. 1, FIG. 2) JP-A-5-24128 (0005 to 0014, FIG. 1 and FIG. 2)

However, in the case of inserting a blank sheet between the press devices in Patent Document 1, an entry space for the device for insertion is required, and the height of the press device needs to be increased so that the press device can be opened largely. There is. However, a press apparatus with a high height is disadvantageous in terms of strength when the nozzle of the injection apparatus provided in the horizontal direction in the next step is touched by the mold and receives a force from the lateral direction. And if it was going to secure the intensity | strength with respect to the horizontal direction of a high press apparatus, it would lead to cost increase, such as thickening a tie bar.

In Patent Document 2, since the material for flow stamping molding is supplied by pulling the lower die out of the press, there is no problem of the mold opening interval when the material is directly supplied between the press devices. However, in Patent Document 2, it is necessary to use two lower molds having different cavity surface shapes, which increases the mold cost. In addition, since the two lower molds move, there is a problem that the lower mold moving device is costly and that a lower mold moving space is required on both sides. Furthermore, since the side opposite to the side where the material supply mechanism for performing the flow stamping molding is provided also becomes the lower mold moving space, it is practically difficult to provide the injection device on the opposite side. For this reason, there is a problem that the installation space of the entire apparatus becomes L-shaped and there are many restrictions on factory installation. Further, the material supply method of Patent Document 2 has a problem that it may take time to move from the supply of the molten resin to the press apparatus.

Therefore, the compression molding apparatus and the compression molding method of the present invention supply a material made of a solid or semi-solid prepreg to the lower die, compress the material made of the prepreg between the upper die and the lower die, and then perform injection compression. An object of the present invention is to provide a compression molding apparatus and a compression molding method capable of suppressing the cost of the entire apparatus when molding a composite molded product. The second problem is to provide a compression molding apparatus and a compression molding method capable of reducing the height of the press apparatus by supplying a material made of a solid or semi-solid prepreg outside the press apparatus. Objective.

A compression molding apparatus for a composite molded article containing a fiber material according to claim 1 of the present invention supplies a material composed of a solid or semi-solid prepreg to a lower mold, and a material composed of a prepreg between the upper mold and the lower mold. In a compression molding apparatus for composite molded products containing fiber materials that are further molded by injection molding or injection compression molding to form a composite molded product, pressure is applied when compression molding and injection compression molding are performed continuously. A vertical press device to be performed; a moving device for moving the lower die between a press position of the press device and a material supply position outside the press device; and a solid or semi-solid prepreg on the lower die at the material supply position Is not completely opened between the material supply device for supplying the material and the cavity surface of the upper die or the lower die and the primary molded product formed from the compression prepreg material. space An injection device for injecting a molten material, characterized in that is provided.

A compression molding apparatus for a composite molded article containing a fiber material according to claim 2 of the present invention supplies a material comprising a solid or semi-solid prepreg to a lower mold, and a material comprising a prepreg between the upper mold and the lower mold. In the compression molding apparatus of a composite molded product including a fiber material that is further molded by injection molding or injection compression molding to form a composite molded product, pressurization is performed when compression molding and injection molding are continuously performed. A vertical pressing device, a die member that forms a secondary cavity for core back molding by a retreating operation of the die member moving device after the compression molding, a pressing position of the pressing device, and a material supply position outside the pressing device. A moving device that moves the lower die between, a material supply device that supplies a material consisting of a solid or semi-solid prepreg to the lower die at the material supply position, a cavity surface of the upper die or the lower die, and compression molding An injection device for injecting molten material into the space that is not fully mold opening which is formed between the primary molded article formed from the made material from the prepreg, characterized in that is provided.

According to a third aspect of the present invention, there is provided a compression molding method for a composite molded article comprising a fiber material, wherein a material comprising a solid or semi-solid prepreg is supplied to a lower mold, and the material comprising a prepreg between the upper mold and the lower mold. In a compression molding method of a composite molded article including a fiber material, which is further molded by injection molding or injection compression molding to form a composite molded article, a material comprising a solid or semi-solid prepreg from a material supply device to a lower mold , Press molding is activated and the upper die is lowered to perform compression molding of the prepreg material, and then the press device is actuated or the die member is moved to compress the cavity surface of the upper die or the lower die. A space that is not completely opened is formed between the molded product formed from a solid or semi-solid prepreg material, and molten resin from the injection device is formed in the space. Injection, and characterized by compressing the injected molten resin to mold a composite molded article in said space by operating the press machine or die member moving device after the injection start simultaneously with or injection.

