JP2016083839A - Prepreg molded article manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a prepreg molded article manufacturing method high in releasability from a mold and capable of preventing quality deterioration.SOLUTION: The method for manufacturing a prepreg molded article 1 by die-molding a plurality of stacked prepregs 10 formed by impregnating sheet fiber base materials with thermoplastic resins as matrix resins includes the sanding step of vertically sandwiching the plurality of stacked prepregs 10 between metal foils 20 having thicknesses of 10 μ or more to 300 μ or less and executing discrete ultrasonic fusion for the prepregs 10 to integrate them, the die-molding step of setting the integrated prepreg 10 in a mold 100 to execute heating pressure treatment, and the peeling step of peeling the metal foils 20 stuck to the upper and lower surfaces of the prepreg 10 taken out from the mold 100 after the heating pressure treatment from the prepreg 10.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for producing a prepreg molded product by molding a prepreg, and particularly relates to a mold release property for a mold.

  As shown in FIG. 5, a plurality of, for example, five, prepregs 10 are stacked and heated and pressed as a set between the upper mold 101 and the lower mold 102 of the mold 100, thereby forming a dish shape as shown in FIG. It is generally known to produce a prepreg molded product 1.

Here, when a plurality of prepregs 10 formed by impregnating a sheet-like fiber base material with a thermoplastic resin (CFRTP) as a matrix resin is molded with the mold 100, the mold release is performed when the mold 100 is removed. Sex matters. Usually, before the prepreg 10 is set, the mold 100 is easily released by spraying a release agent on the upper mold 101 and the lower mold 102 of the mold 100 or only on the lower mold 102. .
However, among thermoplastic resins (CFRTP), especially when using so-called super engineering plastics such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as matrix resin, after molding, The prepreg 10 is unlikely to be detached from the mold 100, particularly the lower mold 102, and the molded product or the mold 100 may be damaged if it is forcibly removed.

  In addition, generation of wrinkles is caused by using a release paper having a clay coat layer on the side overlapping with the prepreg 10, for example, a quality paper made of a silicone release agent, kraft paper, glassine paper, or parchment paper. What to prevent is disclosed (for example, refer to Patent Document 1).

Japanese Patent Laid-Open No. 2007-2217

  However, in the invention described in Patent Document 1, since the prepreg 10 is heated and pressurized while being sandwiched between rolls and is not set in the mold, the releasability from the mold is not a problem. . Super engineering plastics also have heat resistance problems due to their high melting temperature

  Accordingly, an object of the present invention is to provide a method for producing a prepreg molded product that is excellent in releasability from a mold and can prevent quality deterioration.

In order to achieve the above object, the method for producing a prepreg molded product of the present invention is a method in which one or a plurality of prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin are stacked. Is a method for producing a prepreg molded product (1) by molding
One or a plurality of the prepregs (10) stacked are sandwiched from above and below by a metal foil (20) having a thickness of 10 μm or more and 300 μm or less, and discretely ultrasonically bonded to the prepreg (10). Integrated sand process,
A mold forming step in which the integrated prepreg (10) is set in the mold (100) and subjected to heat and pressure treatment;
A peeling step of peeling off the metal foil (20) bonded to the upper and lower surfaces of the prepreg (10) taken out from the mold (100) after the heat and pressure treatment from the prepreg (10) is provided. To.
The prepreg (10) here means that a so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.

The method for producing a prepreg molded product according to the present invention is a method for molding a prepreg molded product by molding one or a plurality of prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin. A method for producing (1), comprising:
Sandwiching one or a plurality of the prepregs from above and below with a metal foil (20) having a thickness of 30 μm or more and 300 μm or less and adhering to the prepreg (10) by static electricity; ,
A mold forming step in which the integrated prepreg (10) is set in the mold (100) and subjected to heat and pressure treatment;
A peeling step of peeling off the metal foil (20) bonded to the upper and lower surfaces of the prepreg (10) taken out from the mold (100) after the heat and pressure treatment from the prepreg (10) is provided. To.
The prepreg (10) here means that a so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.

  In the sand step, the metal foil (20) may have an area larger than the area of the prepreg (10), and the end of the metal foil (20) may be disposed outside the prepreg (10). The prepreg is sandwiched from above and below in a state of projecting to the top.

  In the sand step, the present invention is characterized in that a wax (30) having a melting point lower than that of the thermoplastic resin is inserted between the metal foil (20) and the prepreg (10). .

