JP2016147377A5 - - Google Patents
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- JP2016147377A5 JP2016147377A5 JP2015023862A JP2015023862A JP2016147377A5 JP 2016147377 A5 JP2016147377 A5 JP 2016147377A5 JP 2015023862 A JP2015023862 A JP 2015023862A JP 2015023862 A JP2015023862 A JP 2015023862A JP 2016147377 A5 JP2016147377 A5 JP 2016147377A5
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- 238000000465 moulding Methods 0.000 claims description 122
- 239000000835 fiber Substances 0.000 claims description 46
- 239000000945 filler Substances 0.000 claims description 39
- 229920005989 resin Polymers 0.000 claims description 27
- 239000011347 resin Substances 0.000 claims description 27
- 239000000463 material Substances 0.000 claims description 22
- 230000000875 corresponding Effects 0.000 claims description 12
- 238000010438 heat treatment Methods 0.000 claims description 12
- 229920005992 thermoplastic resin Polymers 0.000 claims description 11
- 230000005611 electricity Effects 0.000 claims description 8
- 238000004519 manufacturing process Methods 0.000 claims description 5
- 238000003825 pressing Methods 0.000 claims description 4
- 238000005485 electric heating Methods 0.000 claims description 3
- 230000002093 peripheral Effects 0.000 description 13
- 239000002184 metal Substances 0.000 description 10
- 229910052751 metal Inorganic materials 0.000 description 10
- 238000000034 method Methods 0.000 description 7
- 238000007493 shaping process Methods 0.000 description 6
- 238000009413 insulation Methods 0.000 description 5
- 229920000049 Carbon (fiber) Polymers 0.000 description 4
- 239000004698 Polyethylene (PE) Substances 0.000 description 4
- 239000004917 carbon fiber Substances 0.000 description 4
- -1 polyethylene Polymers 0.000 description 4
- 229920000573 polyethylene Polymers 0.000 description 4
- 238000002844 melting Methods 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 229910000831 Steel Inorganic materials 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical group [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 2
- 239000003365 glass fiber Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 206010037660 Pyrexia Diseases 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005755 formation reaction Methods 0.000 description 1
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 1
- 239000010931 gold Substances 0.000 description 1
- 229910052737 gold Inorganic materials 0.000 description 1
- 230000020169 heat generation Effects 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
Description
上記目的を達成するため、本発明の特徴は、繊維強化樹脂を成形したＦＲＰ製品の表面の一部に対応する３次元形状に形成された第１成型部を有する第１金型と、ＦＲＰ製品の表面の他の一部に対応する３次元形状に形成された第２成型部を有して第１金型に対向配置される第２金型と、第１金型および第２金型のうちの少なくとも一方に電気を流して第１成型部および第２成型部のうちの少なくとも一方を加熱するための給電手段とを備え、第１成型部と第２成型部との間にＦＲＰ製品の材料を配置してＦＲＰ製品を成型するＦＲＰ製品の成型方法において、第１成型部および第２成型部のうちの少なくとも一方に繊維をシート状の集合体とした繊維シートを配置する繊維シート配置工程と、第１成型部と第２成型部との間に熱可塑性樹脂材からなる充填材を充填する充填材配置工程と、充填材配置工程の後に第１金型および第２金型を開いた状態で第１金型および第２金型のうちの少なくとも一方に電気を流すことにより第１成型部および第２成型部のうちの少なくとも一方を加熱して充填材を溶融する通電加熱工程と、第１金型と第２金型とを閉じて第１成型部および第２成型部によって前記溶融した充填材に圧力を加えてＦＲＰ製品に成型する成型工程とを含むことにある。
In order to achieve the above object, the present invention is characterized in that a first mold having a first molding part formed in a three-dimensional shape corresponding to a part of the surface of an FRP product obtained by molding a fiber reinforced resin, and an FRP product. A second mold having a second molding part formed in a three-dimensional shape corresponding to another part of the surface of the first mold and disposed opposite to the first mold, and the first mold and the second mold Power supply means for heating at least one of the first molding part and the second molding part by supplying electricity to at least one of them, and the FRP product between the first molding part and the second molding part. In the FRP product molding method for molding an FRP product by arranging materials, a fiber sheet arranging step of arranging a fiber sheet in which fibers are formed into a sheet-like aggregate in at least one of the first molding part and the second molding part And a thermoplastic resin between the first molded part and the second molded part A filler arranging step of filling a filler consisting, on at least one electrical of the first mold and the second mold with open first mold and the second mold after the filler arranging step An electric heating step of heating at least one of the first molding part and the second molding part by flowing to melt the filler, and closing the first mold and the second mold to close the first molding part and the first molding part And a molding step of molding the FRP product by applying pressure to the molten filler by the molding unit.
この場合、繊維シート配置工程は、充填材配置工程の前に実行してもよいし、充填材配置工程の後に実行されてもよい。また、繊維シート配置工程は、充填材配置工程の前後にそれぞれ実行されてもよい。また、充填材配置工程は、通電加熱工程の前に実行してもよいし、通電加熱工程の後に実行されてもよい。また、充填材配置工程は、成形工程の実行中に実行されてもよい。
In this case, the fiber sheet arranging step may be executed before the filler arranging step or after the filler arranging step. Further, the fiber sheet arranging step may be executed before and after the filler arranging step. Moreover, a filler arrangement | positioning process may be performed before an electrical heating process , and may be performed after an electrical heating process . Moreover, a filler arrangement | positioning process may be performed during execution of a formation process.