According to a fourth aspect of the present invention, there is provided a compression molding method for a composite molded article comprising a fiber material, wherein a material comprising a solid or semi-solid prepreg is supplied to a lower mold, and the material comprising a prepreg between the upper mold and the lower mold. In a compression molding method of a composite molded article including a fiber material, which is further molded by injection molding or injection compression molding to form a composite molded article, a material comprising a solid or semi-solid prepreg from a material supply device to a lower mold , Press molding is activated and the upper mold is lowered to compress the material made of prepreg, and then the mold member is moved to compress or mold the solid or semi-solid with the cavity surface of the upper or lower mold A secondary cavity for core back molding that is not completely opened is formed between the primary molded product formed of a material made of a prepreg of the prepreg, and an injection device is provided in the secondary cavity. The melting resin injection to be characterized by molding a composite molded article.

The compression molding apparatus for a composite molded article including the fiber material of the present invention supplies a material composed of a solid or semi-solid prepreg to the lower mold, and after compression molding the material composed of the prepreg between the upper mold and the lower mold, Further, in a compression molding apparatus for a composite molded article including a fiber material for molding a composite molded article by injection molding or injection compression molding, a vertical press apparatus that pressurizes when performing compression molding and injection compression molding continuously. And a moving device for moving the lower mold between the press position of the press apparatus and the material supply position outside the press apparatus, and supplying a material made of solid or semi-solid prepreg to the lower mold at the material supply position. The molten material is injected into a space that is not completely opened between the material supply device and the primary molded product formed from the material comprising the cavity surface of the upper mold or the lower mold and the prepreg formed by compression molding. That an injection device, since is provided a composite molded article comprising a fiber material can be molded by compression molding apparatus with a simplified structure.

It is a top view of the compression molding apparatus of the composite molded product containing the fiber material of this embodiment. It is a front view of the compression molding apparatus of the composite molded product containing the fiber material of this embodiment. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state immediately after the start of supply of molten material from a material supply apparatus. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state just before completion | finish of supply of molten material from a material supply apparatus. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state by which the lower mold | type was moved to the pressurization position of a press apparatus. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state by which compression molding (stamping molding) of the molten material was performed between the lower mold | type and the upper mold | type. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state in which the space was formed between the cavity surface and the compression molded primary molded product after compression molding. is there. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state by which the injection compression molding (injection) was started. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state of the compression process after the injection in an injection compression molding, or the cooling process. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state by which injection compression molding was completed and the mold was opened. It is a figure which shows the compression molding method of the composite molded product containing the fiber material of this embodiment, Comprising: It is a figure which shows the state by which a lower mold | type is carried out from a press apparatus and the composite molded product is taken out.

A compression molding apparatus 11 for a composite molded product including the fiber material of the present embodiment will be described with reference to FIGS. A compression molding apparatus 11 for a composite molded article including a fiber material according to the present embodiment includes a vertical press apparatus 14 that compresses a molten material M including a fiber material between an upper mold 12 and a lower mold 13, and the fiber material. A material supply device 15 for the molten material M to be included and a horizontal injection device 16 for injecting the molten material are provided. A moving device 17 for the lower mold 13 is provided between the supply position a1 of the molten material M containing the fiber material to the lower mold 13 by the press device 14 and the material supply device 15.

The press device 14 will be described. As shown in FIG. 2, four tie bars 19 are erected in the vicinity of the four corners of the fixed plate 18 that is the lower plate, and the upper portion of the tie bar 19 is the pressure receiving pressure that is the upper plate. It is fixed near the four corners of the panel 20. Further, a movable platen 21 is inserted between the fixed platen 18 and the pressure receiving plate 20 through the tie bar 19 so as to be movable in the vertical direction. The pressure receiving plate 20 is provided with a mold clamping cylinder 22 (pressurizing cylinder) as a pressurizing mechanism, and the ram 23 of the mold clamping cylinder 22 is fixed to the back surface of the movable platen 21. A mold opening / closing cylinder 24 that is a mold opening / closing mechanism is provided between the pressure receiving plate 20 and the movable platen 21. A half nut 25 is attached to the movable platen 21 so that it can be engaged with an engagement groove (not shown) formed in the tie bar 19. Note that the mold clamping cylinder 22 and the mold opening / closing cylinder 24 may be ones using an electric mechanism, for example, a press apparatus that performs compression molding by a toggle mechanism.