  In the present invention, the metal foil (20) is a stainless steel foil or a nickel foil.

  In the invention, it is preferable that the thermoplastic resin is PEEK (polyether ether ketone) or PEKK (polyether ketone ketone).

  Note that symbols in parentheses indicate corresponding elements or corresponding matters described in the drawings and modes for carrying out the invention described later.

  According to the method for producing a prepreg molded product of the present invention, a single or a plurality of stacked prepregs sandwiched from above and below by metal foil is set in a mold and molded by heating and pressurization. The prepreg can be easily removed from the mold by contact. In particular, a prepreg formed by impregnating a sheet-like fiber base material with a highly adhesive resin such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin does not directly contact the mold. Easy to release.

Moreover, since the metal foil has a thickness of 10 μm or more and 300 μm or less, it easily deforms and easily follows the shape even when pressed with a mold. In addition, the upper and lower metal foils are integrated by discrete ultrasonic bonding or electrostatic bonding to the upper and lower surfaces of the prepreg, respectively, so when peeling the metal foil from the molded product taken out from the mold Therefore, even a prepreg made by impregnating a sheet-like fiber base material with a highly adhesive resin such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin may be used. It can be peeled cleanly.
If the thickness of the metal foil is less than 10 μm, there is a risk of tearing at the time of peeling. Therefore, the thickness is preferably 10 μm or more, and if the thickness of the metal foil exceeds 300 μm, it is difficult to follow the deformation during pressing. Since release may be difficult, it is preferably 300 μm or less.

  Moreover, in this invention, since stainless steel foil or nickel foil was used as metal foil, it is excellent in intensity | strength and workability.

  Further, according to the present invention, the area of the metal foil is made larger than the area of the prepreg, and the prepreg is sandwiched from above and below with the end of the metal foil protruding outward from the prepreg. The metal foil can be easily peeled from the prepreg while grasping the end of the prepreg with the hand of the operator.

  Further, according to the present invention, the wax having a melting point lower than the melting point of the thermoplastic resin is inserted between the metal foil and the prepreg so that the prepreg is sandwiched between the prepreg taken out from the mold and the metal. The foil can be peeled off more easily.

  As in the method for producing a prepreg molded product of the present invention, the prepreg is sandwiched from above and below with a metal foil having a thickness of 10 μm or more and 300 μm or less, and discretely ultrasonically bonded to the prepreg or bonded with static electricity. The above-mentioned Patent Document 1 completely describes that the integrated product is molded with a mold to improve the releasability from the mold and prevent the quality of the molded product from deteriorating. Absent.

It is sectional drawing which shows the state by which the prepreg was pinched | interposed with the stainless steel foil at the sand process in the manufacturing method of the prepreg molded product which concerns on embodiment of this invention. It is a top view which shows the state by which the prepreg was pinched | interposed with the stainless steel foil at the sand process in the manufacturing method of the prepreg molded product which concerns on embodiment of this invention. It is sectional drawing which shows the state which peels stainless steel foil from a prepreg at the peeling process in the manufacturing method of the prepreg molded product which concerns on embodiment of this invention. It is sectional drawing which shows the state by which the prepreg was pinched | interposed with the stainless steel foil at the sand process in the manufacturing method of the prepreg molded product which concerns on another embodiment of this invention. It is sectional drawing which shows the manufacturing method of the prepreg molded product which concerns on a prior art example. It is sectional drawing which shows the manufactured prepreg molded product.

A method for manufacturing a prepreg molded product according to an embodiment of the present invention will be described with reference to the drawings.
In the present embodiment, a plurality of prepregs 10 formed by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin (N sheets, here 5 sheets), and the stacked ones as shown in FIG. Molding is performed by using the mold 100, and the prepreg molded product 1 as shown in FIG. 6 is manufactured. Here, among the thermoplastic resins (CFRTP), a prepreg 10 using super engineering plastic having a high adhesive property such as PEEK (polyether ether ketone) or PEKK (polyether ketone ketone) as a matrix resin is laminated. ing.
The prepreg 10 referred to in the present embodiment also includes a so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin.

  As described below, the method for manufacturing a prepreg molded product includes a sand process, a mold forming process, and a peeling process.