具体的には、ＦＲＰ製品の製造方法は、繊維強化樹脂を成形したＦＲＰ製品の表面の一部に対応する３次元形状に形成された第１成型部を有する第１金型と、ＦＲＰ製品の表面の他の一部に対応する３次元形状に形成された第２成型部を有して第１金型に対向配置される第２金型と、第１金型および第２金型のうちの少なくとも一方に電気を流して第１成型部および第２成型部のうちの少なくとも一方を加熱するための給電手段とを備え、第１成型部と第２成型部との間にＦＲＰ製品の材料を配置してＦＲＰ製品を成型するＦＲＰ製品の製造方法において、第１成型部および第２成型部のうちの少なくとも一方に繊維をシート状の集合体とした繊維シートを配置する繊維シート配置工程と、第１成型部と第２成型部との間に熱可塑性樹脂材からなる充填材を充填する充填材配置工程と、充填材配置工程の後に第１金型および第２金型を開いた状態で第１金型および第２金型のうちの少なくとも一方に電気を流すことにより第１成型部および第２成型部のうちの少なくとも一方を加熱して充填材を溶融する通電加熱工程と、第１金型と第２金型とを閉じて第１成型部および第２成型部によって前記溶融した充填材に圧力を加えてＦＲＰ製品に成型する成型工程とを含むことにある。これによっても、上記ＦＲＰ製品の成型方法の発明と同様の作用効果を期待することができる。
Specifically, the manufacturing method of the FRP product includes a first mold having a first molding part formed in a three-dimensional shape corresponding to a part of the surface of the FRP product obtained by molding a fiber reinforced resin, A second mold having a second molding part formed in a three-dimensional shape corresponding to another part of the surface and disposed opposite to the first mold, and the first mold and the second mold And a power supply means for heating at least one of the first molding part and the second molding part by supplying electricity to at least one of the first and second molding parts, and the material of the FRP product between the first molding part and the second molding part In the manufacturing method of the FRP product in which the FRP product is molded by arranging the fiber sheet, a fiber sheet arranging step of arranging a fiber sheet in which fibers are formed into a sheet-like aggregate in at least one of the first molding part and the second molding part; Is the thermoplastic resin material between the first molding part and the second molding part? Flow and the filling member disposing step of filling the filler, on at least one electrical of the first mold and the second mold with open first mold and the second mold after the filler arranging step comprising Accordingly, the first heating part and the second molding part are closed by heating at least one of the first molding part and the second molding part to melt the filler, and the first mold and the second mold are closed. And forming a FRP product by applying pressure to the molten filler by a molding unit. Also by this, the same effect as the invention of the method for molding the FRP product can be expected.
（成型装置１００の構成）
成型装置１００は、一対の第１金型１１０および第２金型１２０を備えている。第１金型１１０は、第２金型１２０と協働してＦＲＰ製品ＰＲの成型加工を行う鋼製の型であり、第１成型部１１１、第１羽根成型部１１２、柱状嵌合部１１３、第１外周部１１４および第１空洞部１１５をそれぞれ備えて構成されている。
(Configuration of molding apparatus 100)
The molding apparatus 100 includes a pair of first mold 110 and second mold 120. The first mold 110 is a steel mold that performs the molding process of the FRP product PR in cooperation with the second mold 120, and includes a first molding part 111, a first blade molding part 112, and a columnar fitting part 113. The first outer peripheral portion 114 and the first hollow portion 115 are provided.
第１羽根成型部１１２は、被成型材料に熱および圧縮力を加えてＦＲＰ製品ＰＲの周縁部に形成される羽根部Ｗｉの表面の一部を成型加工する部分であり、羽根部Ｗｉの表面の一部の形状に対応する３次元形状、すなわち、同表面の一部の３次元形状を反転させた３次元形状に形成されている。本実施形態において第１羽根成型部１１２は、羽根部Ｗｉにおける図示下側表面の凸形状に対応して図示上側に対して凹状に凹んだ形状に形成されている。また、第１羽根成型部１１２の肉厚は、ＦＲＰ製品ＰＲにおける羽根部Ｗｉの成型加工に必要な熱条件および圧力条件を確保できる範囲で必要最小限の厚さに形成されている。
The first blade molding portion 112 is a portion that applies heat and compression force to the material to be molded and molds a part of the surface of the blade portion Wi formed on the peripheral portion of the FRP product PR, and the surface of the blade portion Wi Are formed into a three-dimensional shape corresponding to a part of the shape, that is, a three-dimensional shape obtained by inverting a part of the three-dimensional shape on the surface. In the present embodiment, the first blade molding portion 112 is formed in a concave shape with respect to the upper side of the drawing corresponding to the convex shape of the lower surface of the blade portion Wi . Moreover, the thickness of the 1st blade | wing shaping | molding part 112 is formed in the minimum necessary thickness in the range which can ensure the thermal conditions and pressure conditions required for the shaping | molding process of the blade | wing part Wi in FRP product PR.