An upper die 12 can be attached to the lower surface of the movable platen 21 of the press device 14. In addition, the lower mold 13 can be fixed and moved at a pressure position a2 on the upper surface of the fixed platen 18. The lower die 13 of the press device 14 is attached to the lower die attachment plate 26, and moves in the X-axis direction in FIG. 1 between the pressurization position a2 inside the press device 14 and the supply position a1 outside the press device 14. It is possible. A moving device 17 of the lower mold 13 is connected and fixed to one side (left side in FIG. 1) of the fixed platen 18. The upper surface of the moving device 17 of the lower mold 13 has the same height as the upper surface of the fixed platen 18, and two guide rails 27 for moving the lower mold 13 are provided over both upper surfaces. . The lower die mounting plate 26 is moved along the guide rail 27. Although not shown, the lower mold mounting plate 26 is provided with rolling balls or axles and wheels via springs, and the lower mold mounting plate 26 pressurizes the lower mold 13 inside the press device 14. When moving between the position a <b> 2 and the supply position a <b> 1 outside the press device 14, the lower surface of the lower mold mounting plate 26 is lifted from the upper surface of the fixed plate 18 and the upper surface of the moving device 17. When the upper die 12 and the lower die 13 are closed at the pressurization position a2 of the fixed plate 18 and compression molding (including injection compression molding) is performed, the spring is contracted and clamped by a clamp (not shown). The upper surface of the fixed platen 18 and the lower surface of the lower mold mounting plate 26 are in close contact with each other.

The drive source of the moving device 17 of the lower mold 13 is a servo motor 28, and the servo motor 28 is fixed to the side surface of the moving device 17 on the supply position a1 side. A ball screw 29 is provided in parallel with the guide rail 27. One of the ball screws 29 is rotatably fixed to the upper surface of the moving device 17 via a bearing, and the other is rotatable to the upper surface of the stationary platen 18 via a belling. It is fixed to. A driven pulley 30 is fixed in the vicinity of the end of the ball screw 29 further to the one side than the bearing, and a driving belt 31 for driving force transmission is stretched between the driving pulley 31 of the servo motor 28. Further, a ball screw nut 33 is fixed to the side surface of the lower mold mounting plate 26, and the ball screw 29 is inserted into the ball screw nut 33. When the servo motor 28 is driven, the ball screw 29 is rotated, and the ball screw nut 33, the lower die mounting plate 26, and the lower die 13 are linearly moved in the X-axis direction. The ball screw nut 33 of the moving device 17 of the lower die 13 may be attached to the back surface of the lower die attaching plate 26, and the structure is not limited to this. The lower mold 13 may be drawn out of the press device 14 by a rotary table, and the movement path of the lower mold by the moving device in this case is an arc.

The dies 13 and 14 attached to and used in the press device 14 will be described. The lower mold 13 is preferably a concave mold (cavity mold) so that the molten material M containing the supplied fiber material does not spill, and the upper mold 12 Is preferably a convex type (core type). Further, since the lower mold 13 moves after supplying the molten material M containing the fiber material, it is desirable to have a heating mechanism so that the solidification of the molten material M containing the fiber material does not proceed during that time. As the heating mechanism, a heater or a mechanism capable of switching a medium supplied into the mold between a heating medium and a cooling medium is used. Further, a heat source such as infrared irradiation or a heater may be provided so that solidification of the molten material M including the fiber material supplied above the moving device 17 of the lower mold 13 does not proceed. When the lower mold 13 is provided with a heating mechanism, it is desirable that the upper mold 12 is also provided with a heating mechanism because of the problem of warping of the molded product.

The lower mold 13 is provided with a hot runner 76 that communicates between the cavity surface 13 a and the nozzle touch surface 75. The hot runner 76 is provided with a gate valve (not shown), and the gate valve is closed during compression molding.

The lower mold 13 includes an ejector plate of the ejector device 61 and a plurality of projecting pins 62 standing on the ejector plate. A drive source 63 and an ejector rod for the ejector device 61 are provided below the material supply position a1 of the moving device 17. When the composite molded product P reaches the material supply position a1, the ejector device 61 is actuated to project the composite molded product P from the lower mold 13. The position where the ejector device 61 is provided may be on the fixed platen 18 side or the movable platen 21 side of the press device 14.

In addition, the unloader 64 is movable above the material supply position a1 of the moving device 17. The take-out machine 64 is movable in the horizontal and vertical directions by a servo motor (not shown), and sucks the composite molded product P by a suction cup 65 connected to the negative pressure suction means and sucked by negative pressure.
Therefore, in the present embodiment, the material supply position a1 is also the take-out position of the composite molded product P, and the space above the material supply position a1 has a shape in which the take-out machine 64 and the material supply device 15 alternately enter ( In FIG. 1, the take-out machine 64 is omitted, and in FIG. 2, the take-out machine 64 stands by above the material supply device 15. Thus, by supplying the molten material M including the fiber material for stamping molding to one lower mold 13 outside the press apparatus 14 and taking out the composite molded product P, the mold opening interval of the press apparatus 14 is reduced. Thus, the height of the press device 14 can be reduced.