(Sand process)
In the first sanding process, as shown in FIG. 1, five prepregs 10 are sandwiched from above and below with a stainless steel foil 20 used as a metal foil 20, and as shown in FIG. On the other hand, the stainless steel foil 20 is integrated by ultrasonic welding.
The area of the stainless steel foil 20 is larger than the area of the prepreg 10, and the prepreg 10 is sandwiched from above and below with the end of the stainless steel foil 20 protruding outward from the prepreg 10.

  In the present embodiment, the thickness of the coating made of stainless steel foil 20 is 100 μm. If the thickness of the stainless steel foil 20 is less than 10 μm, there is a possibility that tearing may occur at the time of peeling. Therefore, the thickness is preferably 10 μm or more. If the thickness of the stainless steel foil 20 exceeds 300 μm, the deformation at the time of pressing follows. Is preferably 300 μm or less.

  The ultrasonic fusion is also called ultrasonic thermal fusion or ultrasonic welding, and is a thermoplastic resin (here, PEEK (polyetheretherketone) or PEKK ( Polyetherketoneketone)) is instantaneously melted and joined to the stainless steel foil 20, and a plurality of ultrasonic fusion points 15 are discretely formed.

  Here, a stainless steel foil having excellent strength and workability is used as the metal foil 20, but a nickel foil, a magnesium foil, a titanium foil, or the like can be used instead.

(Molding process)
In the next mold forming step, five prepregs 10 are sandwiched from above and below by stainless steel foil 20, and the prepreg 10 integrated by ultrasonic fusion is combined with the upper mold 101 of the mold 100 as shown in FIG. After setting between the lower molds 102, the upper mold 101 is pushed into the lower mold 102 and subjected to heat and pressure treatment.

(Peeling process)
And in a peeling process, after cooling the prepreg 10 taken out from the metal mold | die 100 after heat-pressing process, the stainless steel foil 20 adhere | attached on the upper and lower surfaces of the prepreg 10 is peeled from the prepreg 10 by an operator's hand. . In addition, the stainless steel foil 20 can also be peeled from the prepreg 10 using a tool or a peeling apparatus.
In particular, since the stainless steel foil 20 is thin and easily deforms, it follows the shape even when pressed, and as shown in FIG. 3, the peel angle can be as high as 90 degrees, so that PEEK (polyether ether ketone) or PEKK ( Even a highly adhesive resin such as polyether ketone ketone can be easily peeled off.

  At this time, since the prepreg is sandwiched from above and below with the area of the stainless steel foil 20 larger than the area of the prepreg 10 and the end of the stainless steel foil 20 protruding outward from the prepreg 10, the end of the stainless steel foil 20 Is easily grasped by the operator's hand.

  As described above, when the sand process, the mold forming process, and the peeling process are performed in this order and the process is completed, the prepreg molded product 1 as shown in FIG. 6 is completed.

  According to such a method of manufacturing a prepreg molded product, a plurality of stacked prepregs 10 sandwiched from above and below by stainless steel foil 20 are set in a mold 100 and molded by heating and pressurization. , And the prepreg 10 itself does not directly contact the mold 100, so that the prepreg 10 can be easily taken out from the mold 100.

Moreover, since the stainless steel foil 20 has a thickness of 10 μm or more and 300 μm or less (here, 100 μm is used), the stainless steel foil 20 is easily deformed and can easily follow the shape even when pressed with the mold 100.
Further, since the upper and lower stainless steel foils 20 are integrated by discrete ultrasonic welding to the upper and lower surfaces of the prepreg 10, when the stainless steel foil 20 is peeled from the prepreg 10 taken out from the mold 100. The prepreg 10 in which a sheet-like fiber base material is impregnated with a highly adhesive resin such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) as a matrix resin can be easily obtained. Moreover, it can be removed cleanly.

As shown in FIG. 4, in the above-described sand process, the wax (WAX) 30 having a melting point lower than that of PEEK (polyether ether ketone) or PEKK (polyether ketone ketone) is replaced with the stainless steel foil 20 and the prepreg 10. It can also be inserted between.
Thus, by interposing the wax 30 between the stainless steel foil 20 and the prepreg 10, the stainless steel foil 20 can be more easily peeled from the prepreg 10 taken out from the mold 100.

  Examples of the wax 30 that decomposes at a melting point lower than that of PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) include paraffin type wax and microcrystal wax. Plant-derived carnauba wax, candelilla wax, wood wax, rice bran wax, and the like can also be used.