ここで、羽根部Ｗｉとは、ＦＲＰ製品ＰＲの外周部にフランジ状に張り出して形成される平板リング状の部分であり、第１成型部１１１側に配置される繊維シートＦＳと第２成型部１２１側に配置される繊維シートＦＳとを貼り合わせる部分であるとともに、後述する充填材ＦＭの漏出を防止するための部分である。この羽根部Ｗｉは、ＦＲＰ製品ＰＲの形状の一部を構成する場合や、ＦＲＰ製品ＰＲの成型後に除去されてＦＲＰ製品ＰＲの形状の一部を構成しない場合がある。
Here, the blade portion Wi is a flat ring-shaped portion that is formed in a flange shape on the outer periphery of the FRP product PR, and the fiber sheet FS and the second molded portion arranged on the first molded portion 111 side. While being a part which bonds the fiber sheet FS arrange | positioned at 121 side, it is a part for preventing the leakage of the filler FM mentioned later. The blade portion Wi may constitute a part of the shape of the FRP product PR, or may be removed after molding of the FRP product PR and may not constitute a part of the shape of the FRP product PR.
第２金型１２０は、第１金型１１０と協働してＦＲＰ製品ＰＲの成型加工を行う鋼製の型であり、第２成型部１２１、第２羽根成型部１２２、筒状嵌合部１２３、第２外周部１２４および第２空洞部１２５をそれぞれ備えて構成されている。
The second mold 120 is a steel mold that performs molding of the FRP product PR in cooperation with the first mold 110, and includes a second molding part 121, a second blade molding part 122, and a cylindrical fitting part. 123, the 2nd outer peripheral part 124, and the 2nd cavity part 125, respectively.
第２羽根成型部１２２は、前記第１羽根成型部１１２と同様に、被成型材料に熱および圧縮力を加えて前記羽根部Ｗｉの表面の他の一部を成型加工する部分であり、羽根部Ｗｉの表面の他の一部の形状に対応する３次元形状、すなわち、同表面の他の一部の３次元形状を反転させた３次元形状に形成されている。本実施形態において第２羽根成型部１２２は、羽根部Ｗｉにおける図示上側表面の凸形状に対応して図示下側に対して凹状に凹んだ形状に形成されている。また、第２羽根成型部１２２の肉厚は、ＦＲＰ製品ＰＲにおける羽根部Ｗｉの成型加工に必要な熱条件および圧力条件を確保できる範囲で必要最小限の厚さに形成されている。
Similarly to the first blade molding portion 112, the second blade molding portion 122 is a portion that applies heat and compression force to the material to be molded and molds another part of the surface of the blade portion Wi. The three-dimensional shape corresponding to the other part of the surface of the portion Wi , that is, the three-dimensional shape obtained by inverting the other part of the surface of the part, is formed. In the present embodiment, the second blade molding portion 122 is formed in a concave shape with respect to the lower side of the drawing corresponding to the convex shape of the upper surface of the blade portion Wi shown in the drawing. Further, the thickness of the second blade molding portion 122 is formed to the minimum necessary thickness within a range in which the thermal conditions and pressure conditions necessary for the molding processing of the blade portion Wi in the FRP product PR can be secured.
第２外周部１２４は、前記第１外周部１１４と同様に、第２成型部１２１、第２羽根成型部１２２および筒状嵌合部１２３をそれぞれ支持しつつ後述する第２空洞部１２５を形成する部分であり、筒状嵌合部１２３の外側の周囲に円筒状に形成されている。したがって、第２外周部１２４は、第２金型１２０が第１金型１１０からの反力を受ける際に、第２成型部１２１および第２羽根成型部１２２の各変形を抑えることができる肉厚で形成されている。本実施形態においては、第２金型１２０の第２外周部１２４の肉厚が約１５０ｍｍに形成されている。
Similarly to the first outer peripheral portion 114, the second outer peripheral portion 124 forms a second cavity portion 125 described later while supporting the second molding portion 121, the second blade molding portion 122, and the cylindrical fitting portion 123, respectively. And is formed in a cylindrical shape around the outside of the cylindrical fitting portion 123. Therefore, the second outer peripheral portion 124 can suppress the deformation of the second molding portion 121 and the second blade molding portion 122 when the second die 120 receives a reaction force from the first die 110. It is formed with a thickness. In the present embodiment, the thickness of the second outer peripheral portion 124 of the second mold 120 is formed to be about 150 mm.
第１電極１３４ａは、第１金型１１０に対して給電するための銅製の部品であり、第１外周部１１４の図示上面に接触させることができる大きさの方形板状に形成されている。この第１電極１３４ａは、絶縁支持体１３４ｃの図示下面に取り付けられている。第２電極１３４ｂは、第２金型１２０に対して給電するための銅製の部品であり、第２外周部１２４の図示下面に接触させることができる大きさの方形板状に形成されている。この第２電極１３４ｂは、絶縁支持体１３４ｃの図示上面に取り付けられている。
The first electrode 134a is a copper part for supplying power to the first mold 110, and is formed in a rectangular plate size that can be brought into contact with the upper surface of the first outer peripheral portion 114 in the drawing. The first electrode 134a is attached to the lower surface of the insulating support 134c. The second electrode 134b is a copper component for supplying power to the second mold 120 , and is formed in a rectangular plate size that can be brought into contact with the lower surface of the second outer peripheral portion 124 in the drawing. The second electrode 134b is attached to the upper surface of the insulating support 134c.