Next, the material supply device 15 will be described with reference to FIGS. The material supply device 15 can be moved in the X-axis direction, which is the same direction as the moving device 17 of the lower mold 13 and the moving direction, by the moving device 35 for forward and backward movement.

As shown in FIG. 2, the moving device 35 of the material supply device 15 is provided with two guide rails 36 on the base or floor surface, and the base 37 of the material supply device 15 can move on the guide rail 36. It has become. A ball screw 38 is rotatably disposed on the base or floor surface, and a ball screw nut 50 fixed to the base 37 is inserted through the ball screw 38. A driven pulley 39 is fixed near the end of the ball screw 38, and a timing belt 42 is stretched between the servo pulley 40 and the driving pulley 41. Therefore, by driving the servo motor 40, the base 37 of the material supply device 15 and a ball screw nut (not shown) are linearly moved. The moving device 35 may be attached between the base 37 and the side surface of the moving device 17, and the structure is not limited.

Mounted on the base 37 of the material supply device 15 is a device having a plasticizing function and an injection function having substantially the same functions as the injection device of the injection molding machine. A heating cylinder 44 to which a heater is attached is inserted through a front plate 43 that is fixedly erected on the base 37. The front plate 43 is provided with a supply port 45 for the molding material in the vertical direction, and the lower part of the supply port 45 communicates with the inside of the heating cylinder through the hole of the heating cylinder 44. A molding material feed device 46 having a feed screw is connected above the supply port 45. A nozzle 47 to which a heater is attached is attached to the tip of the heating cylinder 44. A die 49 with a supply hole 48 directed downward is attached to the tip of the nozzle 47. The supply hole 48 of the die 49 has a predetermined width and length. In the present embodiment, a die 49 having a supply hole 48 that is slightly shorter than the length of the rectangular cavity surface 13a of the lower mold 13 in the direction orthogonal to the X-axis direction is attached. Accordingly, a resin sheet containing a fiber material having a length slightly shorter than the length of the cavity surface 13a in the direction orthogonal to the X-axis direction can be continuously supplied. The portion of the die 49 attached to the tip of the nozzle 47 can be replaced with an optimum one according to the shape and area of the cavity surface 13a of the lower mold 13. The die 49 is exchanged for a different die 49 depending on the molding material due to problems such as fluidity of the molten material M containing the fiber material and breakage of the fibers contained in the molten material M containing the fiber material. A valve (not shown) for opening and closing the flow path is often provided in the die 49 at the tip of the nozzle 47 or the portion of the nozzle 47 in front of it.

A rear plate 51 is provided behind the front plate 43 at a predetermined distance in parallel with the front plate. Servo motors 52 for injection are provided on both sides of the heating cylinder 44 on the front side of the front plate 43, and ball screw nuts 53 are provided on both sides of the rear plate 51, respectively. A ball screw 54 directly connected to the drive shaft of the servo motor 52 is inserted through the ball screw nut 53. A general screw (not shown) for injection molding, to which a backflow prevention valve is attached, is disposed inside the heating cylinder 44, and the rear end of the screw shaft is connected to the rear via a sleeve, a coupling, or the like. It is fixed to the drive shaft of a measuring servo motor 55 fixed to the rear surface of the plate 51.

Accordingly, the screw in the heating cylinder is rotated by driving the metering servo motor 55 and is moved forward and backward by driving the injection servo motor 52. The structure of the material supply device 15 is not limited to the one described above, and may have three plates, and one injection servomotor may be used. The drive source for injection or metering may use hydraulic pressure. Furthermore, a material supply device that extrudes the molten material M containing the fiber material with a plunger, or an extrusion-type material supply device that extrudes the molten material by only rotating the screw in the heating cylinder may be used as the material supply device.

In the present embodiment, a horizontal injection device 16 is disposed on the other side (right side in FIG. 1) of the vertical press device 14. Therefore, a material supply device 15 for molten material is provided on one side of the press device 14, and a horizontal injection device 16 with the nozzle 58 facing the press device 14 is provided on the other side. Since the structure of the injection device 16 is similar to the material supply device 15 which is a material supply device, an outline will be described. In the forward / backward moving device of the injection device 16, the cylinder cylinder 57 a of the shift cylinder 57 is fixed to the base 56, and the rod 57 b of the shift cylinder 57 is fixed to the side surface of the stationary platen 18. The shift cylinder 57 generates a nozzle touch force when the nozzle 58 of the injection device 16 is brought into contact with the nozzle touch surface 75 of the lower mold 13.

A heating cylinder 67 to which a heater is attached is inserted into the front plate 66 fixedly standing on the base 56. The front plate 66 is provided with a molding material supply port 68 in the vertical direction, and the lower part of the supply port 68 communicates with the inside of the heating cylinder through a hole of the heating cylinder 67. A molding material feed device 69 having a feed screw is connected above the supply port 68. A nozzle 58 to which a heater is attached is attached to the tip of the heating cylinder 44.