In the embodiment of the present invention, the stainless steel foil is integrated as the metal foil 20 by discrete ultrasonic welding to the upper surface and the lower surface of the prepreg 10, but static electricity is used instead. The stainless steel foil 20 can be adhered to the prepreg 10.
Also by this, the stainless steel foil 20 can be easily peeled off from the prepreg 10.

  In addition, among the thermoplastic resins (CFRTP), the case where so-called super engineering plastic such as PEEK (polyetheretherketone) or PEKK (polyetherketoneketone) is used as a matrix resin has been described. , As thermoplastic resin (CFRTP), PA (nylon), PPS (polyphenylene sulfide), PEI (polyetherimide), PC (polycarbonate), PAI (polyamideimide), TPI (thermoplastic polyimide), PES, PSU, LCP , PAR, PTFE, FEP, PFA, PCTFE, ETFE, ECTFE, PVDF, PVF, PET (polyether terephthalate) and the like as a matrix resin impregnated into a sheet fiber base 1 It can be similarly applied to the case of producing a molded article from.

  In this embodiment, a plurality of (five) prepregs 10 that are sandwiched from above and below by stainless steel foil 20 are pressed by the mold 100. However, the prepreg 10 is a single piece (single unit). Can be applied to the case where the stainless steel foil 20 is pressed from above and below with the mold 100 and the stainless steel foil 20 is peeled off from the prepreg 10 after the molding process.

1 Prepreg molded product 10 Prepreg 15 Ultrasonic fusion point 20 Metal foil (stainless steel foil)
30 Wax 100 Mold 101 Upper mold 102 Lower mold

The method for producing a prepreg molded product according to the present invention is a method for molding a prepreg molded product by molding one or a plurality of prepregs (10) obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin. A method for producing (1), comprising:
Sand process for sandwiching one or a plurality of the prepregs from above and below with a metal foil (20) having a thickness of 10 μm or more and 300 μm or less and bonding them to the prepreg (10) by static electricity. When,
A mold forming step in which the integrated prepreg (10) is set in the mold (100) and subjected to heat and pressure treatment;
A peeling step of peeling off the metal foil (20) bonded to the upper and lower surfaces of the prepreg (10) taken out from the mold (100) after the heat and pressure treatment from the prepreg (10) is provided. To.
The prepreg (10) here means that a so-called semi-preg formed by semi-impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin is also included.

Claims (6)

A method for producing a prepreg molded product by mold-molding one or a plurality of prepregs obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
Sandwiching one or more of the prepregs from above and below with a metal foil having a thickness of 10 μm or more and 300 μm or less, and discretely ultrasonically bonding to the prepreg, respectively, and a sand step,
A mold forming step in which the integrated prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a prepreg molded product, comprising: a peeling step of peeling the metal foil adhered to the upper and lower surfaces of the prepreg taken out from the mold after the heat and pressure treatment from the prepreg. A method for producing a prepreg molded product by mold-molding one or a plurality of prepregs obtained by impregnating a sheet-like fiber base material with a thermoplastic resin as a matrix resin,
Sandwiching one or a plurality of the prepregs from above and below with a metal foil having a thickness of 30 μm or more and 300 μm or less and adhering to the prepreg by static electricity, and integrating them,
A mold forming step in which the integrated prepreg is set in a mold and subjected to heat and pressure treatment;
A method for producing a prepreg molded product, comprising: a peeling step of peeling the metal foil adhered to the upper and lower surfaces of the prepreg taken out from the mold after the heat and pressure treatment from the prepreg.   In the sand step, the area of the metal foil is made larger than the area of the prepreg, and the prepreg is sandwiched from above and below with the end of the metal foil protruding outward from the prepreg. The manufacturing method of the prepreg molded product of Claim 1 or 2.   4. The sanding process according to claim 1, wherein a wax having a melting point lower than that of the thermoplastic resin is inserted between the metal foil and the prepreg. 5. Manufacturing method of prepreg molded product.   The said metal foil is stainless steel foil or nickel foil, The manufacturing method of the prepreg molded product as described in any one of Claims 1 thru | or 4 characterized by the above-mentioned.   The said thermoplastic resin is PEEK (polyetheretherketone) or PEKK (polyetherketoneketone), The manufacturing method of the prepreg molded product as described in any one of Claim 1 thru | or 5 characterized by the above-mentioned.