これらの入力電極１３４および金型間通電電極１３５は、第１金型１１０および第２金型１２０の近傍に電極配置装置１３６によってそれぞれ支持されている。電極配置装置１３６は、入力電極１３４および金型間通電電極１３５を第１金型１１０および第２金型１２０との間に対して配置または退避させるための機械装置であり、入力電極１３４および金型間通電電極１３５をそれぞれ可動的に支持する油圧または空気圧のシリンダで構成されている。この電極配置装置１３６は、制御装置１４０によって作動が制御される。
The input electrode 134 and the inter-mold conducting electrode 135 are supported by the electrode placement device 136 in the vicinity of the first mold 110 and the second mold 120, respectively. Electrode deployment device 136 is a mechanical device for placement or retracted from the between the input electrode 134 and the mold between the powered electrode 135 of the first mold 110 and second mold 120, the input electrode 134 and the gold It is composed of a hydraulic or pneumatic cylinder that movably supports the inter-mold energization electrodes 135. The operation of the electrode placement device 136 is controlled by the control device 140.
また、入力電極１３４には、給電装置１３７が接続されている。給電装置１３７は、第１金型１１０と第２金型１２０とに流す電流を供給するための電源装置である。この給電装置１３７は、制御装置１４０に制御されて入力電極１３４を介して第１金型１１０および第２金型１２０に対して交流電流を供給する。したがって、給電装置１３７は、図示しない高周波インバータや整合トランスなどを備えている。本実施形態においては、給電装置１３７は、電力が１００ｋＷで周波数が５０ｋＨｚの交流電流を入力電極１３４に出力可能に構成されている。なお。この給電装置１３７が出力する交流電流は、被成型材料の成型加工条件に応じて適宜設定されるものであることは当然である。
Further, a power feeding device 137 is connected to the input electrode 134 . The power feeding device 137 is a power supply device for supplying a current that flows through the first mold 110 and the second mold 120. The power feeding device 137 is controlled by the control device 140 to supply an alternating current to the first mold 110 and the second mold 120 via the input electrode 134. Therefore, the power feeding device 137 includes a high-frequency inverter, a matching transformer, and the like (not shown). In the present embodiment, the power feeding device 137 is configured to be able to output an alternating current having a power of 100 kW and a frequency of 50 kHz to the input electrode 134. Note that. Naturally, the alternating current output by the power supply device 137 is appropriately set according to the molding processing conditions of the material to be molded .
（成型装置１００の作動）
次に、このように構成した成型装置１００を用いたＦＲＰ製品ＰＲの成型方法および製造方法の過程について図３に示すフローチャート参照しながら説明する。まず、作業者は、第１工程として、ＦＲＰ製品ＰＲの原料となる被成型材料を用意する。具体的には、作業者は、繊維シートＦＳ、樹脂シートＰＣおよび充填材ＦＭをそれぞれ用意する。この場合、繊維シートＦＳは、ガラス繊維、炭素繊維または金属繊維などの繊維を複数集めてシート状に成形したものである。また、樹脂シートＰＳは、熱可塑性樹脂材（例えば、ポリエチレン樹脂）をフィルム状やシート状に成形したものである。また、充填材ＦＭは、固形体であるペレット状や粘性を有する粘土状の熱可塑性樹脂材（例えば、ポリエチレン樹脂）を単体でまたはこの熱可塑性樹脂材にガラス繊維、炭素繊維または金属繊維などの繊維を混ぜたものである。
(Operation of molding apparatus 100)
Next, the process of the FRP product PR molding method and manufacturing method using the molding apparatus 100 configured as described above will be described with reference to the flowchart shown in FIG. First, an operator prepares a material to be molded as a raw material for the FRP product PR as the first step. Specifically, the operator prepares a fiber sheet FS, a resin sheet PC, and a filler FM. In this case, the fiber sheet FS is formed by collecting a plurality of fibers such as glass fibers, carbon fibers, or metal fibers into a sheet shape. Further, the resin sheet PS is obtained by molding a thermoplastic resin material (for example, polyethylene resin) into a film shape or a sheet shape. In addition, the filler FM is a solid pellet-like or viscous clay-like thermoplastic resin material (for example, polyethylene resin), or a glass fiber, carbon fiber, metal fiber, or the like added to the thermoplastic resin material. It is a mixture of fibers.