A rear plate 70 is provided behind the front plate 66 in parallel with the front plate 66 at a predetermined distance. Servo motors 71 for injection are provided on both sides of the heating cylinder 67 on the front side of the front plate 66, and ball screw nuts 72 are provided on both sides of the rear plate 70, respectively. A ball screw 73 directly connected to the drive shaft of the injection servo motor 71 is inserted into the ball screw nut 72. In addition, a screw (not shown) generally used for injection molding, to which a backflow prevention valve is attached, is disposed inside the heating cylinder 67, and the rear end of the screw shaft is connected to the rear via a sleeve, a coupling, or the like. It is fixed to the drive shaft of a measuring servo motor 74 fixed to the rear surface of the plate 70.

Therefore, the screw in the heating cylinder 67 is rotated by driving the measuring servo motor 74 and is moved forward and backward by driving the injection servo motor 71. The structure and arrangement of the injection device 16 are not limited. For example, the injection device 16 is provided in the vertical direction, and the nozzle is made of gold through a hole provided in the center of the fixed plate or the movable plate. It may be abutted against the mold. However, in view of the ease of maintenance of the injection device 16 and the height of the factory ceiling, the injection device 16 is preferably a horizontal injection device.

Further, the nozzle 58 of the injection device 16 can be exchanged, and a die 49 such as the material supply device 15 can be attached to supply a secondary molding material for stamping molding. Further, the lower mold 13 of the compression molding apparatus 11 is fixedly provided, and the compression molding apparatus 11 can be used as a single injection molding machine (including an injection compression molding machine) or various usage methods are possible.

Next, compression molding of a composite molded product using the compression molding apparatus 11 of the present embodiment will be described with reference to FIGS. In the present embodiment, an example in which a molten material M containing a carbon fiber material in a thermoplastic resin (for example, polycarbonate) is used as a material to be used will be described. As the molding material, in the case of a thermoplastic resin, at least one kind of resin such as polypropylene, polyethylene, polyethylene terephthalate, polyamide, and ABS is selected in addition to polycarbonate. In the case of a thermosetting resin, it is selected from at least one kind of resin such as epoxy, polyurethane and phenol, and may be a mixed resin of thermoplastic and thermosetting resin. In addition to carbon fibers, the fiber material may contain other fibers such as glass fibers, plant fibers, and chemical fibers. The compression molding apparatus 11 of the present embodiment is also suitable for molding a mixture of a material having poor fluidity such as a mixture of carbon and resin and a resin.

As a molding procedure, first, with the press device 14 opened, the servo motor 28 is driven to move the lower die mounting plate 26 and the lower die 13 to the supply position a1 outside the press device 14, and once positioning is performed. Stopped. (The removal of the composite molded product P will be described later.) The material supply device 15 rotates the measuring servo motor 40 and the back pressure by the injection servo motor 52 until the lower mold 13 is moved to the supply position a1. In addition, the carbon fiber-containing polycarbonate resin, which is the molten material M including the fiber material ahead of the screw in the heating cylinder 44, is measured (stored) and is waiting at the supply position a1. When taking out the composite molded product P at the material supply position a1, the material supply device 15 is in the rear position during the extraction, and moves forward along the X-axis direction after the extraction to the supply position. The stop position of the material supply device 15 is determined by the positional relationship between the press device 14 and the upper die 12 and the lower die 13, but a position as close as possible to the press device 14 is desirable because the moving distance of the lower die 13 can be shortened. .

As described above, the cavity surface 13a of the lower mold 13 at this time is heated. Then, the molten material M containing the carbon fiber material is supplied from the material supply device 15 onto the cavity surface 13 a of the lower mold 13. Supply of the molten material M including the carbon fiber material is performed by opening a valve (not shown) of the nozzle 47 of the material supply device 15, driving the servo motor 52 for injection, and moving the screw forward, from the supply hole 48 of the die 49. This is done by dropping the molten material M containing the carbon fiber material. As described above, the length of the supply hole 48 of the die 49 of this embodiment (the length in the direction orthogonal to the X axis) is shorter than the length of the substantially rectangular cavity surface 13a in the direction orthogonal to the X axis. ing. Accordingly, the molten material M including the supplied carbon fiber material is supplied in a sheet shape so as to cover the cavity surface 13a.

As shown in FIG. 3, the supply of the molten material M containing the carbon fiber material from the material supply device 15 of the present embodiment to the lower mold 13 is near the front end of the cavity surface 13 a of the lower mold 13 (close to the press apparatus 14). The molten material M containing the carbon fiber material is first dropped on the side). Then, with the material supply device 15 stopped at the current position, the servo motor 28 of the moving device 17 is driven to move the lower die 13 to the press device 14 side, so that a majority portion of the cavity surface 13a of the lower die 13 is obtained. The molten material M containing the carbon fiber material can be supplied so as to cover the surface. The supply of the molten material M including the carbon fiber material may be performed with the lower mold 13 and the material supply device 15 fixed, or may be performed by moving the material supply device 15. Furthermore, both may be moved, for example, the material supply device 15 is moved backward while the lower die 13 is moved forward toward the press device 14. Further, the lower mold 13 and the material supply device 15 may move in another direction such as a direction orthogonal to the X-axis direction.

Next, as shown in FIG. 4, the lower die 13 moves forward and the supply hole 48 of the die 49 of the material supply device 15 is positioned above the vicinity of the rear end of the cavity surface 13 a (the side far from the press device 14). In this state, the material supply from the material supply device 15 is stopped. Explaining from the material supply device 15 side, when the lower mold 13 reaches the position of FIG. 4, the screw in the heating cylinder 44 is advanced to a predetermined position and the valve of the nozzle 47 is closed. Made.

Next, as shown in FIG. 5, the lower mold 13 for which the supply of the molten material M including the carbon fiber material has been completed is continuously moved by the moving device 17 to the pressing position a <b> 2 of the pressing device 14. At the pressurization position a2 of the press device 14, the lower die mounting plate 26 is stopped in positioning, and further fixed by positioning pins, clamps or the like (not shown). By adopting such a material supply method, the time from when the molten material M containing the carbon fiber material is supplied to the lower mold 13 to when the lower mold 13 reaches the pressing position a2 of the press device 14 is shortened. be able to. At this time, when the composite molded product P that has been molded at the supply position a1 is taken out, the material supply device 15 is retracted in preparation for the entry of the take-out machine 64.

Next, as shown in FIGS. 2 and 6, the die opening / closing cylinder 24 of the press device 14 is actuated to lower the upper die 12, and the convex portion of the upper die is fitted with the concave portion of the lower die 13. Immediately before, the half nut 25 is actuated and the engagement groove of the half nut 25 and the tie bar 19 is engaged. Then, the mold clamping cylinder 22 is driven. At this time, the lower mold attachment plate 26 slightly floating with respect to the fixed platen 18 is brought into close contact with the fixed platen 18 and the pressure is transmitted to the fixed platen 18 as described above. And the cavity surface 13a of the recessed part of the lower mold | type 13 and the convex part of the cavity surface of an upper mold | type are fitted, and the molten material M containing a carbon fiber material is pressurized and compressed in the cavity formed between them, and it is shaped Is done. In addition, when the lower mold | type 13 and the upper mold | type 12 are heated initially, it switches to cooling from the middle of being compressed, cooling solidification of the molten material M containing a carbon fiber material is accelerated | stimulated, and 1 containing a carbon fiber material is included. The next molded product M1 is molded. Note that the movement of the mold when the vertical press device 14 is closed may be such that the lower mold 13 is raised and the upper mold 12 is closed.

Next, as shown in FIG. 7, when a predetermined time elapses, the clamping cylinder 22 of the pressing device 14 is operated in the mold opening direction, and the upper mold 12 is slightly lifted from the lower mold 13 without being completely opened. Let At that time, the primary molded product M1 containing the carbon fiber material is left in the lower mold 13, and the space C having a height H is separated from the primary molded product M1 and the cavity surface 12a of the upper mold 12. (Secondary cavity) is formed. At this time, the primary molded product M1 is attached to the upper mold 12 and released, and a space C (secondary cavity) is formed between the primary molded product M1 containing the carbon fiber material and the cavity surface 13a of the lower mold 13. You may be made to do. Alternatively, instead of the operation of the press device 14, the mold member (nesting) in the mold may be moved backward by the mold member moving device to form the space C (secondary cavity) (core back molding). Furthermore, the mold may be slightly opened almost simultaneously with the injection by the injection device 16.

Next, as shown in FIG. 8, the nozzle 58 of the injection device 16 is brought into contact with the nozzle touch surface 75 formed on the other side surface (the right side in FIG. 1) of the lower mold 13. Then, the gate valve of the hot runner 76 of the lower mold 13 is opened. In the injection by the injection device 15, the servo motor 71 for injection is operated to advance a screw (not shown) in the heating cylinder 67. As a result, injection of the molten resin M2 into the space C (secondary cavity) formed between the primary molded product M1 on the lower mold 13 and the cavity surface 12a of the upper mold 12 is started via the hot runner. In the present embodiment, polycarbonate used as a binder resin together with a carbon fiber material for primary molding (compression molding) is also used for secondary molding. However, the binder resin of the resin M1 including the carbon fiber material used in the primary molding and the resin M2 used in the secondary molding may be different resins.