本実施形態においては、作業者は、繊維シートＦＳとして２枚の炭素繊維シートを用意し、樹脂シートＰＳとして２枚のポリエチレン製の樹脂シートを用意し、充填材ＦＭとしてポリエチレン樹脂材に炭素繊維を混ぜて混練機で練った粘土状の樹脂材、所謂長繊維強化樹脂材の塊を用意する。この場合、作業者は、充填材ＦＭについてこの充填材ＦＭを構成する樹脂材が溶融した場合における体積がキャビティＣｖの容積以上（厳密には、キャビティＣｖ内に配置される繊維シートＦＳや樹脂シートＰＳの体積を除いた容積）となる量で用意する。また、この場合、繊維シートＦＳは第１羽根成型部１１２および第２羽根成型部１２２の外側にはみ出る大きさに形成されるとともに、樹脂シートＰＳは第１羽根成型部１１２内および第２羽根成型部１２２内にそれぞれ収まる大きさに形成される。
In the present embodiment, the operator prepares two carbon fiber sheets as the fiber sheet FS, prepares two polyethylene resin sheets as the resin sheet PS, and uses carbon fiber as a filler FM on the polyethylene resin material. A clay-like resin material kneaded with a kneader, that is, a so-called long fiber reinforced resin material lump is prepared. In this case, the operator, when the resin material constituting the filler FM is melted with respect to the filler FM has a volume equal to or larger than the volume of the cavity Cv (strictly speaking, the fiber sheet FS or resin sheet disposed in the cavity Cv) The volume of the volume excluding the volume of PS) is prepared. In this case, the fiber sheet FS is formed to have a size that protrudes outside the first blade molding portion 112 and the second blade molding portion 122, and the resin sheet PS is formed in the first blade molding portion 112 and the second blade molding. It is formed in a size that can be accommodated in each portion 122.
次いで、作業者は、第１金型１１０における第１成型部１１１上および第１羽根成型部１１２上に１枚の繊維シートＦＳを配置した後、この１枚の繊維シートＦＳ上に１枚の樹脂シートＰＳを配置する。次いで、作業者は、第１成型部１１１上および第１羽根成型部１１２上の樹脂シートＰＳ上に充填材ＦＭを配置する。次いで、作業者は、第１成型部１１１上および第１羽根成型部１１２上の充填材ＦＭ上に１枚の樹脂シートＰＳを配置した後、この１枚の樹脂シートＰＳ上に１枚の繊維シートＦＳを配置する。
Next, the operator arranges one fiber sheet FS on the first molding part 111 and the first blade molding part 112 in the first mold 110, and then one sheet on the one fiber sheet FS. A resin sheet PS is disposed. Next, the operator places the filler FM on the resin sheet PS on the first molding part 111 and the first blade molding part 112. Next, the operator places one resin sheet PS on the filler FM on the first molding part 111 and the first blade molding part 112, and then one fiber on the one resin sheet PS. The sheet FS is disposed.
次に、作業者は、第４工程として、第１金型１１０および第２金型１２０にそれぞれ通電させる。具体的には、作業者は、操作パネル１４１を操作して制御装置１４０に対して第１金型１１０および第２金型１２０への通電を指示する。この指示に応答して、制御装置１４０は、給電装置１３７を作動制御して入力電極１３４を介して第１金型１１０および第２金型１２０に対して通電を開始する。これにより、給電装置１３７から出力された電流は、第１電極１３４ａ（または第２電極１３４ｂ）を介して第１金型１１０（または第２金型１２０）内に供給された後、金型間通電電極１３５を介して第２金型１２０（または第１金型１１０）内を流れて第２電極１３４ｂ（または第１電極１３４ａ）を介して給電装置１３７に戻る。
Next, an operator energizes each of the first mold 110 and the second mold 120 as the fourth step. Specifically, the operator operates the operation panel 141 to instruct the control device 140 to energize the first mold 110 and the second mold 120. In response to this instruction, the control device 140 controls the operation of the power feeding device 137 and starts energizing the first mold 110 and the second mold 120 via the input electrode 134. Thereby, the current output from the power feeding device 137 is supplied into the first mold 110 (or the second mold 120) via the first electrode 134a (or the second electrode 134b), and then between the molds. It flows in the second mold 120 (or the first mold 110) via the energizing electrode 135 and returns to the power feeding device 137 via the second electrode 134b (or the first electrode 134a).
この場合、第１金型１１０および第２金型１２０は、第１空洞部１１５および第２空洞部１２５によって主として第１成型部１１１、第１羽根成型部１１２、第２成型部１２１および第２羽根成型部１２２に高周波電流が流れる。これにより、第１成型部１１１、第１羽根成型部１１２、第２成型部１２１および第２羽根成型部１２２は、通電によって発熱を開始して熱可塑性樹脂材の融点以上まで加熱されることによって充填材ＦＭおよび樹脂シートＰＳを溶融させる。この場合、制御装置１４０は、第１金型１１０および第２金型１２０の温度を熱可塑性樹脂材の融点以上（例えば、４００°程度）に維持するように通電量を制御する。この第３工程における充填材ＦＭを溶融させる工程が、本発明に係る通電加熱工程に相当する。
In this case, the first mold 110 and the second mold 120 are mainly composed of the first molding part 111, the first blade molding part 112, the second molding part 121, and the second by the first cavity part 115 and the second cavity part 125. A high-frequency current flows through the blade forming part 122. Thereby, the 1st shaping | molding part 111, the 1st blade | wing shaping | molding part 112, the 2nd shaping | molding part 121, and the 2nd blade | wing shaping | molding part 122 start heat_generation | fever by electricity supply, and are heated to more than melting | fusing point of a thermoplastic resin material. Filler FM and resin sheet PS are melted. In this case, the control device 140 controls the energization amount so as to maintain the temperature of the first mold 110 and the second mold 120 at or above the melting point of the thermoplastic resin material (for example, about 400 °). The step of melting the filler FM in the third step corresponds to the energization heating step according to the present invention.