The shape of the molds 12 and 13 and the contact position of the nozzle 58 of the injection device 16 are not limited to the above, and various types can be used. For example, the nozzle 58 may be brought into contact with the parting surface, or the nozzle 58 may be brought into contact with any one of the fixed platen 18, the movable platen 21, and the upper mold 12. Further, by providing the gate in the direction perpendicular to the surface of the primary molded product M1 and in the center, the molten material M2 can flow evenly, and the adhesion to the resin M1 containing the carbon fiber material can be improved. it can. The molds 12 and 13 are flat type molds in which the upper mold 12 and the lower mold 13 are in contact with each other even if the upper mold 12 and the lower mold 13 are fitted. May be. In the case of the flat die, the side wall around the cavity surface 13a and the like of the lower die 13 (or the upper die 12) is moved up and down by a spring, so that The portion comes into surface contact with the contact surface of the side wall.

Next, as shown in FIG. 9, the mold clamping cylinder 22 of the press device 14 is operated, the upper mold 12 is lowered again, and the molten resin M2 injected into the space C (secondary cavity) is pressurized and compressed. At that time, it is desirable to start compression molding (injection compression molding) by the clamping cylinder 22 at the same time as injection or during injection at the screw position or the like. By expanding the space C (secondary cavity) in the first stage, the molten resin M2 can be easily injected well. Further, by starting compression molding (injection compression molding) by the press device 14 from the middle stage, it is possible to promote the flow of the molten resin M2 to the end of the space C (secondary cavity). By compressing the primary molded product M1 containing carbon fiber and the molten resin M2, the adhesion between the surface of the primary molded product M1 containing carbon fiber and the layer of the molten resin M2 injected secondarily becomes good. Then, the molds 12 and 13 that have been heated are switched to cooling from the middle of compression molding (injection compression molding), and cooling and solidification of the molten material M is promoted. Alternatively, in the case of a mold having no heating function, it is cooled as it is. Therefore, in this embodiment, compression molding and injection compression molding are continuously performed in a state where the mold is not completely opened between the lower mold 13 and the upper mold 12 (the step of forming the space C without opening the mold). What is sandwiched is included in the category of continuous molding).

When the above core back molding is performed, the mold member is moved backward by another mold member moving device or by operating the mold clamping cylinder 22 of the press device 14 so that the mold member moves backward. In addition, although the injection compression molding of the molten material M2 in the space C (secondary cavity) is performed, the injection molding without compression may be performed.

As shown in FIG. 10, when a predetermined time elapses, the mold clamping cylinder 22 and the mold opening / closing cylinder 24 of the press device 14 are operated in the mold opening direction, and the upper mold 12 is lifted from the lower mold 13 to the lower mold 13. The composite molded product P including the remaining carbon fiber material can be taken out.

Next, as shown in FIG. 2 and FIG. 11, the lower mold 13 in which the composite molded product P containing the carbon fiber material is held on the cavity surface 13a by the drive of the servo motor 28 of the moving device 17 is pressed position a2. To the material supply position a2 (extraction position). And the drive source 63 of the ejector apparatus 61 is driven, the protrusion pin 62 protrudes through an ejector rod and an ejector board, and the composite molded product P containing a carbon fiber material protrudes from the cavity surface 13a. At substantially the same time, the suction cup 65 of the take-out machine 64 is adsorbed on the upper surface of the composite molded product P containing the carbon fiber material, holds the composite molded product P containing the carbon fiber material, and carries it out to another process. At this time, the composite molded product P including the carbon fiber material is protruded by the protruding pin 62 on the side of the primary molded product M1 including the carbon fiber material which is the back surface. No problem.

Further, in this embodiment, since the unloader 64 is not inserted into the press device 14 together with the material supply device 15, the mold opening interval of the vertical press device 14 is small, and as a result, the height of the vertical press device 14 is high. The thickness can be lowered. And when receiving the nozzle touch force by the horizontal injection device 16 from the direction orthogonal to the direction of the tie bar 19 of the press device 14, the strength of the vertical press device 14 can be lowered because the height of the vertical press device 14 is low. , It can lead to cost reduction.

The present invention is not enumerated one by one, but is not limited to that of the above-described embodiment, and it goes without saying that those skilled in the art also apply modifications made in accordance with the spirit of the present invention. is there. In the present embodiment, the example in which the resin layers M2 are stacked in layers on the resin M containing the carbon fiber material has been described. However, by performing mold opening twice, the resin M containing the fiber material is formed on both sides. It is also possible to coat the resin layer M2. In addition, the resin layer M2 may be formed by forming a composite molded product P including fibers by partially joining the resin layer M2 without being covered in a layered manner, for example, only the surrounding portion. Furthermore, the material to be injection compression molded may also include a fiber material. In that case, it is desirable to reduce the carbon fiber content as compared to the primary molded product. Further, the number of injection devices for injection compression molding is not limited to one, and a composite molded product including a fiber layer may be formed by multiple layers or multiple materials.