次いで、制御装置１４０は、図５に示すように、金型間通電電極１３５を第１金型１１０と第２金型１２０との間から撤去した後、金型駆動装置１３３の作動を制御して第２金型１２０を第１金型１１０に押し付けて金型を閉じる。この場合、制御装置１４０は、バキューム装置１３２の作動を制御してキャビティＣｖ内の空気を吸引しながら金型を閉じる。これにより、第１金型１１０および第２金型１２０の間に配置した充填材ＦＭおよび樹脂シートＰＳは、第１金型１１０および第２金型１２０の余熱によって完全に溶融（全体が当初の粘度よりも低くなっている状態）してキャビティＣｖ内を流動可能となる。この場合、充填材ＦＭは、キャビティＣｖの容量よりも大きな体積である充填されているため、パスカルの原理によってキャビティＣｖ内の圧力が均一となる。
Next, as shown in FIG. 5, the control device 140 removes the inter-mold conducting electrode 135 from between the first mold 110 and the second mold 120, and then controls the operation of the mold driving device 133. The second mold 120 is pressed against the first mold 110 to close the mold. In this case, the control device 140 controls the operation of the vacuum device 132 to close the mold while sucking air in the cavity Cv . Thereby, the filler FM and the resin sheet PS arranged between the first mold 110 and the second mold 120 are completely melted by the residual heat of the first mold 110 and the second mold 120 (the whole is the original It is possible to flow in the cavity Cv. In this case, since the filling material FM is filled with a volume larger than the capacity of the cavity Cv, the pressure in the cavity Cv becomes uniform according to the Pascal principle.
また、この場合、第２金型１２０を閉じる過程でキャビティＣｖ内の空気を吸引しているため、繊維シートＦＳ、および溶融した熱可塑性樹脂の各内部に気泡を生じさせることを防止することができる（図４破線矢印参照）。また、第１羽根成型部１１２および第２羽根成型部１２２よりも外側に延びた繊維シートＦＳは、柱状嵌合部１１３と筒状嵌合部１２３との嵌合によって切断されて第１外周部１１４と第２外周部１２４との隙間を介してキャビティＣｖ内から除去される。
In this case, since air in the cavity Cv is sucked in the process of closing the second mold 120, it is possible to prevent bubbles from being generated in each of the fiber sheet FS and the molten thermoplastic resin. Yes (see dashed arrows in FIG. 4). Further, the fiber sheet FS extending outward from the first blade molding portion 112 and the second blade molding portion 122 is cut by the fitting between the columnar fitting portion 113 and the cylindrical fitting portion 123 to be the first outer peripheral portion. It is removed from the cavity Cv through a gap between 114 and the second outer peripheral portion 124 .
また、本発明においては、充填材ＦＭを繊維シートＦＳで挟んで成型する場合においても、１枚の繊維シートＦＳを折って充填材ＦＭを挟むことができるとともに、充填材ＦＭに対して両側に複数枚ずつの繊維シートＦＳを配置することで充填材ＦＭを挟んでＦＲＰ製品ＰＲを成型することもできる。また、本発明においては、繊維シートＦＳに対して複数枚の樹脂シートＰＳを連続してまたは複数の繊維シートＦＳと複数の樹脂シートＰＳとを交互に隣接配置してＦＲＰ製品ＰＲを成型することができるとともに、図６に示すように樹脂シートＰＳを省略してＦＲＰ製品ＰＲを成型することもできる。なお、繊維シートＦＳとしては、繊維シートＦＳに熱可塑性樹脂を予め含浸させた所謂プリプレグを用いることもできる。
Further, in the present invention, even when the filler FM is sandwiched between the fiber sheets FS and molded, one fiber sheet FS can be folded to sandwich the filler FM, and on both sides of the filler FM. By arranging a plurality of fiber sheets FS, the FRP product PR can be molded with the filler FM interposed therebetween. Further, in the present invention, the FRP product PR is formed by continuously arranging a plurality of resin sheets PS on the fiber sheet FS or alternately arranging a plurality of fiber sheets FS and a plurality of resin sheets PS. In addition, the FRP product PR can be molded by omitting the resin sheet PS as shown in FIG. As the fiber sheet FS , a so-called prepreg obtained by impregnating the fiber sheet FS with a thermoplastic resin in advance can be used.
また、上記実施形態においては、第１金型１１０および第２金型１２０に通電して加熱する際に第２金型１２０を樹脂シートＰＳに接触させない位置まで第１金型１１０に近接させて配置した。しかし、第２金型１２０は、繊維シートＦＳを押し付ける位置まで第１金型１１０に近接配置することもできる。具体的には、例えば、図７に示すように、作業者は、第１金型１１０における第１成型部１１１および第１羽根成型部１１２上に配置した最上部（第２金型１２０に対向する）の繊維シートＦＳ上に絶縁シート１５０を被せた後、第２金型１２０を第１金型１１０側に近接配置する。
Moreover, in the said embodiment, when it energizes and heats the 1st metal mold | die 110 and the 2nd metal mold | die 120, the 2nd metal mold | die 120 is made to adjoin to the 1st metal mold | die 110 to the position which does not contact the resin sheet PS. Arranged. However, the 2nd metal mold | die 120 can also be arrange | positioned close to the 1st metal mold | die 110 to the position which presses the fiber sheet FS. Specifically, for example, as shown in FIG. 7, the operator places the uppermost part (opposite the second mold 120) disposed on the first molding part 111 and the first blade molding part 112 in the first mold 110. The second mold 120 is placed close to the first mold 110 side after the insulating sheet 150 is placed on the fiber sheet FS.