Furthermore, in this embodiment, the primary molded product is supplied in a molten state from the material supply device 15, but a material containing a fiber material such as a solid or semi-solid prepreg is supplied at a supply position a <b> 1 outside the press device 14. It may be what you do. In that case, a fiber material such as a solid or semi-solid prepreg is further included at any one of the supply position a1, the press position a2 of the press apparatus 14 and the supply position a1, and the press position a2 of the press apparatus 14. It is desirable to preheat the material. Subsequent compression molding and injection compression molding are the same as in the above embodiment.

DESCRIPTION OF SYMBOLS 11 Compression molding apparatus 12 Upper mold | type 12a, 13a Cavity surface 13 Lower mold | type 14 Press apparatus 15 Material supply apparatus 16 Injection apparatus 17 Movement apparatus 18 Fixed board 21 Movable board 26 Lower mold attachment plate 47, 58 Nozzle 48 Supply hole M A fiber is included. Molten material (molten material containing carbon fiber)
M1 Primary molded product M2 Molten resin P Composite molded product containing fiber material (composite molded product containing carbon fiber material)
X Lower mold movement direction

Claims (4)

Fiber that supplies a solid or semi-solid prepreg material to the lower mold, compression-molds the prepreg material between the upper mold and the lower mold, and further molds a composite molded product by injection molding or injection compression molding In a compression molding apparatus for composite molded products containing materials,
A vertical press device that applies pressure when continuously performing compression molding and injection compression molding;
A moving device for moving the lower mold between a press position of the press device and a material supply position outside the press device;
A material supply device for supplying a material comprising a solid or semi-solid prepreg to the lower mold at the material supply position;
An injection device for injecting a molten material into a space that is not completely opened, formed between a cavity surface of an upper die or a lower die and a primary molded product formed from a material made of compression-prepared prepreg;
A compression molding apparatus for a composite molded article including a fiber material, characterized in that is provided. Fiber that supplies a solid or semi-solid prepreg material to the lower mold, compression-molds the prepreg material between the upper mold and the lower mold, and further molds a composite molded product by injection molding or injection compression molding In a compression molding apparatus for composite molded products containing materials,
A vertical press device for applying pressure when continuously performing compression molding and injection molding ;
A mold member that forms a secondary cavity for core back molding by a retreat operation of the mold member moving device after the compression molding;
A moving device for moving the lower mold between a press position of the press device and a material supply position outside the press device;
A material supply device for supplying a material comprising a solid or semi-solid prepreg to the lower mold at the material supply position;
An injection device for injecting a molten material into a space that is not completely opened, formed between a cavity surface of an upper die or a lower die and a primary molded product formed from a material made of compression-prepared prepreg;
A compression molding apparatus for a composite molded article including a fiber material, characterized in that is provided. Fiber that supplies a solid or semi-solid prepreg material to the lower mold, compression-molds the prepreg material between the upper mold and the lower mold, and further molds a composite molded product by injection molding or injection compression molding In a compression molding method of a composite molded article including a material,
Supply material consisting of solid or semi-solid prepreg from the material supply device to the lower mold,
Press molding to lower the upper mold and compress the material made of prepreg,
Thereafter, the press device is operated or the mold member is moved to completely move between the cavity surface of the upper mold or the lower mold and the primary molded product formed of the compression-molded solid or semi-solid prepreg material. Forming a space that is not open to the mold,
Injecting molten resin from the injection device into the space,
A composite molded article including a fibrous material, characterized by molding a composite molded article by operating a press device or a mold member moving device simultaneously with the start of injection or after injection to compress the molten resin injected into the space. Compression molding method. Fiber that supplies a solid or semi-solid prepreg material to the lower mold, compression-molds the prepreg material between the upper mold and the lower mold, and further molds a composite molded product by injection molding or injection compression molding In a compression molding method of a composite molded article including a material,
Supply material consisting of solid or semi-solid prepreg from the material supply device to the lower mold,
Press molding to lower the upper mold and compress the material made of prepreg,
Thereafter, the mold member is moved so that the core is not completely opened between the cavity surface of the upper mold or the lower mold and the primary molded product formed from the compression-molded solid or semi-solid prepreg material. Forming a secondary cavity for back molding ,
A compression molding method of a composite molded article including a fiber material, wherein a molten resin is injected into the secondary cavity from an injection device to form a composite molded article.