また、上記実施形態においては、給電装置１３７は、第１金型１１０および第２金型１２０に対して交流電流を供給するように構成した。しかし、給電装置１３７は、第１金型１１０および第２金型１２０に対して直流電流を供給するように構成しても良い。また、給電装置１３７が出力する電気量は、被成型材料やＦＲＰ製品ＰＲの種類、大きさまたは成型精度に応じて適宜設定されるものであり、上記実施形態に限定されるものではない。
In the above embodiment, the power feeding device 137 is configured to supply an alternating current to the first mold 110 and the second mold 120. However, the power feeding device 137 may be configured to supply a direct current to the first mold 110 and the second mold 120. The amount of electricity output from the power feeding device 137 is appropriately set according to the type, size, or molding accuracy of the material to be molded or the FRP product PR, and is not limited to the above embodiment.
ＰＲ…ＦＲＰ製品、Ｗｉ…羽根部、Ｗａ１，Ｗａ２…壁部、ＰＳ…樹脂シート、ＦＳ…繊維シート、ＦＭ…充填材、Ｃｖ…キャビティ、
１００…成型装置、
１１０…第１金型、１１１…第１成型部、１１２…第１羽根成型部、１１３…柱状嵌合部、１１４…第１外周部、１１４ａ…排水孔、１１５…第１空洞部、１１６…第１受け板、１１７…給水管、１１８…断熱絶縁ベース、１１９…第１取付板、
１２０…第２金型、１２１…第２成型部、１２２…第２羽根成型部、１２３…筒状嵌合部、１２４…第２外周部、１２４ａ…排水孔、１２４ｂ…吸気孔、１２５…第２空洞部、１２６…第２受け板、１２７…給水管、１２８…断熱絶縁ベース、１２９…第２取付板、
１３１…給水ポンプ、１３２…バキューム装置、１３３…金型駆動手段、１３４…入力電極、１３４ａ…第１電極、１３４ｂ…第２電極、１３４ｃ…絶縁支持体、１３５…金型間通電電極、１３６…電極配置装置、１３７…給電装置、
１４０…制御装置、１４１…操作パネル、
１５０…絶縁シート、
１６０…スプル、
１７０…絶縁層、１７１…第１電極、１７２…第２電極、１７３…金型間通電電極。
PR ... FRP product, Wi ... blade part, Wa1, Wa2 ... wall part, PS ... resin sheet, FS ... fiber sheet, FM ... filler, Cv ... cavity,
100 ... Molding device,
DESCRIPTION OF SYMBOLS 110 ... 1st metal mold | die, 111 ... 1st molding part, 112 ... 1st blade molding part, 113 ... Columnar fitting part, 114 ... 1st outer peripheral part, 114a ... Drain hole, 115 ... 1st cavity part, 116 ... 1st receiving plate, 117 ... water supply pipe, 118 ... heat insulation insulation base, 119 ... 1st mounting plate,
DESCRIPTION OF SYMBOLS 120 ... 2nd metal mold | die, 121 ... 2nd molding part, 122 ... 2nd blade molding part, 123 ... Cylindrical fitting part, 124 ... 2nd outer peripheral part, 124a ... Drain hole, 124b ... Intake hole, 125 ... 1st 2 cavity parts, 126 ... 2nd receiving plate, 127 ... water supply pipe, 128 ... heat insulation insulation base, 129 ... 2nd attachment plate,
DESCRIPTION OF SYMBOLS 131 ... Water supply pump, 132 ... Vacuum device, 133 ... Mold drive means, 134 ... Input electrode, 134a ... First electrode, 134b ... Second electrode, 134c ... Insulation support, 135 ... Inter-mold conduction electrode, 136 ... Electrode placement device, 137 ... power feeding device,
140 ... control device, 141 ... operation panel,
150 ... insulating sheet,
160 ... sprue,
170: insulating layer, 171: first electrode, 172: second electrode, 173: inter-mold conducting electrode .
Claims (2)
前記ＦＲＰ製品の表面の他の一部に対応する３次元形状に形成された第２成型部を有して前記第１金型に対向配置される第２金型と、
前記第１金型および前記第２金型のうちの少なくとも一方に電気を流して前記第１成型部および前記第２成型部のうちの少なくとも一方を加熱するための給電手段とを備え、
前記第１成型部と前記第２成型部との間に前記ＦＲＰ製品の材料を配置して前記ＦＲＰ製品を成型するＦＲＰ製品の成型方法において、
前記第１成型部および前記第２成型部のうちの少なくとも一方に繊維をシート状の集合体とした繊維シートを配置する繊維シート配置工程と、
前記第１成型部と前記第２成型部との間に熱可塑性樹脂材からなる充填材を充填する充填材配置工程と、
前記充填材配置工程の後に前記第１金型および前記第２金型を開いた状態で前記第１金型および前記第２金型のうちの少なくとも一方に電気を流すことにより前記第１成型部および前記第２成型部のうちの少なくとも一方を加熱して前記充填材を溶融する通電加熱工程と、
前記第１金型と前記第２金型とを閉じて前記第１成型部および前記第２成型部によって前記溶融した充填材に圧力を加えて前記ＦＲＰ製品に成型する成型工程とを含むことを特徴とするＦＲＰ製品の成型方法。
A first mold having a first molding part formed in a three-dimensional shape corresponding to a part of the surface of the FRP product molded with fiber reinforced resin;
A second mold having a second molding part formed in a three-dimensional shape corresponding to the other part of the surface of the FRP product and disposed opposite to the first mold;
Power supply means for heating at least one of the first molding part and the second molding part by supplying electricity to at least one of the first mold and the second mold;
In the FRP product molding method of molding the FRP product by arranging the material of the FRP product between the first molding part and the second molding part,
A fiber sheet arrangement step of arranging a fiber sheet in which fibers are made into a sheet-like aggregate in at least one of the first molding part and the second molding part;
A filler placement step of filling a filler made of a thermoplastic resin material between the first molding part and the second molding part;
The first molding part by flowing electricity to at least one of the first mold and the second mold in a state where the first mold and the second mold are opened after the filler arranging step. And an electric heating step of heating at least one of the second molding parts to melt the filler,
Including a molding step of closing the first mold and the second mold and applying pressure to the molten filler by the first molding section and the second molding section to mold the FRP product. A method for molding FRP products.
前記ＦＲＰ製品の表面の他の一部に対応する３次元形状に形成された第２成型部を有して前記第１金型に対向配置される第２金型と、
前記第１金型および前記第２金型のうちの少なくとも一方に電気を流して前記第１成型部および前記第２成型部のうちの少なくとも一方を加熱するための給電手段とを備え、
前記第１成型部と前記第２成型部との間に前記ＦＲＰ製品の材料を配置して前記ＦＲＰ製品を成型するＦＲＰ製品の製造方法において、
前記第１成型部および前記第２成型部のうちの少なくとも一方に繊維をシート状の集合体とした繊維シートを配置する繊維シート配置工程と、
前記第１成型部と前記第２成型部との間に熱可塑性樹脂材からなる充填材を充填する充填材配置工程と、
前記充填材配置工程の後に前記第１金型および前記第２金型を開いた状態で前記第１金型および前記第２金型のうちの少なくとも一方に電気を流すことにより前記第１成型部および前記第２成型部のうちの少なくとも一方を加熱して前記充填材を溶融する通電加熱工程と、
前記第１金型と前記第２金型とを閉じて前記第１成型部および前記第２成型部によって前記溶融した充填材に圧力を加えて前記ＦＲＰ製品に成型する成型工程とを含むことを特徴とするＦＲＰ製品の製造方法。
A first mold having a first molding part formed in a three-dimensional shape corresponding to a part of the surface of the FRP product molded with fiber reinforced resin;
A second mold having a second molding part formed in a three-dimensional shape corresponding to the other part of the surface of the FRP product and disposed opposite to the first mold;
Power supply means for heating at least one of the first molding part and the second molding part by supplying electricity to at least one of the first mold and the second mold;
In the method for manufacturing an FRP product, the material of the FRP product is disposed between the first molding part and the second molding part, and the FRP product is molded.
A fiber sheet arrangement step of arranging a fiber sheet in which fibers are made into a sheet-like aggregate in at least one of the first molding part and the second molding part;
A filler placement step of filling a filler made of a thermoplastic resin material between the first molding part and the second molding part;
The first molding part by flowing electricity to at least one of the first mold and the second mold in a state where the first mold and the second mold are opened after the filler arranging step. And an electric heating step of heating at least one of the second molding parts to melt the filler,
Including a molding step of closing the first mold and the second mold and applying pressure to the molten filler by the first molding section and the second molding section to mold the FRP product. A method for producing a characteristic FRP product.
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| WO (1) | WO2016129566A1 (en) |
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| JP2000327839A (en) * | 1999-05-19 | 2000-11-28 | Seibu Electric & Mach Co Ltd | Biodegradable material composition, container made of biodegradable material comprising same and preparation thereof |
| JP5513079B2 (en) * | 2009-11-06 | 2014-06-04 | 三菱レイヨン株式会社 | Mold and method for producing thermoplastic resin fiber reinforced composite material molded article |
| JP5716290B2 (en) * | 2010-04-20 | 2015-05-13 | 三菱レイヨン株式会社 | Method for producing fiber reinforced thermoplastic resin |
| JP5107417B2 (en) * | 2010-12-24 | 2012-12-26 | 株式会社キャップ | Molding apparatus and molding method using the molding apparatus |
| JP5809484B2 (en) * | 2011-08-29 | 2015-11-11 | 三光合成株式会社 | Forming method |
| JP2014156012A (en) * | 2013-02-14 | 2014-08-28 | Toray Ind Inc | Method for manufacturing thermoplastic resin molding |
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